Training Manual

with Repair Information

S0807AC+
S0808AC+
S1008AC+
S1012AC+
S1212AC+
S1412AC+
S1612AC+
S1614AC+

Part Number: SM012430101

Version Number: Rev1.1
September 2024 Printing
 TRAINING MANUAL

Record of Version

Record of Version
Version Number Create Date

SM012430101_Rev1.0……………………………………………………………………………2024-05

SM012430101_Rev1.1 (Update display) ………………………………………………………2024-09

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 TRAINING MANUAL

Contents

Contents
1 Safety Rules ............................................................................................................................. 1
2 Specification ........................................................................................................................... 11
2.1 S0807AC+.......................................................................................................................... 11
2.2 S0808AC+.......................................................................................................................... 12
2.3 S1008AC+.......................................................................................................................... 13
2.4 S1012AC+.......................................................................................................................... 14
2.5 S1212AC+.......................................................................................................................... 15
2.6 S1412AC+.......................................................................................................................... 16
2.7 S1612AC+.......................................................................................................................... 17
2.8 S1614AC+.......................................................................................................................... 18
3 Maintenance ........................................................................................................................... 19
3.1 Checklist A Procedures ..................................................................................................... 22
3.2 Checklist B Procedures ..................................................................................................... 26
3.3 Checklist C Procedures..................................................................................................... 35
3.4 Checklist D Procedures..................................................................................................... 37
3.5 Checklist E Procedures ..................................................................................................... 38
4 Repair ..................................................................................................................................... 40
4.1 Safety ................................................................................................................................ 40
4.2 General Operating Requirements ..................................................................................... 40
4.3 Power Supply .................................................................................................................... 45
4.3.1 Charger ................................................................................................................... 46
4.3.2 Battery ..................................................................................................................... 49
4.3.3 Relays & Contactor ................................................................................................. 51
4.4 Control System .................................................................................................................. 52
4.4.1 Ground Control Panel ............................................................................................. 52
4.4.2 Display .................................................................................................................... 53
4.4.2.1 Information Interface..................................................................................... 53
4.4.2.2 Setting Interface ........................................................................................... 54
4.4.3 Platform Control Panel............................................................................................ 57
4.5 Security Configuration ....................................................................................................... 59
4.5.1 Motor Controller ...................................................................................................... 59
4.5.2 Angle Potentiometer ............................................................................................... 60
4.5.3 Load System ........................................................................................................... 61
4.5.4 Limit Switches ......................................................................................................... 63
4.5.5 Beacon & Buzzers .................................................................................................. 64
4.6 Drive System ..................................................................................................................... 65
4.6.1 Drive Motor ............................................................................................................. 65
4.6.2 Steer Actuator ......................................................................................................... 66
4.7 Lift System......................................................................................................................... 67
4.8 Emergency system............................................................................................................ 68
4.8.1 Emergency Lowering .............................................................................................. 68

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 TRAINING MANUAL

Contents

4.8.2 Brake Release ........................................................................................................ 69

4.8.3 Emergency Steering ............................................................................................... 71
5 Fault Code ............................................................................................................................. 73
5.1 Machine Code ................................................................................................................... 73
5.2 Motor-controller Code ....................................................................................................... 78
5.3 BMS Code ......................................................................................................................... 80
5.4 PCU & Steer Code ............................................................................................................ 82
6 Electrical Schematic .............................................................................................................. 84
6.1 S0807AC+ ......................................................................................................................... 84
6.2 S0808AC+ ~ S1614AC+ .................................................................................................... 85
6.3 Harness ............................................................................................................................. 86
7 Hydraulic Schematic .............................................................................................................. 87

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 TRAINING MANUAL

Safety Rules

1 Safety Rules

Danger Hazard Classification

Failure to obey the instructions and DINGLI product decals use symbols, color
coding and signal words to identify the
safety rules in this manual will following:
result in death or serious injury.
Do Not Operate Unless:
Safety alert symbol — used to alert
√ You learn and practice the principles of personnel to potential personal injury hazards.
safe machine operation contained in this Obey all safety messages that follow this
operator's manual. symbol to avoid possible injury or death.

1 Avoid hazardous situations.

Red — used to indicate the
Know and understand the safety rules
presence of an imminently hazardous situation
before going on to the next section.
which, if not avoided, will result in death or
2 Always perform a pre-operation
serious injury.
inspection.
3 Always perform function tests prior to Orange — used to indicate
use. the presence of a potentially hazardous
4 Inspect the workplace. situation which, if not avoided, could result in
5 Only use the machine as it was death or serious injury.
intended.
Yellow with safety alert
√ You read, understand and obey the
symbol — used to indicate the presence of a
manufacturer's instructions and safety
potentially hazardous situation which, if not
rules — operator's manual and machine
avoided, may cause minor or moderate injury.
decals.

√ You read, understand and obey employer's Blue without safety alert
safety rules and worksite regulations. symbol — used to indicate the presence of a
potentially hazardous situation which, if not
√ You read, understand and obey all avoided, may result in property damage.
applicable governmental regulations.

√ You are properly trained to safely operate

the machine.

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 TRAINING MANUAL

Safety Rules

The relevant conditions of using

the equipment
The surface of work ground should be flat and
hard with no obstacles in air and the safety
distance between the equipment and
high-tension line is adequate.
Maintain safe distances from electrical power
The environment temperature should be within
lines and apparatus in accordance with
-20℃~40℃; Height above sea level ≤1000m.
applicable governmental regulations and the
The environment humidity ≤ 90%. following chart.

Electrical power: AC 110~230V±10%, Minimum Safe

Voltage
50~60Hz. Approach Distance
Phase to Phase
Meters
0 to 300V Avoid Contact
Intended Use
300V to 50kV 3.05
This machine is intended to be used only to lift
50kV to 200kV 4.60
personnel, along with their tools and materials
to an aerial work site. 200kV to 350kV 6.10

Never use in the conditions outside design 350kV to 500kV 7.62

without approval of Dingli.
500kV to 750kV 10.67

750kV to 1000kV 13.72

Safety Sign Maintenance Allow for platform movement, electrical line
Replace any missing or damaged safety signs. sway or sag and beware of strong or gusty
Keep operator safety in mind at all times. winds.

Use mild soap and water to clean safety signs. Keep away from the machine if it contacts
energized power lines. Personnel on the
Do not use solvent-based cleaners because
ground or in the platform must not touch or
they may damage the safety sign material.
operate the machine until energized power
lines are shut off.

Electrocution Hazard Do not operate the machine during lightning or

storms.
This machine is not electrically insulated and
will not provide protection from contact with or Do not use the machine as a ground for
proximity to electrical current. welding.

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 TRAINING MANUAL

Safety Rules

Tip-over Hazard Maximum occupants (Outdoor use) (Option) 1

Occupants, equipment and materials must not Platform allowable maximum load 408kg
exceed the maximum platform capacity or the Extension deck allowable maximum load 113kg
maximum capacity of the platform extension.
Maximum capacity – S1612AC+
Do not overload the work platform
Maximum occupants (Indoor use) 2
Maximum capacity – S0807AC +
Maximum occupants (Outdoor use) (Option) 1
Maximum occupants (Indoor use) 2
Platform allowable maximum load 363kg
Maximum occupants (Outdoor use) 1
Extension deck allowable maximum load 136kg
Platform allowable maximum load 272kg
Maximum capacity – S1614AC+
Extension deck allowable maximum load 113kg
Maximum occupants (Indoor use) 2
Maximum capacity – S0808AC+
Maximum occupants (Outdoor use) (Option) 1
Maximum occupants (Indoor use) 2
Platform allowable maximum load 363kg
Maximum occupants (Outdoor use) 1
Extension deck allowable maximum load 136kg
Platform allowable maximum load 408kg

Extension deck allowable maximum load 113kg

Platform retracted Platform extended
Maximum capacity – S1008AC+

Maximum occupants (Indoor use) 2

Maximum occupants (Outdoor use) (Option) 1

Extension Platform
Platform allowable maximum load 272kg
only only
Extension deck allowable maximum load 113kg
Maximum capacity – S1012AC+
Work Area Safety
Maximum occupants (Indoor / Outdoor use) 2
Do not raise the platform unless the machine
Platform allowable maximum load 450kg is on a firm, level surface.
Extension deck allowable maximum load 113kg Do not drive over maximum speed with the
Maximum capacity – S1212AC+ platform raised. Refer to specifications.

Maximum occupants (Indoor use) 2

Maximum occupants (Outdoor use) 1

Platform allowable maximum load 408kg

Extension deck allowable maximum load 113kg

Maximum capacity – S1412AC+
Do not depend on the tilt alarm as a level
Maximum occupants (Indoor use) 3 indicator. The tilt alarm sounds on the chassis

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 TRAINING MANUAL

Safety Rules

and in the platform when the machine is on a conditions with the platform raised.
slope.
Do not push off or pull toward any object
If the tilt alarm sounds: outside of the platform.
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.
For outdoor use machine, do not raise the
platform when wind speeds may exceed 12.5
m/s. If wind speeds exceed 12.5 m/s when the
platform is raised, lower the platform and do Maximum allowable manual force
not continue to operate the machine. Manual Maximum
Model Application
Do not choose indoor features unless it is used force occupants
indoor and wind speeds = 0 m/s. Outdoor 200N 1
S0807AC+
Do not operate the machine in strong or gusty Indoor 400N 2
winds. Do not increase the surface area of the
Outdoor 200N 1
platform or the load. Increasing the area S0808AC+
exposed to the wind will decrease machine Indoor 400N 2
stability. Outdoor
200N 1
S1008AC+ (Option)
Indoor 400N 2

Outdoor 400N 2
S1012AC+
Indoor 400N 2

Outdoor 200N 1
S1212AC+
Do not use the platform controls to free a Indoor 400N 2
platform that is caught, snagged or otherwise Outdoor
prevented from normal motion by an adjacent 200N 1
S1412AC+ (Option)
structure. All personnel must be removed from
Indoor 400N 3
the platform before attempting to free the
platform using the ground controls. Outdoor
200N 1
S1612AC+ (Option)
Use extreme care and slow speeds while
Indoor 400N 2
driving the machine in the stowed position
across uneven terrain, debris, unstable or Outdoor
200N 1
slippery surfaces and near holes and S1614AC+ (Option)
drop-offs. Indoor 400N 2

Do not drive the machine on or near uneven Never alter the MEWP without Dingli’s written
terrain, unstable surfaces or other hazardous approval.

