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DINGLI MV060-E Setup And Operation Service Manual

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Operation Service Manual
All models prior to and including Series 1
MV060-E
&
MV075-E

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Summary of Contents for DINGLI MV060-E

  • Page 1 Operation Service Manual All models prior to and including Series 1 MV060-E & MV075-E...
  • Page 2 OPERATION AND SAFTY MANUAL FOREWORD This manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. Due to continuous product improvements, the manufacturer reserves the right to make specification changes without prior notification.
  • Page 3 OPERATION AND SAFTY MANUAL SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION.
  • Page 4 OPERATION AND SAFTY MANUAL TABLE OF CONTENTS SUBJECT-SECTION, PARAGRAPH PAGE NO. FOREWORD……………………………………………………………………………………………………… ..1 SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS……………………………………………..2 SECTION 1 - SAFETY PRECAUTIONS 1 . 1 G E N E R A L … … … … … … … … … … … … … … … … … … … … … … … … … … . … … … … … … … … … … … . . . 6 1 .
  • Page 5 OPERATION AND SAFTY MANUAL Battery Charging Status Indicators…………………………………………………….…………………………….……….25 3.5 GROUND CONTROL STATION – OPERATION……...……………………………………………..……….25 Main Power Selector Switch………………………………………………………...…………………….……25 Emergency Stop/Shut Down Button…………………………………...………………………………………26 Brake Release Button……………………………………………………...…………………………………..26 Platform Up……………………………………………………………………………………………………….26 Platform Down ………………………………………………………………………………………… ..……….26 Manual Descent Control Valve ………………………………………………………………………………… 27 Machine Status LCD Display………………………………………………………………………….………..28 LCD Display Fault Conditions………………………………………………………………………….………...
  • Page 6 OPERATION AND SAFTY MANUAL Platform Data …………………………………………………………………………………………………… .48 Machine Component Weights………………………………………………………………………………….48 Serial Number Locations ……………………………………………………………………………………….48 5.4 OPERATOR MAINTENANCE …………………………… .…………………………………… .………………48 L ubr ic at io n……………………………………………………………………………… . .……………………… 4 8 Hydraul ic Di agram……………………………………… ………………………………………………………49 SECTION 6 - ELECTRICAL SCHEMATIC ELECTRICAL SCHEMATIC……………………………………………………………...
  • Page 7 OPERATION AND SAFTY MANUAL SECTION 1. SAFETY PRECAUTIONS 1.1 GENERAL This section outlines the necessary precautions for proper and safe machine usage and maintenance. For proper machine use, it is mandatory that a daily routine be established based on the content of this manual. A maintenance program, using the information provided in this manual and the Service and Maintenance Manual, must also be established by a qualified person and must be followed to ensure that the machine is safe to operate.
  • Page 8 OPERATION AND SAFTY MANUAL this range. Machine Inspection  Before machine operation, perform inspections and functional checks. Refer to Section 2 of this manual for detailed instructions. Do not operate this machine until it has been serviced and maintained according to requirements specified in the ...
  • Page 9 OPERATION AND SAFTY MANUAL Before operating the machine, make sure all railing and gates are fastened in their proper position.     Keep both feet firmly positioned on the platform floor at all times. Never use ladders, boxes, steps, planks, or similar ...
  • Page 10 OPERATION AND SAFTY MANUAL Maintain a clearance of at least 10 ft (3m) between any part of the machine and its occupants, their tools, and their equipment from any electrical line or apparatus carrying up to 50,000 volts. One foot (0.3m) additional clearance is required for every additional 30,000 volts or less.
  • Page 11 OPERATION AND SAFTY MANUAL Crushing And Collision Hazard  Personal protection equipment must be worn by all operating and ground personnel.  Check work area clearances above, on sides, and bottom of platform while driving and lifting or lowering platform ...
  • Page 12 OPERATION AND SAFTY MANUAL ● Nameplate Page 11...
  • Page 13 OPERATION AND SAFTY MANUAL ● Warning labels SERIES DECAL INSPECTION Page 12...
  • Page 14 OPERATION AND SAFTY MANUAL Page 13...
  • Page 15 OPERATION AND SAFTY MANUAL Page 14...
  • Page 16 OPERATION AND SAFTY MANUAL Part No. Description Qty. Name plate Notice-Keyswitch Important-Brake release Warning-Battery charge Emmergency lower Forklift Pocket No forklift Door Bar Capacity Notice-Manual box IPAF Occupancy Warning- Crush Hazard Forklift Pocket Warning-Crush Hazard Warning-Falling Hazard Danger- Explosion/burn Hazard Crane Hole Decal Tie Hole Decal Logo...