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 TRAINING MANUAL

Safety Rules

Do not use the machine as a crane. Do not place ladders or scaffolds in the
platform or against any part of this machine.
Do not place or attach fixed or overhanging
loads to any part of this machine. Do not transport tools and materials unless
they are evenly distributed and can be safely
Do not push the machine or other objects with
handled by person(s) in the platform.
the platform.
Do not use the machine on a moving or mobile
Do not operate the machine with the chassis
surface or vehicle.
trays open.
Be sure all tires are in good condition, air-filled
Do not contact adjacent structures with the
tires are properly inflated and lug nuts are
platform.
properly tightened.
Do not alter or disable the limit switches.
Crushing Hazard
Do not tie the platform to adjacent structures. Keep hands and limbs out of scissors.
Do not place loads outside the platform Keep hands clear when folding rails.
perimeter.
Maintain a firm grasp on the platform rail when
removing the rail pins. Do not allow the
platform guard rails to fall.
Use common sense and planning when
operating the machine with the controller from
the ground. Maintain safe distances between
the operator, the machine and fixed objects.

Operation on Slopes Hazard

Do not alter or disable machine components
that in any way affect safety and stability. Do not drive the machine on a slope that
exceeds the slope and side slope rating of the
Do not replace items critical to machine machine.
stability with items of different weight or
specification. Slope rating applies to machines only in the
stowed position.
Do not use batteries that weigh less than the
original equipment. Batteries are used as
counterweight and are critical to machine
stability.

The battery must weigh a minimum of 44 kg.

Maximum slope rating stowed
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.
Maximum side slope rating stowed

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 TRAINING MANUAL

Safety Rules

Close the entry gate before operating.

Model A B
Do not operate the machine unless the guard
S0807AC+ 25% (14°) 25% (14°) rails are properly installed and the entry is
S0808AC+ 25% (14°) 25% (14°) secured for operation.

Do not enter or exit the platform unless the

S1008AC+ 25% (14°) 25% (14°)
machine is in the stowed position.
S1012AC+ 25% (14°) 25% (14°) Do not get on and off the work platform when
elevated.
S1212AC+ 25% (14°) 25% (14°)
Be careful when traveling.
S1412AC+ 25% (14°) 25% (14°)
Collision Hazard
S1612AC+ 25% (14°) 25% (14°)

S1614AC+ 25% (14°) 25% (14°)

Note: Slope rating is subject to ground

conditions and adequate traction.
Be aware of limited sight distance and blind
Fall Hazard
spots when driving or operating.
The guard rail system provides fall protection.
Be aware of extended platform position(s)
If occupant(s) of the platform are required to
when moving the machine.
wear personal fall protection equipment (PFPE)
due to job site or employer rules, PFPE Check the work area for overhead obstructions
equipment and its use shall be in accordance or other possible hazards.
with the PFPE manufacturer’s instructions and
applicable governmental requirements. Attach
the lanyard to the anchor provided in the
platform.
Do not sit, stand or climb on the platform guard
rails. Maintain a firm footing on the platform
floor at all times.
Be aware of crushing hazards when grasping
the platform guard rail.

Operators must comply with employer, job site

and governmental rules regarding use of
personal protective equipment.

Observe and use color-coded direction arrows

on the platform controls for drive and steer
Do not climb down from the platform when functions.
raised.
Do not operate a machine in the path of any
Keep the platform floor clear of debris. crane or moving overhead machinery unless

6
 TRAINING MANUAL

Safety Rules

the controls of the crane have been locked out When charging the machine, please choose
and/or precautions have been taken to prevent an open and ventilated place, and avoid
any potential collision. charging the machine in a narrow crowded and
cluttered environment.
No stunt driving or horseplay while operating a
machine. It is forbidden to store anything in the cabin,
which would result in high temperature
Do not lower the platform unless the area
spontaneous combustion or short circuit and
below is clear of personnel and obstructions.
then fire as a disaster.

Limit travel speed according to the condition of

the ground surface, congestion, slope, location
of personnel, and any other factors which may
cause collision.

Component Damage Hazard

Do not use any battery charger greater than
33V to charge the batteries.
Damaged Machine Hazard
The charger must match the battery. The
Do not use a damaged or malfunctioning
lithium battery cannot by the lead-acid battery
machine.
charger. The lead-acid battery cannot by the
lithium battery charger. Conduct a thorough pre-operation inspection
of the machine and test all functions before
Do not use the machine as a ground for each work shift. Immediately tag and remove
welding. from service a damaged or malfunctioning
Do not replace or modify the recharge plug (if machine.
equipped) and other electric connectors Be sure all maintenance has been performed
without written authorization from Dingli. as specified in this manual.
Be sure all decals are in place and legible.
Explosion and Fire Hazard Be sure the operator’s manual is complete,
legible and in the storage container located in
Do not operate the machine or charge the the platform.
batteries in hazardous locations where
potentially flammable or explosive gases or
particles may be present.

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 TRAINING MANUAL

Safety Rules

Modification to the intended acid with plenty of water.

use If the lithium battery local fire, can be buried in

sand, such as hot gas, it needs a lot of water
In the event of any special working methods or foam to cool treatment.
conditions which are outside those specified
by the “intended use”, you shall obtain the Explosion Hazard
guidance and approval of the manufacturer.

National traffic regulations

Follow your national traffic regulations.

Bodily Injury Hazard Keep sparks, flames and lighted tobacco away
Do not operate the machine with a hydraulic oil from batteries. Batteries emit explosive gas.
or air leak. An air leak or hydraulic leak can Avoid fire and risk of explosion caused by
penetrate and/or burn skin. short circuits.
Improper contact with components under any
The battery tray should remain open during the
cover will cause serious injury. Only trained
entire charging cycle.
maintenance personnel should access
compartments. Access by the operator is only Do not contact the battery terminals or the
advised when performing a pre-operation cable clamps with tools that may cause
inspection. All compartments must remain sparks.
closed and secured during operation. Component Damage Hazard
Battery Safety Do not use any battery charger greater than
Burn Hazard 33V to charge the batteries.
The charger must match the battery. The
lithium battery cannot by the lead-acid battery
charger. The lead-acid battery cannot by the
lithium battery charger.
Pressure relief valves are used as breathable
Batteries contain acid. Always wear protective plugs. If open the pressure relief valves, the
clothing and eye wear when working with battery will be destroyed.
batteries.
The battery must always be kept clean and dry
Avoid spilling or contacting battery acid. in order to prevent leakage currents. Do not
Neutralize battery acid spills with baking soda rinse with water or wipe with a wet towel.
and water.
Please do not change the location of the
Rinse eyes or skin splashed with acid using battery, and cannot be inverted. Do not block
plenty of clean water and consult a doctor the vent hole of safety valve when placing.
immediately. Wash clothing contaminated with

8
 TRAINING MANUAL

Safety Rules

Do not attempt to open or modify the battery in Environmental Hazard

any way.
30°C battery temperature is considered the
The series/parallel connection must be rated temperature. Higher temperatures
approved by Dingli. Only accessories reduce the service life, while lower
approved by Dingli can be used for connection temperatures reduce the available
of battery blocks. capacity.45°C is the upper limit temperature
Electrocution/ Burn Hazard and is not permissible as an operating
temperature.
Connect the battery charger to
a grounded, AC 3-wire The rated temperature range of lithium battery
electrical outlet only. is-30℃～55℃.if it is found that the
temperature of the battery exceeds 60℃
Inspect daily for damaged
cords, cables and wires. during use, the battery should be stopped
Replace damaged items before operating. immediately and put aside separately.

Metallic parts of the battery cells are always Batteries must not be exposed to sunlight
electriferous. Therefore, no foreign objects or without protection.
tools may be placed on the batteries. Transportation and storage
Avoid electrical shock from contact with Hazard
battery terminals. Remove all rings, watches
Charge the battery as soon as receive the
and other jewelry.
machine or after long distance transportation
If the battery terminal is to be touched, it
When the battery is stored for a long time, it
should be operated with insulating gloves to
needs to be charged regularly. Failure to
prevent the risk of high voltage electric shock.
charge in time may permanently damage the
Tip-over Hazard battery.
Do not use batteries that weigh less than the pollute Hazard
original equipment. Batteries are used as
counterweight and are critical to machine
stability.

The battery must weigh a minimum of 44 kg.

Lifting Hazard
Old batteries with this marking are recyclable
Use the appropriate number of people and goods and must be sent for recycling.
proper lifting techniques when lifting hooks
must not cause any damage to cells, Used batteries which are not sent for recycling
connectors and connecting cables. are to be disposed of as special waste under
the relevant regulations.
The lithium battery shall be operated smoothly
in the process of handling and assembly, and
collision and other impact phenomena are
strictly prohibited.

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TRAINING MANUAL

Safety Rules

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 Push in the red Emergency Stop buttons to
“off” position.

5 Push in the main power switch to “off”

position
6 Chock the wheels.

7 Charge the batteries.

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 TRAINING MANUAL

Specification

2 Specification
2.1 S0807AC+
Height, working maximum 7.8 m Tire size Φ323×100 mm

Height, platform maximum 5.8 m Airborne noise emissions <70 dB

Height, stowed maximum Maximum sound level at normal operating

2.15 m
Rails up workstations (A-weighted)
Height, stowed maximum Vibration value does not exceed 2.5m/s2
1.83 m
Rails folded
Maximum slope rating,
Width 0.76 m 25% (14°)
Stowed position

Length, platform retracted 1.86 m Maximum side slope rating,

25% (14°)
Stowed position
Length, platform extended 2.76 m
Note: Slope rating is subject to ground
Platform dimensions conditions and adequate traction.
1.67×0.74 m
(length × width)
Maximum working X-1.5°(side to side)
Platform extension length 0.9 m slope Y-3°(front to rear)

Maximum load capacity 272 kg Drive speeds

Maximum wind speed 12.5 m/s Stowed, maximum 5.5 km/h

Wheelbase 1.36 m Platform raised, maximum 0.6 km/h

Turning radius (outside) 1.64 m Floor loading information

Turning radius (inside) 0m Tire load, maximum 710 kg

Ground clearance 9 cm 10.4 kg/cm2

Tire contact pressure
1019 kPa
Ground clearance
1.6 cm 1373 kg/m2
Pothole guards deployed Occupied floor pressure
13.5 kPa
Weight (See Serial Label)
Note: Floor loading information is approximate
Machine weights vary with option configurations and does not incorporate different option
configurations. It should be used only with
Controls Proportional adequate safety factors.

AC outlet in platform Standard Continuous improvement of our products is a

DINGLI policy. Product specifications are
Maximum hydraulic pressure
180 bar subject to change without notice or obligation.
(functions)

System voltage 28 V

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 TRAINING MANUAL

Specification

2.2 S0808AC+
Height, working maximum 8m Tire size Φ381×127 mm

Height, platform maximum 6m Airborne noise emissions <70 dB

Height, stowed maximum Maximum sound level at normal operating

2.23 m workstations (A-weighted)
Rails up
Height, stowed maximum Vibration value does not exceed 2.5m/s2
1.77 m
Rails folded
Maximum slope rating,
25% (14°)
Width 0.83 m Stowed position

Length, platform retracted 2.48 m Maximum side slope rating,

25% (14°)
Stowed position
Length, platform extended 3.38 m
Note: Slope rating is subject to ground
Platform dimensions conditions and adequate traction.
2.27×0.81 m
(length × width)
Maximum working X-1.5°(side to side)
Platform extension length 0.9 m slope Y-3°(front to rear)

Maximum load capacity 408 kg Drive speeds

Maximum wind speed 12.5 m/s Stowed, maximum 6.0 km/h

Wheelbase 1.87 m Platform raised, maximum 0.8 km/h

Turning radius (outside) 2.1 m Floor loading information

Turning radius (inside) 0m Tire load, maximum 1000 kg

Ground clearance 10 cm 11.3 kg/cm2

Tire contact pressure
1104.6 kPa
Ground clearance
1.9 cm 1360.7 kg/m2
Pothole guards deployed Occupied floor pressure
13.3 kPa
Weight (See Serial Label)
Note: Floor loading information is approximate
Machine weights vary with option configurations and does not incorporate different option
configurations. It should be used only with
Controls Proportional adequate safety factors.

AC outlet in platform Standard Continuous improvement of our products is a

DINGLI policy. Product specifications are
Maximum hydraulic pressure subject to change without notice or obligation.
220 bar
(functions)

System voltage 28 V

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 TRAINING MANUAL

Specification

2.3 S1008AC+
Height, working maximum 10 m Maximum hydraulic pressure
220 bar
(functions)
Height, platform maximum 8m
System voltage 28 V
Height, working maximum
8.1 m Tire size Φ381×127 mm
(Outdoor) (Option)
Height, platform maximum Airborne noise emissions <70 dB
6.1 m
(Outdoor) (Option) Maximum sound level at normal operating
Height, stowed maximum workstations (A-weighted)
2.36 m
Rails up
Vibration value does not exceed 2.5m/s2
Height, stowed maximum
1.9 m Maximum slope rating,
Rails folded 25% (14°)
Stowed position
Width 0.83 m
Maximum side slope rating,
25% (14°)
Length, platform retracted 2.48 m Stowed position

Length, platform extended 3.38 m Note: Slope rating is subject to ground

conditions and adequate traction.
Platform dimensions
2.27×0.81 m Maximum working X-1.5°(side to side)
(length × width)
slope Y-3°(front to rear)
Platform extension length 0.9 m
Drive speeds
Maximum load capacity 272 kg
Stowed, maximum 6.0 km/h
Maximum wind speed 0 m/s
Platform raised, maximum 0.8 km/h
Maximum wind speed (Option) 12.5 m/s
Floor loading information
Wheelbase 1.87 m
Tire load, maximum 960 kg
Turning radius (outside) 2.1 m
10.8 kg/cm2
Turning radius (inside) 0m Tire contact pressure
1062.7 kPa
Ground clearance 10 cm 1309.1 kg/m2
Occupied floor pressure
12.8 kPa
Ground clearance
1.9 cm
Pothole guards deployed Note: Floor loading information is approximate
and does not incorporate different option
Weight (See Serial Label) configurations. It should be used only with
adequate safety factors.
Machine weights vary with option configurations

Controls Proportional Continuous improvement of our products is a

DINGLI policy. Product specifications are
AC outlet in platform Standard subject to change without notice or obligation.

13
 TRAINING MANUAL

Specification

2.4 S1012AC+
Height, working maximum 10 m Tire size Φ381×127 mm

Height, platform maximum 8m Airborne noise emissions <70 dB

Height, stowed maximum Maximum sound level at normal operating

2.36 m workstations (A-weighted)
Rails up
Height, stowed maximum Vibration value does not exceed 2.5m/s2
1.83 m
Rails folded
Maximum slope rating,
25% (14°)
Width 1.15 m Stowed position

Length, platform retracted 2.48 m Maximum side slope rating,

25% (14°)
Stowed position
Length, platform extended 3.38 m
Note: Slope rating is subject to ground
Platform dimensions conditions and adequate traction.
2.27×1.12 m
(length × width)
Maximum working X-1.5°(side to side)
Platform extension length 0.9 m slope Y-3°(front to rear)

Maximum load capacity 450 kg Drive speeds

Maximum wind speed 12.5 m/s Stowed, maximum 6.0 km/h

Wheelbase 1.87 m Platform raised, maximum 0.8 km/h

Turning radius (outside) 2.2 m Floor loading information

Turning radius (inside) 0m Tire load, maximum 1240 kg

Ground clearance 10 cm 12.2 kg/cm2

Tire contact pressure
1198 kPa
Ground clearance
1.9 cm 1189.4 kg/m2
Pothole guards deployed Occupied floor pressure
11.7 kPa
Weight (See Serial Label)
Note: Floor loading information is approximate
Machine weights vary with option configurations and does not incorporate different option
configurations. It should be used only with
Controls Proportional adequate safety factors.

AC outlet in platform Standard Continuous improvement of our products is a

DINGLI policy. Product specifications are
Maximum hydraulic pressure subject to change without notice or obligation.
220 bar
(functions)

System voltage 28 V

14
 TRAINING MANUAL

Specification

2.5 S1212AC+
Height, working maximum 12 m Tire size Φ381×127 mm

Height, platform maximum 10 m Airborne noise emissions <70 dB

Height, stowed maximum Maximum sound level at normal operating

2.49 m workstations (A-weighted)
Rails up
Height, stowed maximum Vibration value does not exceed 2.5m/s2
1.96 m
Rails folded
Maximum slope rating,
25% (14°)
Width 1.15 m Stowed position

Length, platform retracted 2.48 m Maximum side slope rating,

25% (14°)
Stowed position
Length, platform extended 3.38 m
Note: Slope rating is subject to ground
Platform dimensions conditions and adequate traction.
2.27×1.12 m
(length × width)
Maximum working X-1.5°(side to side)
Platform extension length 0.9 m slope Y-3°(front to rear)

Maximum load capacity 408 kg Drive speeds

Maximum wind speed 12.5 m/s Stowed, maximum 6.0 km/h

Wheelbase 1.87 m Platform raised, maximum 0.8 km/h

Turning radius (outside) 2.2 m Floor loading information

Turning radius (inside) 0m Tire load, maximum 1310 kg

Ground clearance 10 cm 12.9 kg/cm2

Tire contact pressure
1267.4 kPa
Ground clearance
1.9 cm 1258.4 kg/m2
Pothole guards deployed Occupied floor pressure
12.3 kPa
Weight (See Serial Label)
Note: Floor loading information is approximate
Machine weights vary with option configurations and does not incorporate different option
configurations. It should be used only with
Controls Proportional adequate safety factors.

AC outlet in platform Standard Continuous improvement of our products is a

DINGLI policy. Product specifications are
Maximum hydraulic pressure subject to change without notice or obligation.
220 bar
(functions)

System voltage 28 V

15
 TRAINING MANUAL

Specification

2.6 S1412AC+
Height, working maximum 13.8 m AC outlet in platform Standard

Height, platform maximum 11.8 m Maximum hydraulic pressure

220 bar
(functions)
Height, working maximum
10.5 m System voltage 28 V
(Outdoor) (Option)
Height, platform maximum Tire size Φ381×127 mm
8.5 m
(Outdoor) (Option)
Airborne noise emissions <70 dB
Height, stowed maximum
2.62 m Maximum sound level at normal operating
Rails up
workstations (A-weighted)
Height, stowed maximum
2.09 m Vibration value does not exceed 2.5m/s2
Rails folded

Width 1.19 m Maximum slope rating,

25% (14°)
Stowed position
Length, platform retracted 2.48 m
Maximum side slope rating,
25% (14°)
Length, platform extended 3.38 m Stowed position

Platform dimensions Note: Slope rating is subject to ground

2.27×1.12 m conditions and adequate traction.
(length × width)

Platform extension length 0.9 m Maximum working X-1.5°(side to side)

slope Y-3°(front to rear)
Maximum load capacity 408 kg
Drive speeds
Maximum wind speed 0 m/s
Stowed, maximum 6.0 km/h
Maximum wind speed
12.5 m/s Platform raised, maximum 0.8 km/h
(Option)

Wheelbase 1.87 m Floor loading information

Turning radius (outside) 2.2 m Tire load, maximum 1280 kg

Turning radius (inside) 0m 11.2 kg/cm2

Tire contact pressure
1097.5 kPa
Ground clearance 10 cm
1184.6 kg/m2
Ground clearance Occupied floor pressure
1.9 cm 11.6 kPa
Pothole guards deployed
Note: Floor loading information is approximate
Weight (See Serial Label) and does not incorporate different option
configurations. It should be used only with
Machine weights vary with option configurations adequate safety factors.
Controls Proportional
Continuous improvement of our products is a
DINGLI policy. Product specifications are
subject to change without notice or obligation.

16
 TRAINING MANUAL

Specification

2.7 S1612AC+
Height, working maximum 15.7 m AC outlet in platform Standard

Height, platform maximum 13.7 m Maximum hydraulic pressure

220 bar
(functions)
Height, working maximum
9.0 m System voltage 28 V
(Outdoor) (Option)
Height, platform maximum Tire size Φ381×127 mm
7.0 m
(Outdoor) (Option)
Airborne noise emissions <70 dB
Height, stowed maximum
2.62 m Maximum sound level at normal operating
Rails up
workstations (A-weighted)
Height, stowed maximum
2.09 m Vibration value does not exceed 2.5m/s2
Rails folded

Width 1.25 m Maximum slope rating,

25% (14°)
Stowed position
Length, platform retracted 2.84 m
Maximum side slope rating,
25% (14°)
Length, platform extended 3.74 m Stowed position

Platform dimensions Note: Slope rating is subject to ground

2.64×1.12 m conditions and adequate traction.
(length × width)

Platform extension length 0.9 m Maximum working X-1.5°(side to side)

slope Y-3°(front to rear)
Maximum load capacity 363 kg
Drive speeds
Maximum wind speed 0 m/s
Stowed, maximum 6.0 km/h
Maximum wind speed
12.5 m/s Platform raised, maximum 0.8 km/h
(Option)

Wheelbase 2.24 m Floor loading information

Turning radius (outside) 2.65 m Tire load, maximum 1350 kg

Turning radius (inside) 0m 11.8 kg/cm2

Tire contact pressure
1159.2 kPa
Ground clearance 10 cm
1028.4 kg/m2
Ground clearance Occupied floor pressure
1.9 cm 10.1 kPa
Pothole guards deployed
Note: Floor loading information is approximate
Weight (See Serial Label) and does not incorporate different option
configurations. It should be used only with
Machine weights vary with option configurations adequate safety factors.
Controls Proportional
Continuous improvement of our products is a
DINGLI policy. Product specifications are
subject to change without notice or obligation.