  • Page 17 OPERATION AND SAFTY MANUAL SECTION 2. PREPARATION AND INSPECTION 2.1 PERSONNEL TRAINING The aerial platform is a personnel-handling device; so it is necessary that it be operated and maintained only by trained personnel. Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical control must not operate this machine.
  • Page 18 OPERATION AND SAFTY MANUAL Table 2-1. Inspection and Maintenance Table PRIMARY SERVICE TYPE FREQUENCY REFERENCE RESPONSIBILITY QUALIFICATION Pre-Start Before using each day, or whenever there’s User or Operator User or Operator Operator and Safety Manual Inspection an Operator change. Pre-Delivery Service and Maintenance Owner, Dealer, or Qualified...
  • Page 19 OPERATION AND SAFTY MANUAL 7. Function Check – Check all machine controls for operation. (See Section 2.5) If optional equipment is installed on this machine refer to Section 3 for specific Pre-Start Inspection and Operation instructions. 2.4 DAILY WALK-AROUND INSPECTION Begin the “Walk –...
  • Page 20 OPERATION AND SAFTY MANUAL Figure 2-1. Daily Walk-Around Inspection for Machines. 1. Drive and Caster Wheels 4. Motor/Pump/Reservoir Unit 7. Platform Control Console 2. Base Frame 5. Batteries (Open Cover Doors) 8. Ground Control Console 3. Manual Descent Control Valve 6.
  • Page 21 OPERATION AND SAFTY MANUAL NOTE: Ensure Pot-Hole-Protection device is fully engaged (both bars down) when the platform is elevated. b. Ensure that all machine functions are disabled when the Emergency Stop Button is activated. c. Check Manual Control valve is operating properly. 2.
  • Page 22 OPERATION AND SAFTY MANUAL SECTION 3. MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-1-Machine Operating Specifications MV060-E MV075-E Maximum Occupants: Maximum Work Load (Capacity): Standard: 150kg 125kg Extendible: 125kg 100kg Maximum Travel Grade (Grade ability): 15-20% Maximum Travel Grade 5° (Side Slope):(Platform STOWED ONLY)
  • Page 23 OPERATION AND SAFTY MANUAL 3.1 GENERAL IMPORTANT THE MANUFACTURER HAS DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES. This section provides the necessary information needed to understand control function and operation. 3.2 MACHINE DESCRIPTION The Model Lifts are electric self-propelled machines with an aerial work platform mounted to an elevating aluminum mast mechanism.
  • Page 24 OPERATION AND SAFTY MANUAL Figure 3-1. Battery Charger Location. Battery Charger Battery Charger Front Panel 2. ON/OFF switch 3. AC Input Voltage Selector Battery Low Voltage Warning Indicators The Platform Control Console and Ground Control Station indicate battery low voltage at three (3) Warning Levels. Page 23...
  • Page 25 OPERATION AND SAFTY MANUAL Table 3-2. Battery Low Voltage Warning Indicators. IMPORTANT：The 3 Levels of Battery Low Voltage Warning indication will activate on Ground Control Modules and platform control console. Machines must follow the indicator guidelines and battery charging cycles to maximize battery life.
  • Page 26 OPERATION AND SAFTY MANUAL 3. Plug a heavy duty AC extension cord into the Charger AC Input Receptacle on the center rear cover of the machine. Battery Charging Status Indicators The battery charging status indicator is located in the middle of the cover, different status indicate different colors. FULL CHARGED THE INDICATOR IS GREEN COLOR.
  • Page 27 OPERATION AND SAFTY MANUAL Emergency Stop/Shut Down Button POWER OFF POWER ON PUSH IN-To Engage TURN CLOCKWISE and RELEASE-To Reset Emergency Stop Emergency Stop Brake Release Button PUSH and RELEASE-TO DISENGAGE Brakes PUSH and RELEASE AGAIN-TO ENGAGE Brakes NOTE: The brakes only DISENGAGE (electrically) when the joystick control is moved off center during driving or are manually DISENGAGED (electrically) using the Brake Release Button.
  • Page 28 OPERATION AND SAFTY MANUAL Manual Descent Control Valve DRAW-OUT TO LOWER Platform RELEASE TO –STOP Platform Descent ↑ Figure 3-2. Ground Control Station. (Machine Rear View) Machine Status LCD Display Platform Up Hydraulic Oil Reservoir Main Power Selector Switch Platform Down 10.