17
 TRAINING MANUAL

Specification

2.8 S1614AC+
Height, working maximum Maximum hydraulic pressure
15.7 m 220 bar
(Indoor) (functions)

Height, platform maximum System voltage 28 V

13.7 m
(Indoor) Tire size Φ381×127 mm
Height, working maximum Airborne noise emissions <70 dB
11.0 m
(Outdoor) (Option)
Maximum sound level at normal operating
Height, platform maximum workstations (A-weighted)
9.0 m
(Outdoor) (Option) Vibration value does not exceed 2.5m/s2
Height, stowed maximum
2.62 m Maximum slope rating,
Rails up 25% (14°)
Stowed position
Height, stowed maximum
2.09 m Maximum side slope rating,
Rails folded 25% (14°)
Stowed position
Width 1.39 m
Note: Slope rating is subject to ground
Length, platform retracted 2.84 m conditions and adequate traction.

Length, platform extended 3.74 m Maximum working X-1.5°(side to side)

slope Y-3°(front to rear)
Platform dimensions
2.64×1.12 m Drive speeds
(length × width)
Platform extension length 0.9 m Stowed, maximum 6.0 km/h

Maximum load capacity 363 kg Platform raised, maximum 0.8 km/h

Maximum wind speed 0 m/s Floor loading information

Maximum wind speed (Option) 12.5 m/s Tire load, maximum 1420 kg

Wheelbase 2.24 m 12.4 kg/cm2

Tire contact pressure
1216.5 kPa
Turning radius (outside) 2.70 m
966.6 kg/m2
Turning radius (inside) 0m Occupied floor pressure
9.5 kPa
Ground clearance 10 cm Note: Floor loading information is approximate
Ground clearance and does not incorporate different option
1.9 cm configurations. It should be used only with
Pothole guards deployed
adequate safety factors.
Weight (See Serial Label)
Continuous improvement of our products is a
Machine weights vary with option configurations
DINGLI policy. Product specifications are
Controls Proportional subject to change without notice or obligation.
AC outlet in platform Standard

18
 TRAINING MANUAL

Maintenance

3 Maintenance

Observe and Obey: Indicates that dealer service will be

required to perform this procedure.
√ Only routine maintenance items specified in
this manual shall be performed by the
operator. Pre-delivery Preparation Report
√ Scheduled maintenance inspections shall The pre-delivery preparation report contains
be completed by qualified service checklists for each type of scheduled
technicians, according to the inspection.
manufacturer's specifications and the
Make copies of the Pre-delivery Preparation
requirements specified in this manual.
report to use for each inspection. Store
√ Before maintaining the machine, the completed forms as required.
workers must wear the personnel
protective equipment such as gloves,
safety shoes, safety cap and so on. Maintenance Schedule
√ Need to comply with local national laws and There are five types of maintenance
regulations of regular inspection and inspections that must be performed according
inspection frequency requirements. to a schedule— daily, quarterly, semi-annually,
annually, and two year. The Scheduled
Maintenance Symbols Legend Maintenance Procedures Section and the
Maintenance Inspection Report have been
The following symbols have divided into five subsections—A, B, C, D, and
been used in this manual to help communicate E. Use the following chart to determine which
the intent of the instructions. When one or group(s) of procedures are required to perform
more of the symbols appear at the beginning a scheduled inspection.
of a maintenance procedure, it conveys the
meaning below. Inspection Checklist
Daily or every 8 hours A
Indicates that tools will be required to Quarterly or every 250 hours A+B
perform this procedure.
Semi-annually or every 500 hours A+B+C

Indicates that new parts will be required Annually or every 1000 hours A+B+C+D
to perform this procedure. Two year or every 2000 hours A+B+C+D+E

19
 TRAINING MANUAL

Maintenance

Maintenance Inspection Report Use this form to record the results. Place a
check in the appropriate box after each part is
The maintenance inspection report contains completed. Follow the instructions in the
checklists for each type of scheduled operator’s manual.
inspection.
If any inspection receives an N, remove the
Make copies of the Maintenance Inspection machine from service, repair and re-inspect it.
Report to use for each inspection. Maintain After repair, place a check in the R box.
completed forms for a minimum of 4 years or
in compliance with your employer, jobsite and
governmental regulations and requirements.
Legend
Y = yes, completed
Pre-delivery Preparation Report N = no, unable to complete
R = repaired
Fundamentals
Comments
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 Pre-Delivery Preparation Y N R
designed to discover if anything is apparently Pre-operation inspection
wrong with a machine before it is put into completed
service. Maintenance items
A damaged or modified machine must never completed
be used. If damage or any variation from Function tests completed
factory delivered condition is discovered, the
machine must be tagged and removed from
service.
Model
Repairs to the machine may only be made by
Serial number
a qualified service technician, according to the
manufacturer’s specifications. Date
Scheduled maintenance inspections shall be Machine owner
performed by qualified service technicians,
according to the manufacturer’s specifications Inspected by (print)
and the requirements listed in this manual. Inspector signature
Instructions Inspector title
Use the operator’s manual on your machine.
Inspector company
The Pre-delivery Preparation consists of
completing the Pre-operation Inspection, the
Maintenance items and the Function Tests.

20
 TRAINING MANUAL

Maintenance

Maintenance Inspection Report

Model Checklist A Y N R
Serial number A-1 Inspect the manuals and decals
Date A-2 Pre-operation inspection
Hour meter A-3 Check the Batteries
Machine owner A-4 Check the Hydraulic Oil Level
Inspected by (print) A-5 Function tests
Inspector signature A-6 Lanyard anchorage point
Inspector title Perform after 40 hours:
Inspector company A-7 30 day service
Instructions Checklist B Y N R
• Make copies of this report to use for each B-1 Batteries
inspection. B-2 Electrical wiring
• Select the appropriate checklist(s) for the B-3 Tires and wheels
type of inspection to be performed.
B-4 Emergency stop
□ Daily or 8 hours Inspection: A B-5 Key switch
Quarterly or 250 hours B-6 Horn (if equipped)
□ A+B
Inspection:
Semi-annually or 500 B-7 Drive brakes
□ A+B+C
hours Inspection: B-8 Drive speed - stowed
Annually or 1000 hours B-9 Drive speed - raised
□ A+B+C+D
Inspection:
Two year or 2000 hours B-10 Hydraulic oil analysis
□ A+B+C+D+E
Inspection: B-11 Tank venting system
• Place a check in the appropriate box after B-12 Latch components
each inspection procedure is completed.
B-13 Test the pothole limit switches
• Use the step-by-step procedures in this and the level Sensor
section to learn how to perform these Checklist C Y N R
inspections.
C-1 Platform overload (if equipped)
• If any inspection receives an “N”, tag and
C-2 Breather cap - models with
remove the machine from service, repair and optional oil
re-inspect it. After repair, place a check in the
Checklist D Y N R
“R’ box.
D-1 Scissor arm wear pads
Legend
D-2 Hydraulic filter
Y = yes, acceptable
N = no, remove from service Checklist E Y N R
R = repaired E-1 Hydraulic oil

21
 TRAINING MANUAL

Maintenance

3.1 Checklist A Procedures

A-1
Inspect the Manuals and Decals
3 Open the operator’s manual to the decals
Maintaining the operator’s manual in good
inspection section. Carefully and
condition is essential to safe machine
thoroughly inspect all decals on the
operation. Manuals are included with each
machine for legibility and damage.
machine and should be stored in the container
provided in the platform. An illegible or missing ⊙ Result: The machine is equipped with all
manual will not provide safety and operational required decals, and all decals are legible
information necessary for a safe operating and in good condition.
condition.
¤ Result: The machine is not equipped with
In addition, maintaining all of the safety and all required decals, or one or more decals
instructional decals in good condition is are illegible or in poor condition. Remove
mandatory for safe machine operation. Decals the machine from service until the decals
alert operators and personnel to the many are replaced.
possible hazards associated with using this
machine. They also provide users with 4 Always return the manual to the storage
operation and maintenance information. An container after use.
illegible decal will fail to alert personnel of a Note: Contact your authorized DINGLI
procedure or hazard and could result in unsafe distributor or DINGLI machinery if replacement
operating conditions. manuals or decals are needed.
1 Check to make sure that the operator’s
manual is present and complete in the
storage container on the platform.
2 Examine the pages of manual to be sure
that they are legible and in good condition.

⊙ Result: The operator’s 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 the
manual is replaced.

22
 TRAINING MANUAL

Maintenance

A-2 A-3
Perform Pre-operation Inspection Check the Batteries
Completing a Pre-operation Inspection is
essential to safe machine operation. The
Pre-operation Inspection is a visual inspection Proper battery condition is essential to good
performed by the operator prior to each work machine performance and operational safety.
shift. The inspection is designed to discover if Improper fluid levels or damaged cables and
anything is apparently wrong with a machine connections can result in component damage
before the operator performs the function tests. and hazardous conditions.
The Pre-operation Inspection also serves to
Note: This check is not required for machines
determine if routine maintenance procedures
with lithium batteries, sealed batteries, or
are required.
Maintenance - free batteries.
Complete information to perform this
procedure is available in the appropriate Electrocution hazard.
operator’s manual. Refer to the operator’s Contact with hot or live circuits may result in
manual on your machine. death or serious injury. Remove all rings,
watches and other jewelry.

Bodily injury hazard.

Batteries contain acid. Avoid spilling or
contacting battery acid. Neutralize battery acid
spills with baking soda and water.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections
are tight and free of corrosion.

3 Be sure that the battery hold-down bars

are secure.

4 Remove the battery vent caps.

5 Check the battery acid level. If needed,

replenish with distilled water to the bottom
of the battery fill tube. Do not overfill.

6 Install the vent caps.

Note: Adding terminal protectors and a

corrosion preventative sealant will help
eliminate corrosion on the battery terminals
and cables.

23
 TRAINING MANUAL

Maintenance

A-4 A-5
Check the Hydraulic Oil Level Perform Function Tests
Completing the function tests is essential to
safe machine operation. Function tests are
Maintaining the hydraulic oil at the proper level designed to discover any malfunctions before
is essential to machine operation. Improper the machine is put into service. A
hydraulic oil levels can damage hydraulic malfunctioning machine must never be used. If
components. Daily checks allow the inspector malfunctions are discovered, the machine
to identify changes in oil level that might must be tagged and removed from service.
indicate the presence of hydraulic system Complete information to perform this
problems. procedure is available in the appropriate
operator’s manual. Refer to the operator’s
Perform this procedure manual on your machine.
with the platform in the stowed position.
1 Visually inspect the sight of hydraulic oil
level from the side of the hydraulic oil tank.

⊙ Result: The hydraulic oil level should be at

the mark of the fuel tank. (Refer to the
following table).

Model Scale line(L)

S0807AC+ 5.5
S0808AC+
S1008AC+ 15
S1012AC+
S1212AC+
17.5
S1412AC+
S1612AC+
19
S1614AC+
2 Add oil if necessary. Do not overfill.

Original Hydraulic oil

specifications：L-HV46

Customers shall choose the appropriate

hydraulic oil according to the ambient
temperature used.

Example: L-HV32 or L-HV68

24
 TRAINING MANUAL

Maintenance

A-6 A-7
Check Lanyard anchorage point Perform 30 Day Service
The lanyard anchorage point is the key
component of the high-altitude operation
safety system, which is directly related to the The 30 day maintenance procedure is a one
personal safety of the operator. Therefore the time procedure to be performed after the first
regular inspection and maintenance of the 30 days or 40 hours of usage. After this
Lanyard anchorage point are particularly interval, refer to the maintenance tables for
important. continued scheduled maintenance.
Before each use, the comprehensive Perform the following maintenance
inspection of the anchorage points belt should procedures:
be carried out to ensure that there are no
• B-3 Inspect the Tires, Wheels and Castle
cracks or de-welding phenomena in the welds,
Nut Torque
and no cracks or deformations in the structural
components. Ensure the labels are clear and
complete, attach only one lanyard per lanyard
anchorage point.
If signs of damage are found at the anchorage
points, it should be stopped immediately, and
can only be used after the repair is qualified.

25
 TRAINING MANUAL

Maintenance

connection. If there is any, compressed air

3.2 Checklist B Procedures
should be used to clean it.
B-1 6 Make sure the battery is reliable and stable
Inspect the Batteries 7 The battery pack should not be cracked,
bulging, deformed, pole loose and other
abnormal conditions.
DINGLI requires that this procedure be 8 Battery voltage, temperature and other
performed every 250 hours or quarterly, states should also be checked before use
whichever comes first. to ensure that all values are within the
Proper battery condition is essential to good normal range before starting up for use.
machine performance and operational safety.
9 It is forbidden to use the battery over
Improper fluid levels or damaged cables and
discharge to ensure that the cell voltage of
connections can result in component damage
the unit is not lower than 2V.
and hazardous conditions.
All models:
Electrocution / burn hazard.
10 Check each battery pack and verify that
Contact with electrically charged circuits could
the batteries are wired correctly.
result in death or serious injury. Remove all
rings, watches and other jewelry. 11 Inspect the battery charger plug and pigtail
for damage or excessive insulation wear.
Bodily injury hazard. Replace as required.
Batteries contain acid. Avoid spilling or
12 Connect the battery charger to a properly
contacting battery acid. Neutralize battery acid
grounded 110 - 230V / 50 – 60 Hz single
spills with baking soda and water.
phase AC power supply.
1 Put on protective clothing and eye wear.
⊙ Result: The charger should operate and
2 Release the battery pack latch and rotate
the battery pack out and away from the begin charging the batteries.
chassis. ¤ Result: If, simultaneously, the charger alarm
3 Be sure that the battery cable connections sounds and the LEDs blink, correct the
are free of corrosion. charger connections at the fuse and battery.
Note: Adding terminal protectors and a The charger will then operate correctly and
corrosion preventative sealant will help begin charging the batteries.
eliminate corrosion on the battery terminals Note: For best results, use an extension of
and cables. adequate size with a length no longer than
4 Be sure that the battery retainers and 15m.
cable connections are tight.
The following must be measured and recorded
Suitable for lithium batteries once the battery has been fully charged, after
5 The connection between the electrode and a waiting time of at least 12 hours:
the data should be fastened. There should - Total voltage
be no dirt, metal dust or other dirt at the
- Individual voltage of the block battery

26
 TRAINING MANUAL

Maintenance

If significant changes to previous the ground red Emergency Stop button

measurements or differences between the clockwise to the on position. Pull out the
block batteries are identified, then customer platform red Emergency Stop button to the
service must be contacted for further testing or on position.
repairs.
4 Raise the platform until the distance of the
Note: If you have any further questions two sets of scissor at least 0.5m.
regarding the battery charger operation,
5 Lift the safety arm, move it to the center of
please contact the DINGLI Service
the scissor arm and rotate up to a vertical
Department.
position.
B-2 6 Lift the upper safety arm, move it to the
Inspect the Electrical Wiring center of the scissor arm and rotate down
to a vertical position. (for S1412AC+、
S1612AC+、S1614AC+).

DINGLI requires that this procedure be 7 Lower the platform until the safety arm
performed every 250 hours or quarterly, rests securely on the link. Keep clear of
whichever comes first. the safety arm when lowering the platform.

Maintaining electrical wiring in good condition Crushing hazard. Keep

is essential to safe operation and good hands clear of the safety arm when lowering
machine performance. Failure to find and the platform.
replace burnt, chafed, corroded or pinched
wires could result in unsafe operating 8 Inspect the center chassis area and
conditions and may cause component scissor arms for burnt, chafed and pinched
damage. cables.

9 Inspect the following areas for burnt,

Electrocution / burn hazard. chafed, corroded, pinched and loose
Contact with electrically charged circuits could wires:
result in death or serious injury. Remove all
rings, watches and other jewelry. • Scissor arms
• ECU to platform controls
1 Inspect the underside of the chassis for
• Power to platform wiring
damaged or missing ground strap(s).

2 Inspect the following areas for burnt, 10 Inspect for a liberal coating of dielectric
chafed, corroded and loose wires: grease in the following locations:

• Ground control panel • Between the ECU and platform controls

• All wire harness connectors Level sensor
• Hydraulic power unit module tray
11 Raise the platform and return the safety
• Battery pack module tray arm to the stowed position.
• Platform controls 12 Lower the platform to the stowed position
and turn the machine off.
3 Turn the key switch to ground control. Turn

27
 TRAINING MANUAL

Maintenance

B-3 B-4
Inspect the Tires and Wheels Test the Emergency Stop
(including castle nut torque) DINGLI requires that this procedure be
performed every 250 hours or quarterly,
whichever comes first.
DINGLI requires that this procedure be A properly functioning Emergency Stop is
performed every 250 hours or quarterly, essential for safe machine operation. An
whichever comes first. improperly operating red Emergency Stop
Maintaining the tires and wheels in good button will fail to shut off power and stop all
condition is essential to safe operation and machine functions, resulting in a hazardous
good performance. Tire and/or wheel failure situation.
could result in a machine tip-over. Component As a safety feature, selecting and operating
damage may also result if problems are not the ground controls will override the platform
discovered and repaired in a timely fashion. controls, except the platform red Emergency
1 Check the tire surface and sidewalls for Stop button.
cuts, cracks, punctures and unusual wear. 1 Turn the key switch to ground control. Pull
2 Check each wheel for damage, bends and out the platform and ground red
cracks. Emergency Stop button to the on position.

3 Check each bolt for proper torque. 2 Push in the red Emergency Stop button at
the ground controls to the off position.
Bolt torque, dry 125Nm
⊙ Result: No machine functions should
operate.
Bolt torque, lubricated 115Nm
3 Turn the key switch to platform control.
Pull out the platform and ground red
Emergency Stop button to the on position.
4 Push in 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.

28
 TRAINING MANUAL

Maintenance

B-5 B-6
Test the Key Switch Test the Automotive-style Horn (if
DINGLI requires that this procedure be equipped)
performed every 250 hours or quarterly, DINGLI requires that this procedure be
whichever comes first. performed every 250 hours or quarterly,
Proper key switch action and response is whichever comes first.
essential to safe machine operation. The The horn is activated at the platform controls
machine can be operated from the ground or and sounds at the ground as a warning to
platform controls and the activation of one or ground personnel. An improperly functioning
the other is accomplished with the key switch. horn will prevent the operator from alerting
Failure of the key switch to activate the ground personnel of hazards or unsafe
appropriate control panel could cause a conditions.
hazardous operating situation.
1 Turn the key switch to platform control.
Perform this procedure from the ground using Pull out the platform and ground red
the platform controls. Do not stand in the Emergency Stop button to the on position.
platform.
2 Push down the horn button at the platform
1 Pull out the platform and ground red controls.
Emergency Stop button to the on position.
⊙ Result: The horn should sound.
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.

⊙ Result: No function should operate.

29
 TRAINING MANUAL

Maintenance

B-7 ⊙ Result: The machine stops within the

specified braking distance. No action
Test the Drive Brakes
required.

¤ Result: The machine does not stop within

the specified braking distance.
DINGLI requires that this procedure be
performed every 250 hours or quarterly, Note: The brakes must be able to hold the
whichever comes first. machine on any slope it is able to climb.

Proper brake action is essential to safe 8 Replace the brakes and repeat this
machine operation. The drive brake function procedure beginning with step 1.
should operate smoothly, free of hesitation,
jerking and unusual noise. Braking distance, maximum
Hydraulically-released individual wheel brakes
High range on paved surface 61cm±30cm
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.
Pull out the platform and ground red
Emergency Stop button to the on position.

3 Lower the platform to the 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 test
line.
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.

30
 TRAINING MANUAL

Maintenance

B-8 B-9
Test the Drive Speed - Stowed Test the Drive Speed - Raised Position
Position

DINGLI requires that this procedure be

performed every 250 hours or quarterly,
DINGLI requires that this procedure be
whichever comes first.
performed every 250 hours or quarterly,
whichever comes first. Proper drive functions are essential to safe
machine operation. The drive function should
Proper drive functions are essential to safe
respond quickly and smoothly to operator control.
machine operation. The drive function should
Drive performance should also be free of
respond quickly and smoothly to operator
hesitation, jerking and unusual noise over the
control. Drive performance should also be free
entire proportionally controlled speed range.
of hesitation, jerking and unusual noise over
the entire proportionally controlled speed Perform this procedure with the machine on a
range. firm, level surface that is free of obstructions.

Perform this procedure with the machine on a 1 Create start and finish lines by marking
firm, level surface that is free of obstructions. two lines on the ground 12.2 m apart.

1 Create start and finish lines by marking 2 Turn the key switch to platform control.
two lines on the ground 12.2 m apart. Pull out the platform and ground red
Emergency Stop button to the on position.
2 Turn the key switch to platform control.
3 Press the lift function select button.
Pull out the platform and ground red
Emergency Stop button to the on position. 4 Press and hold the function enable switch
on the joystick.
3 Lower the platform to the stowed position.
5 Raise the platform approximately 2 m from
4 Press the drive function select button.
the ground.
5 Choose a point on the machine; i.e.,
6 Press the drive function select button.
contact patch of a tire, as a visual
reference for use when crossing the start 7 Choose a point on the machine; i.e.,
and finish lines. contact patch of a tire, as a visual
reference for use when crossing the start
6 Bring the machine to top drive speed and finish lines.
before reaching the start line. Begin timing
8 Bring the machine to top drive speed
when your reference point on the machine
before reaching the start line. Begin timing
crosses the start line.
when your reference point on the machine
7 Continue at full speed and note the time crosses the start line.
when your reference point on the machine
9 Continue at full speed and note the time
passes over the finish line. Refer to
when your reference point on the machine
specifications.
passes over the finish line. Refer to
specifications.