  • Page 29 OPERATION AND SAFTY MANUAL Machine Status LCD Display At power-up and during operation the LCD display on the Ground Control Module displays the current machine operating status. The following illustration explains the symbol indications. x 00000.0 ↑ xxxxx xxxxx xxxx xxxx xxxx xxxxx LCD Display Symbols 1.
  • Page 30 OPERATION AND SAFTY MANUAL DRIVE Disabled LIFT UP Disabled LIFT DOWN Disabled Both LIFT UP and LIFT DOWN Disabled Drive Speed Cup-Back (Turtle) Mode Engaged (When Platform is Elevated) Battery Charger (AC) Plugged In LCD Display Fault Conditions Table 3-3, LCD Display – Operating Fault Conditions show common LCD display Fault indications which may occur during operation and are usually caused by either an error in machine operation or a work area condition.
  • Page 31 OPERATION AND SAFTY MANUAL Table 3-3. LCD Display – Operating Fault Conditions Fault code Description of fault Conditions to check Battery cable ends loose or corroded at battery posts. Low Battery Voltage Charger DC output wires from charger to batteries damaged or disconnected. Obstruction under Left pothole bar.
  • Page 32 OPERATION AND SAFTY MANUAL Check if the communications cable connections, P5 connector on the Ground Station and the round plug Traction Module-No on the Traction Module are seated properly in their sockets at each end. communication with Check the positive and negative power cable connections from the Ground Station to the Traction Module Ground Module are tight and secure at both ends.
  • Page 33 OPERATION AND SAFTY MANUAL Allows programming of the items shown in Table 3-4, the following is a brief explanation of each programming item. NOTE: There are two production modules available at this time, one for North/South American and European languages, and one for Asian languages. All programmable items between these modules are identical with the exception of language selection.
  • Page 34 OPERATION AND SAFTY MANUAL 1. With machine power OFF, press and hold the Brake Release Button (1) on the Ground Control Station. 2. While holding the Brake Release Button in, power machine up by turning the Main Power Selector Switch (2), to either the Ground Control or Platform Control Mode.
  • Page 35 OPERATION AND SAFTY MANUAL Programming Mode Selection RESET TIMERS PROGRAM ZERO TILT SENSOR 1. Use Platform UP/DOWN buttons (1) to move the selection box (2) up or down to select item to program. 2. Press the Brake Release button (3) to enter selected mode then move on to Selecting Programmable Item to Adjust.
  • Page 36 OPERATION AND SAFTY MANUAL Adjusting Programmable Setting S MINS 1. Adjust the programmable setting using the platform UP/DOWN buttons (1), see Table 3-4 for range of settings for that item. 2. Once parameter is set for the programmable item, press the Brake Release button (2), this will enter the parameter and return you to the Programmable Settings Menu.
  • Page 37 OPERATION AND SAFTY MANUAL 3.7 Driving Machine WARNING WHEN DRIVING WITH PLATFORM LOWERED, DO NOT ATTEMPT TO DRIVE MACHINE UP A RAMP (GRADE) OF GREATER THAN TWENTY PER CENT (20%), AS TIPPING COULD OCCUR. Functions: 1.Lift/Drive shift switch Press left lifting button and the lifting indicator will be flashing, push/pull the joystick to lift/down. Press right drive button and the drive indicator will be flashing, sway the joystick to drive.
  • Page 38 OPERATION AND SAFTY MANUAL 2.Drive speed switch There are five kinds of drive speed you can choose. Press left button to decrease the drive speed and press right button to increase the drive speed. The drive speed indicators will show the current drive speed. 3.Horn Press it when warning.
  • Page 39 OPERATION AND SAFTY MANUAL 3.9 PLATFORM CONFIGURATIONS STANDARD PLATFORM Model Max. Capacity MV060-E 150kg MV075-E 125kg 1. Gullwing Entry Gate 3. Lanyard Attach Point (on mast) 2. Entry Gate Latch 4. Platform Control Console Page 38...
  • Page 40 OPERATION AND SAFTY MANUAL EXTENDIBLE PLATFORM (SLIDING BAR ENTRY ) Model Max. Capacity MV060-E 125kg MV075-E 100kg 1. Platform Control Console 4. Sliding Bar Entry Gate 2. Extension Slide/Lock Handle 5. Sliding Extendible Section 3. Lanyard Attach Point (on mast)
  • Page 41 OPERATION AND SAFTY MANUAL 3.10 FALL PROTECTION – LANYARD ATTACHMENT CAUTION THE MANUFACTURER RECOMMENDS THE OPERATOR IN THE PLATFORM WEAR A FULL BODY HARNESS WITH A LANYARD ATTACHED TO AN AUTHORIZED LANYARD ANCHORAGE POINT. The main lanyard attach point for all machines is located on the lower right side of the mast platform header, just behind the operators platform.