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Maintenance

B-10 B-11
Perform Hydraulic Oil Analysis Inspect the Hydraulic Tank Cap
Venting System

DINGLI requires that this procedure be

performed every 250 hours or quarterly, DINGLI requires that this procedure be
whichever comes first. performed quarterly or every 250 hours,
whichever comes first. Perform this procedure
Replacement or testing of the hydraulic oil is
more often if dusty conditions exist.
essential for good machine performance and
service life. Dirty oil may cause the machine to A free-breathing hydraulic tank cap is essential
perform poorly and continued use may cause for good machine performance and service life.
component damage. Extremely dirty A dirty or clogged cap may cause the machine
conditions may require oil changes to be to perform poorly. Extremely dirty conditions
performed more often. may require that the cap be inspected more
Before replacing the hydraulic oil, the oil may often.
be tested by an oil distributor for specific levels 1 Remove the breather cap from the
of contamination to verify that changing the oil hydraulic tank.
is necessary.
2 Check for proper venting.
If the hydraulic oil is not replaced at the two
⊙ Result: Air passes through the breather
year inspection, test the oil quarterly. Replace
cap.
the oil when it fails the test. See E-1, Test or
Replace the Hydraulic Oil. ¤ Result: If air does not pass through the cap,
clean or replace the cap. Proceed to step
3.

Note: When checking for positive tank cap

venting, air should pass freely through the cap.
3 Using a mild solvent, carefully wash the
cap venting system. Dry using low
pressure compressed air. Repeat step 2.

4 Install the breather cap onto the hydraulic

tank.

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Maintenance

B-12 B-13
Check the Module Tray Latch Test the Pothole Limit Switches and
Components the Level Sensor

DINGLI requires that this procedure be DINGLI requires that this procedure be
performed every 250 hours or quarterly, performed every 250 hours or quarterly,
whichever comes first. whichever comes first.

Maintaining the module tray latch components Maintaining the limit switches is essential to
in good condition is essential to good safe operation and good machine performance.
performance and service life. Failure to detect Operating the machine with a faulty limit switch
worn out latch components may result in could result in reduced machine performance
module trays opening unexpectedly, creating and a potentially unsafe operating condition.
an unsafe operating condition.
Perform these procedures with the machine on
1 Inspect each module tray rotary latch and a firm, level surface that is free of obstructions.
related components for wear. Tighten any
Level sensor
loose fasteners.
1 Remove the platform controls from the
2 Lubricate each module tray rotary latch.
platform.
Using light oil, apply a few drops to each of
the springs and to the sides of the rotary 2 Turn the key switch to platform control.
latch mechanism. Pull out the platform and ground red
Emergency Stop button to the on position.
3 Press the drive function select button

4 Move the machine onto a grade which

exceeds the rating of the level sensor.
Refer to the serial label on the machine.

5 Press the lift function select button.

Standing on the up-hill side of the machine,
attempt to raise the platform to
approximately 2.4 m.

⊙ Result: The LED readout screen shows

code LL, an alarm sounds, and the
machine stops lifting after the pothole
guards are deployed. The machine is
functioning properly.

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 TRAINING MANUAL

Maintenance

¤ Result: The LED readout screen does not pothole limit switch.
show code LL, the alarm does not sound 10 Press the drive function select button.
and the machine will continue to lift the Attempt to steer or drive the machine.
platform after the pothole guards are
deployed. Adjust or replace the level ⊙ Result: The LED readout screen shows
sensor. code 18, an alarm sounds, and the
machine will not steer or drive. The
6 Press the drive function select button.
machine is functioning properly.
Standing on the up-hill side of the machine,
attempt to steer and drive the machine. ¤ Result: The LED readout screen does not
show code 18, the alarm does not sound
⊙ Result: The LED readout screen shows
and the steer and drive functions operate.
code LL, an alarm sounds, and the
Adjust or replace the down limit switch.
machine will not steer or drive. The
machine is functioning properly. 11 Lower the platform to the stowed position
and remove the block under the right
¤ Result: The LED readout screen does not pothole guard.
show code LL, the alarm does not sound
and the steer and drive functions operate. 12 Repeat this procedure beginning with step
Adjust or replace the level sensor. 34 for the left pothole guard.
13 Lower the platform to the stowed position,
Pothole Limit Switches
remove the block under the left pothole
7 Lower the platform to the stowed position. guard.
Move the machine onto a firm, level
14 Turn off the machine.
surface.
8 Place a wooden block approximately 5 cm
tall under the right pothole guard.
9 Press the lift function select button.
Attempt to raise the platform
approximately 2.4m.

⊙ Result: The pothole guard contacts the

block and does not fully deploy, the LED
readout screen shows code 18, an alarm
sounds and the platform will lift to 2.4m or
beyond. The machine is functioning
properly.

¤ Result: The pothole guard contacts the

block and does not fully deploy, the LED
readout screen does not show code 18, the
alarm does not sound and the machine will
continue to lift the platform after the pothole
guards are deployed. Adjust or replace the

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 TRAINING MANUAL

Maintenance

3.3 Checklist C Procedures

C-1
Test the Platform Overload System (if
equipped)

DINGLI requires that this procedure be ⊙ Result: The overload alarm not sounds
performed every 500 hours or six months, during the whole trip, indicating a normal
whichever comes first or when the machine condition.
fails to lift the maximum rated load. ¤ Result: The overload alarm sounds during
Testing the platform overload system regularly the whole trip. Calibrate the platform
is essential to safe machine operation. overload system.
Continued use of an improperly operating
4 The platform should lower to the stowed
platform overload system could result in the
position
system not sensing an overloaded platform
condition. Machine stability could be 5 Add an additional weight to the platform
compromised resulting in the machine tipping not to exceed 20% of the maximum rated
over. load. Raise the platform.

The platform overload system is designed to ⊙ Result: The overload alarm at the platform
prevent machine operation in the event the controls sound, indicating a normal
platform is overloaded. condition.

Note: The overload system will not measure ¤ Result: The overload alarm at the platform
loads at or below the height of the Down Limit. controls does not sound. Calibrate the
platform overload system.
Note: Perform this test from the ground with
the platform controller. Do not stand in the 6 Test all machine functions from the
platform. platform controls.
⊙ Result: All platform control functions should
Perform this procedure with
not operate.
the machine on a firm, level surface.
7 Turn the key switch to ground control.
1 Turn the key switch to platform controls.
8 Test all machine functions from the ground
Pull out the platform and ground red
controls
Emergency Stop button to the on position.
⊙ Result: All ground control functions should
2 Determine the maximum platform capacity.
not operate.
3 Using a suitable lifting device, place an
9 Lift the test weight off the platform floor
appropriate test weight equal to the
using a suitable lifting device.
maximum platform capacity in the center
of the platform floor. Raise the platform.

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 TRAINING MANUAL

Maintenance

⊙ Result: The overload alarm at the platform C-2

controls should not sound, indicating a
Replace the Hydraulic Tank Breather
normal condition.
Cap
¤ Result: The overload alarm at the platform
controls sounds. Calibrate the platform
overload system.
DINGLI requires that this procedure be
10 Test all machine functions from the ground performed every 500 hours or semi-annually,
controls. whichever comes first.
⊙ Result: All ground control functions should The hydraulic tank is a vented-type tank. The
operate. breather cap has an internal air filter that can
11 Turn the key switch to platform controls. become clogged or, over time, can deteriorate.
If the breather cap is faulty or improperly
12 Test all machine functions from the
installed, impurities can enter the hydraulic
platform controls.
system which may cause component damage.
⊙ Result: All platform control functions should Extremely dirty conditions may require that the
operate. cap be inspected more often.
1 Remove and discard the hydraulic tank
breather cap.

2 Install a new cap onto the tank.

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Maintenance

3.4 Checklist D Procedures

D-1
Check the Scissor Arm Wear Pads

DINGLI requires that this procedure be For S0808AC+~S1614AC+:

performed every 1000 hours or annually, ⊙ Result: The measurement is 34mm or more.
whichever comes first.
Proceed to step 2.
Maintaining the condition of the scissor arm
¤ Result: The measurement is less than 34
wear pads is essential to safe machine
mm. Replace both wear pads.
operation. Continued use of worn out wear
pads may result in component damage and 2 Measure the distance between the number
unsafe operating conditions. one arm cross tube and the chassis deck
at the battery pack side of the non-steer
Perform this procedure with the platform in the
end of the machine.
stowed position.
For S0807AC+:
1 Measure the distance between the number
one arm cross tube and the chassis deck ⊙ Result: The measurement is 23mm or more.
at the ground controls side of the non-steer Proceed to step 3.
end of the machine.
¤ Result: The measurement is less than 23
mm. Replace both wear pads.

For S0808AC+~S1614AC+:

⊙ Result: The measurement is 34mm or more.

Proceed to step 3.

¤ Result: The measurement is less than 34

mm. Replace both wear pads.

3 Apply a thin layer of dry film lubricant to the

area of the chassis where the scissor arm
a wear pad wear pads make contact.
b arm cross tube
c chassis deck

For S0807AC+:

⊙ Result: The measurement is 23mm or more.

Proceed to step 2.

¤ Result: The measurement is less than 23

mm. Replace both wear pads.

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Maintenance

Loose the bolt and remove the hydraulic

3.5 Checklist E Procedures 5
power pack form the tray.
E-1
6 Remove the oil drain plug at bottom.
Test or Replace the Hydraulic Oil 7 Drain all of the oil into a suitable container.

8 Loose and remove the bolts and separate

the tank from the pump body.
DINGLI requires that this procedure be
performed every 2000 hours or every two Bodily injury hazard. Spraying
years, whichever comes first. hydraulic oil can penetrate and burn skin.
Replacement or testing of the hydraulic oil is Loosen hydraulic connections very slowly to
essential for good machine performance and allow the oil pressure to dissipate gradually.
service life. Dirty oil may cause the machine to Do not allow oil to squirt or spray.
perform poorly and continued use may cause 9 Clean up any oil that may have spilled.
component damage. Extremely dirty Properly discard the used oil.
conditions may require oil changes to be
10 Clean the inside of the hydraulic tank using
performed more often.
a mild solvent. Allow the tank to dry
Before replacing the hydraulic oil, the oil may completely.
be tested by an oil distributor for specific levels
of contamination to verify that changing the oil 11 Install a new filter onto the tank.
is necessary. 12 Install the hydraulic tank and install and
If the hydraulic oil is not replaced at the two tighten the hydraulic tank retaining
year inspection, test the oil quarterly. Replace fasteners.
the oil when it fails the test. 13 Install the hydraulic power pack into the
Note: Perform this procedure with the platform tray.
in the stowed position. 14 Install the fitting and hydraulic hoses onto
1 Open the power unit module tray. the hydraulic power pack and torque.

2 Disconnect the battery pack from the 15 Install the electric wires to pump motor.
machine. 16 Adding the tank with hydraulic oil until the
fluid is appropriate amount in the hydraulic
Electrocution / burn hazard. tank. Do not overfill.
Contact with electrically charged circuits could
result in death or serious injury. Remove all 17 Activate the pump to fill the hydraulic
rings, watches and other jewelry. system with oil and bleed the system of air.

3 Tag and disconnect the hydraulic pump Component damage hazard.

outlet line and remove the line from the The pump can be damaged if operated without
pump. Cap the fitting on the pump. oil. Be careful not to empty the hydraulic tank
4 Tag and disconnect the electric wires from while in the process of filling the hydraulic
the motor. system. Do not allow the pump to cavitate.

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Record of Maintenance

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4 Repair
4.1 Safety
Maintenance technical requirements
1. Repair procedures must be completed by qualified personnel who have been trained in the
repair of this machine;
2. Repair personnel should read, understand and abide by the safety rules and operating
instructions in the relevant manuals of the machine;
3. The machine to be repaired should be parked on a firm and flat ground, the key switch is in
the off position, the wheels are cushioned with wedges, and the scissor is in the stowed position.

4.2 General Operating Requirements

Disassembly
(1) Before disassembly, the dirt and oil on the outside of the product should be rinsed off to
make the appearance clean;
(2) The specific disassembly degree should be determined according to the actual state of the
product. If the component or assembly can be judged to be in good condition without disassembly,
it should not be disassembled as much as possible. Assemblies and components that need to be
disassembled for maintenance must be disassembled;
(3) When disassembling, special tools should be used as much as possible, and no violent
beating, random knocking, or random chiseling is allowed to avoid damage to parts;
(4) When disassembling parts with specified directions and marks, the corresponding
relationship should be recorded. If the above parts lose their marks, they should be re-marked
according to the correct assembly relationship.

Cleaning
(1) All parts should be thoroughly cleaned of oil stains, carbon deposits, coking and scale, and
the important oil passages and oil pipes should be cleaned with compressed air after cleaning;
(2) The cleaning method should be reasonable. When cleaning the cylinder head, body,
cylinder liner, piston, piston ring, valve, valve seat and other parts with carbon deposits, the mating
surface should not be damaged;
(3) Rubber and electrical components shall not be cleaned with diesel oil or kerosene to
prevent swelling and deterioration;
(4) The acidity and alkalinity caused by cleaning should be neutralized.

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Inspecting
(1) Spring
a. There shall be no cracks, scars, rust and other defects on the surface of the spring;
b. The first-level precision spring shall not have permanent deformation; the permanent
deformation of the second-level precision spring shall ≤1%; and the permanent deformation of the
third-level precision spring shall ≤2%.

(2) Rolling bearings

a. The surfaces of the inner and outer rings and rolling elements of the bearing should be
smooth and free of defects such as rust, pitting, burns and peeling;
b. The cage must not have problems such as cracks, deformation and loose rivets.

(3) Keys and splines

The surface of the key should be smooth, the edges and corners should be blunt, and the
keyway should not be filled with spacers. The mating surface of the spline should not have defects
such as nicks and scratches.

(4) Gear
a. The gear should be free from damage such as broken, glued, cracked, etc.;
b. The pitting corrosion on the tooth surface is not more than 25% of the pressure area. The
surface spalling is not more than 30% of the tooth height and 10% of the tooth length.

Assembly
(1) Basic Rules
a. The parts should be checked before assembly to ensure that the size and accuracy of the
parts meet the assembly technical requirements. Important rotating parts should be tested for
balance;
b. The rust and burrs on the working surface of the parts should be removed, and the bump
damage should be repaired. The friction surface of the kinematic pair and important threads
should be coated with clean oil;
c. Non-metallic gaskets, rubber water pipes, low-pressure hoses and other aging parts should
be replaced with new ones;
d. The locking parts such as split pins, locking plates, safety gaskets, and safety wires should
be replaced and locked as required;
e. Oil seal, floating seal rubber ring, dust ring and "O" type seal should be replaced. All seals
used should be qualified products;
f. All parts and assemblies with specified directions and marks shall be assembled in
accordance with the regulations, and shall not be wrongly assembled or omitted;
g. For parts with relative movement, they should be rotated or moved after assembly to
ensure flexible movement and no jamming;
h. After the whole machine is assembled, the specified amount of oil should be filled in each
oil filling part. Grease should be clean and reused lubricating oil must be filtered before use.

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(2) Assembly of bolts

a. The joint end face of bolts and nuts must be in even contact with the plane of the parts
being fastened, and should not be inclined;
b. For fasteners without special requirements, refer to Table 1 and Table 2 for the tightening
torque; for bolts or nuts with sequence and torque requirements, they should be tightened as
specified. When tightening groups of bolts and nuts arranged around the periphery, they should be
tightened alternately diagonally and in stages;
c. There should be no thread damage during assembly. If damaged, it should be replaced.
The bolts without special requirements should be grade 8.8, and the nuts should be grade 8;
d. Spring washers must be free of cracks, scratches and damage. When the height difference
between the two ends of the spring washer is less than half of the thickness of the washer, it
should be replaced.

(3) Assembly of bearings

a. An appropriate amount of lubricating oil or grease should be injected before and after
bearing assembly to prevent secondary pollution;
b. If there are burrs in the holes and shafts that match the bearings, they should be trimmed.
When the bearing is assembled, the marked end face should face outward;
c. The bearing can be heated or cooled during assembly. The heating temperature is
80~100℃. After installation, it should rotate flexibly without jamming;
d. All bearings without oil lubrication should be filled with grease before assembly;
e. The working surface of the bearing that continues to be used should be smooth and free of
defects such as rust, spots and burns. Bearings should rotate flexibly without jamming.

(4) Assembly of splines

a. Splines with marking requirements shall be assembled according to the marking;
b. The flat head screw of the guide flat key should be embedded in the top plane of the key;
c. The spline connection for sliding fit should be able to move freely without sticking and
uneven tightness.

(5) Assembly of gears and gearboxes

a. The inside of the gearbox must be kept clean without any leakage;
b. The gear should be able to rotate flexibly under no-load condition. During the test run, there
should be no abnormal noise.

(6) Assembly of hydraulic parts

a. Before assembly, the oil pump, valve, oil cylinder and oil pipe should be tested on a bench
with a pressure of 1.5 times the rated pressure, and assembly can only be done after passing the
test;
b. All pipelines should be clean and unobstructed before assembly;
c. The oil pipe after welding shall be subjected to pressure test and pickling and phosphating;
d. The hydraulic system should be tested after installation, and there should be no vibration,
abnormal noise and leakage problems.

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(7) Refurbishment of electrical instruments

a. The instrument should be in good condition, and the electrical components have no
short-circuit and open-circuit faults. Install and connect according to the electrical wiring diagram;
b. The wiring harness is well insulated, the core is not damaged, and meets the electrical
installation specifications;
c. Batteries whose plates have been vulcanized or cracked shall not continue to be used;
d. The normal specific gravity of the electrolyte should be 1.23~1.27g/cm3, and it should be
1.26~1.30g/cm3 in severe cold areas. The normal liquid level should be 10~15mm higher than the
plate;
e. The wiring layout of the electrical system shall meet the requirements of the original
machine, and shall not be rubbed with the edges and corners of the metal or squeezed by other
metal parts;
f. Useless lines should be removed, and electrical components should not be replaced at will.

Painting
(1) Parts should be applied paint before final assembly, and then spray paint after the test run
of the whole machine. Before spraying paint, remove dirt, grease, residual rust, etc., and remove
moisture and dust;
(2) The paint quality and color should meet the relevant national standard requirements;
(3) At least one coat of anti-rust primer should be applied, and more than two finishing coats
should generally be applied. The last finishing coat shall be carried out after the completion
inspection is passed;
(4) The unevenness of the surface should be ground and leveled, and putty can be scraped if
necessary, but no putty should be used to fill the excessively large depressions. After the putty is
dry and polished, touch up paint;
(5) After the paint layer is dry, it should be firmly adhered to the surface of the machine, and
there should be no stickiness, brittle cracking, peeling, blistering, spots and other particles and
impurities. The appearance is uniform and meticulous, bright and smooth, without flow marks and
obvious brush marks;
(6) Rubber pipes, wires, cables, electroplating parts, glass, rubber parts, lamps, instruments,
various valve operating joysticks, operating buttons, etc. shall not be painted or stained with paint.
Before repainting, the above components should be covered;
(7) After painting, each assembly, part nameplate and required signs and icons should be
complete and clear.

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Table 1 Ordinary bolt tightening torque

Nominal diameter (mm)
Bolt Yield
Strength Strength 6 8 10 12 14 16 18 20
Class N/mm2
Tightening torque (N·m)
4.6 240 4~5 10~12 20~25 36~45 55~70 10~110 120~150 170~210
5.6 300 5~6 12~15 25~32 45~55 70~90 110~140 150~190 210~270
6.8 480 7~9 17~23 33~45 58~78 94~124 145~193 199~264 282~376
8.8 640 9~12 22~30 45~59 78~104 124~165 193~257 264~354 376~502
10.9 900 13~16 30~36 65~78 110~130 180~210 280~330 380~450 540~650
12.9 1080 16~21 38~51 75~100 131~175 209~278 326~434 448~597 635~847

Table 2 Ordinary bolt tightening torque

Nominal diameter (mm)
Bolt Yield
Strength Strength 22 24 27 30 33 36 39
Class N/mm2
Tightening torque (N·m)
4.6 240 230~290 300~377 450~530 540~680 670~880 900~1100 928~1237
5.6 300 290~350 370~450 550~700 680~850 825~1100 1120~1400 1160~1546
6.8 480 384~512 488~650 714~952 969~1293 1319~1759 1694~2259 1559~2079
8.8 640 512~683 651~868 952~1269 1293~1723 1759~2345 2259~3012 2923~3898
10.9 900 740~880 940~1120 1400~1650 1700~2000 2437~3298 2800~3350 4111~5481
12.9 1080 864~1152 1098~1464 1606~2142 2181~2908 2968~3958 3812~5082 4933~6577

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4.3 Power Supply

S0807AC+:

Contactor

Battery

Relays
Charger

S0808~1614AC+:

Battery
Charger

Relays &
Contactor

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Repair

4.3.1 Charger

GPSC3024 EPC2436

Code Fault cause Solution

GPSC3024
The battery is not 1. Check battery connection;
E01 connected or the battery 2. Check charger connection;
voltage is too low 3. Check each battery is normal.
Abnormal AC power input 1. Check AC input wire is connected;
E02
(voltage) 2. Make sure AC plug is tightly inserted.
1. Stop charging and let the charger cool down for 15~20
Charger high temperature
E03 minutes;
protection
2. Charge in a well-ventilated environment.
When the battery temperature is >65℃, the charger enters
Battery high temperature the "battery high temperature protection mode", and when the
E04
protection temperature returns to normal, the charger will automatically
restart and continue charging
E05 Output current is too large Factory Repair
Battery voltage is too Check and assure that the correct output battery voltage is
E06
large connected
E07 Relay closing timeout Factory Repair

E09 No “curve” Need to update suitable curve

E10 Relay fault Factory Repair

EPC2436
Error with battery
E01 Check if cables are connected correctly
connection
Mains abnormal (voltage
E02 or frequency exceed Check the AC supply whether within the range of 90V-240V
operation range)
Temperature of battery
E03 Check whether the terminals are tightened.
abnormal
High temperature of Machine should keep in ventilation place and without any
E04
inner-parts foreign matter of the surface
No Communication Please check whether the communication line of lithium
E06
Access battery at charger port is connected properly.