  • Page 42 OPERATION AND SAFTY MANUAL 3.11 QUICK-CHANGE PLATFORM MOUNTING Model Lifts are equipped with quick-change platform mount, which allow quick removal and installation of currently available quick-change platform. NOTE: Models require the installation of the Quick-Change mount kit to use Quick-Chang Platforms. 1.
  • Page 43 OPERATION AND SAFTY MANUAL 3.12 TRANSPORTING, LIFTING AND TIE DOWN PROCEDURES General All Series Model Personnel Lifts may be transported to a work site using the following methods: Driving the machine around on its base wheels if travel surface area permits. ...
  • Page 44 OPERATION AND SAFTY MANUAL Fork-Lift Truck Transport All Model Lifts are equipped with wide forklift pockets running through the base frame. (See Figure 3-11.) This allows the machine to be either transported around a work area or lifted onto a higher level using a standard fork-lift truck. NOTE: Fork-lift trucks must be capable of handling the gross weight of the machine, see the Operating Specifications table at the beginning of this Section.
  • Page 45 OPERATION AND SAFTY MANUAL SECTION 4. EMERGENCY PROCEDURES 4.1 GENERAL INFORMATION This section explains the steps to be taken in case of an emergency situation during operation. 1.2 EMERGENCY OPERATION Operator Unable to Control Machine IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO OPERATE OR CONTROL THE MACHINE: Other personnel should operate the machine from ground controls only as required.
  • Page 46 Service and Maintenance Manual. Other Publications Available Specific to this Machine: Service and Maintenance Manual Illustrated Parts Manual 5.2 GENERAL SPECIFICATIONS Machine Specifications SPECIFICATION MV060-E MV075-E Gross Machine Weight (Platform Empty): 850kg 880kg Machine Height (Platform Stowed):...
  • Page 47 The number of Stored Max. platform Max. working Platform size Rated load persons allowed dimension height height A×B Model on platform L×W×H Person(s) 695×780 MV060-E 6000 7700 1235x780(exte 1360×790×1980 nsion deck) 695×780 MV075-E 7500 9200 1235x780(exte 1360×790×1980 nsion deck) Page 46...
  • Page 48 OPERATION AND SAFTY MANUAL Machine Operating Area Machine Type MV060-E MV075-E 1350 1350 Electrical Specifications SPECIFICATION MV060-E, MV075-E, System Voltage: 24 Volts DC Battery Specifications: Battery Type: Voltage: 12 Volts DC Amp Hour (AH) Rating: 100 Amp Hr. @20Hr. Battery Charger (DC Models) Input: 120/240 Volts AC-50/60 Hz –Voltage Selectable...
  • Page 49 OPERATION AND SAFTY MANUAL Platform Data SPECIFICATION MV060-E MV075-E Occupants: (Persons allowed in Platform) Maximum Work Load Standard: 150kg 125kg (Capacity): Extendible 150kg 125kg Platform Height – Mast Fully Extended – 7.5 m (Ground to Platform Floor): Platform Cycle Performance: Lift Up: 27-36 sec.
  • Page 50 OPERATION AND SAFTY MANUAL Hydraulic Diagram Pump unit 2-Emergency Valve 3-Magnetic valve 4-Pipe 5 Cylinder 6-Throttle Page 49...
  • Page 51 OPERATION AND SAFTY MANUAL Table 5-1. – Lubrication Specifications SPECIFICATIONS MPG- Multipurpose Grease having a minimum dripping point of 350°F. Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.) EPGL- Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or MIL -Spec MIL –L-2105.
  • Page 52 OPERATION AND SAFTY MANUAL Table 5-2. Lubrication Intervals for Various Components INTERVAL NO/TYPE LUBE COMMENTS COMPONENT LUBE/METHOD POINTS MONTHS MONTHS YEARS YEARS HO-Check Hyd. Check fluid level Fill the Oil Level every day. Hydraulic oil √ Reservoir HO-Change Change hydraulic oil Hyd.
  • Page 53 OPERATION AND SAFTY MANUAL SECTION 6. Electrical Schematic Page 52...
  • Page 54 OPERATION AND SAFTY MANUAL SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number: Table 7-1. Inspection and Repair Log Date Comments Page 53...
  • Page 55 OPERATION AND SAFTY MANUAL Table7-1. Inspection and Repair Log Date Comments Page 54...
  • Page 56 OPERATION AND SAFTY MANUAL BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Batteries also contain other harmful chemicals. WASH HANDS AFTER HANDLING! Page 55...

This manual is also suitable for:

Mv075-e