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Charger Curve

Charger Curve
Model Battery Model
GPSC3024 EPC2436
JCPT0807-1012 HOPPECKE 6TB-185
JCPT1212 HOPPECKE 6TB-200 b22 8
JCPT1412-1612 HOPPECKE 12TB-120
JCPT0807 Trojan T-605
JCPT0808-1012 Trojan T-105 Plus
b01 /
JCPT1212 Trojan T-125 Plus
JCPT1412-1612 Trojan T-1275 Plus
For lithium battery, there is no need to modify the curve. When the lithium battery's BMS
connector is connected, the charger will automatically switch its output mode.
Steps to change the charger curve:
1. Connect the charger to the power supply, press and hold the Select button for 5 seconds to
release, the digital tube displays the current charging curve code;
2. Lightly press the Select button for 1 second and release to switch the curve code. If the
curve code is selected, press and hold the Select button for 5 seconds, the code flashes quickly,
release the button, and the curve setting is completed.
(If the charger does not have the required charging curve built in, it can also be changed
through the USB port.)

Temporary power-on, Parameter

valid when pressed for 3s selection button

GPSC3024 EPC2436

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Repair

Battery Connection Method

6V 6V

6V 6V

a. 6V battery; b. switch; c. fuse; d. charger

12 V 12 V

12 V 12 V

a. 12V battery; b. switch; c. fuse; d. charger

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4.3.2 Battery
Lead-acid battery
S0807AC+, S0808AC+
optional S1412AC+,
S1008AC+, S1012AC+ optional
Voltage 6VDC S1612AC+, S1614AC+,

Type 6TB185 Voltage 12VDC

Quantity 4 Type 12TB120

Battery capacity, maximum 185Ah Quantity 4

Maintenance-free Yes Battery capacity, maximum 240Ah

S0807AC+ optional Maintenance-free Yes

Voltage 12VDC S1412AC+,

optional
S1612AC+, S1614AC+,
Type T-605
Voltage 6VDC
Quantity 4
Type 6TB220
Battery capacity, maximum 210Ah
Quantity 4
Maintenance-free No
Battery capacity, maximum 220Ah
S0808AC+
optional
S1008AC+, S1012AC+ Maintenance-free Yes
Voltage 6VDC S1412AC+,
optional
Type T-105 Plus S1612AC+, S1614AC+
Quantity 4 Voltage 12VDC
Battery capacity, maximum 225Ah Type T-1275 Plus
Maintenance-free No Quantity 4
S1212AC+ optional Battery capacity, maximum 150Ah
Voltage 6VDC Maintenance-free No
Type 6TB200
Quantity 4
Battery capacity, maximum 200Ah
Maintenance-free Yes
S1212AC+ optional
Voltage 6VDC
Type T-125 Plus
Quantity 4
Battery capacity, maximum 240Ah
Maintenance-free No

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Lithium battery

S0807AC+ standard
Voltage 28.8VDC
Type TFL28.8-125-DL
Quantity 1
Battery capacity, 125AH
maximum
Maintenance-free Yes

S0808AC+ ,S1008AC+ standard

Voltage 28.8VDC
Type TFL28.8-150-DL
Quantity 1
Battery capacity, 150AH
maximum
Maintenance-free Yes

S1012AC+, S1212AC+,
S1412AC+, S1612AC+, standard
S1614AC+
Voltage 28.8VDC
Type TFL28.8-175-DL
Quantity 1
Battery capacity, 175AH
maximum
Maintenance-free Yes

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4.3.3 Relays & Contactor

S0807 AC+:

KA1

KA2

Contactor

S0808~1614 AC+:

KA1

KA2

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4.4 Control System

4.4.1 Ground Control Panel

1 14

2 3 4 6

7
10 12 13
8 9 11
1 Red Emergency Stop button
9 Menu down button
Push in the red Emergency Stop button
to the off position to stop all functions.
10 Menu enter button
Pull out the red Emergency Stop button
to the on position to operate the
11 Indoor/Outdoor button
machine

2 LED readout screen 12 Standby

3 Overload indicator light 13 将钥匙开关转到右侧“平台”图标位置，

Standby
平台控制器将运行；钥匙开关转到中间
4 Function enable button 14 Key switch
“OFF”位置，机器将关闭；将钥开关
Turn the key switch to the platform
5 Platform down button 转到左侧“底盘”位置，地面控制器将
position and the platform controls will
运行。
operate. Turn the key switch to the off
6 Platform up button
position and the machine will be off.
7 Menu escape button Turn the key switch to the base
position and the ground controls will
8 Menu up button operate

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4.4.2 Display
4.4.2.1 Information Interface

Electric Drive

0.0h
2024-09-15 12:00:00

Press & hold

on “ESC”

Left Motor Controller Right Motor Controller

Speed: 0.0Hz Speed: 0.0Hz
Motor enable: 0 Motor enable: 0
Phase current: 0A Phase current: 0A
Bus current: 0A Bus current: 0A
Controller temperature: 25°C Controller temperature: 25°C
Motor temperature: 20°C Motor temperature: 20°C

Lifting Motor Controller Steering Motor Controller

Speed: 0.0Hz Push rod length: 501mm
Motor enable: 0
Phase current: 0A
Bus current: 0A
Controller temperature: 25°C
Motor temperature: 23°C BMS
Battery voltage: 30.1V
Battery voltage signal: 29.8V
Platform weighing 1: 1981mV
Platform weighing 2: 1869mV Battery current signal: 0.0A
Fork angle sensor 1: 4328mV SOC value: 99%
Fork angle sensor 2: 696mV Max individual voltage: 3323mV
Chassis lifting switch: 0 Max voltage cell No: 2
Chassis descent switch: 0 Min individual voltage: 3304mV
Chassis enable switch: 0 Min voltage cell No: 9
Left pothole protect switch: 0 Maximum temperature: 27
Right pothole protect switch: 0 Max temp cell No: 1*
X-axis: -0.5° Minimum temperature: 27
Y-axis: 0.8° Min temp cell No: 1*
Anti pinch switch: 1 BMS life signals: 46335
Lifting limit walking switch: 0 Battery mode status
Spare0: 0% 动力关断
Relay status: 1

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4.4.2.2 Setting Interface

Pull out the “emergency stop buttons”, press & hold the “Enter” button and turn the key switch
to “ground control”.

The password is “0000”.

Please Enter Password

****

Menu
Set Speed
Set Option
Calibration
Special Mode
Fault History
Other

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Main Menu Items Value

1. Max Fast Speed 100

2. Max Raised Speed 13

1. Set Speed 3. Max Liftup Speed 60

4. Max Slow Speed 50

5. Max Descent Speed 60

Hydraulic drive
1. Machine Type Electrical drive
Small Electrical drive (0807AC+)
2. Pedal Switch Disable/ Enable
3. Pressure Type Weighing dual output
4. Pothole Guard Disable/ Enable
5. Descent Delay Disable/ Enable
6. Motion Alarm Disable/ Enable
7. Load Sensing Disable/ Enable
8. Joystick Direction Push/ Pull to Up
9. Enable InOutdoor Mode Disable/ Enable
10. Lowering Cylinder Dual/ Single Cylinder
11. Test Mode Use with caution!
12. Drain Shut Time Disable/ Enable
Current value is: 010
13. Battery Low Level
2. Set Option Edit value is: ___
14. Enable Priority Disable/ Enable
15. Enable PCU Collision Disable/ Enable
16. X Axis Limit
Use with caution!
17. Y Axis Limit
Current value is: 0
18. Continuous descent delay
Edit value is: ___
19. Disable Chassis Up Disable/ Enable
20. Enable ECU Collision Disable/ Enable
21. Platform Ext or Ret Disable/ Enable
22. Raised Drive Limit Disable/ Enable
23. Segmented Speed Disable/ Enable
24. Platform Disable Motion Disable/ Enable
25. Outdoor Drive Limit Disable/ Enable
26. E-Stop Disable/ Enable
27. Ultrasonic Collision Disable/ Enable

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Main Menu Items Value

1. No load Sensing
2. Full Load Sensing
3. Tilt Sensor
4. Angle Sensor
5. OL Descent High
6. Up Limit
7. Down Limit
3. Calibration
8. Outdoor Limit Height
9. Platform Limit Position
10. Level 1 Speed High
11. Level 2 Speed High
12. Steer Left Limit
13. Steer Right Limit
14. Load Sensor Adjust Value
4. Special Mode 1. Brake Release
NO. 1 ErrID: xxx
Time: ***
Info: ***
NO. 2 ErrID: xxx
5. Fault History Time: ***
Info: ***
…

1. Date & Time

1. English
2. Chinese
2. Language
3. Japanese
6.Other
4. French
ECU: **
3. Revision
HMI : **
4. Hour Meter Reset
5. Fault History Reset

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4.4.3 Platform Control Panel

3
8
1
5 6

4 7

1 Function enable switch 6 Drive function select button

2 Thumb rocker switch 7 Drive speed button

3 Proportional control handle 8 LED readout screen

4 Horn button 9 Red Emergency Stop button

5 Lift function select button

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Description

1 Function enable switch

Press and hold the function enable switch to enable the drive/lift function.
2 Thumb rocker switch
Press the thumb rocker switch in either direction to activate steer function.
3 Proportional control handle
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.
4 Horn Button
Push the horn button and the horn will sound. Release the horn button and the horn will stop.
5 Lift function select button
Press this button to activate the lift function.
6 Drive function select button
Press this button to activate the drive function.
7 Drive speed button
Press this button to activate the slow or fast drive function.
8 LED readout screen
Diagnostic readout and battery charge indicator.
9 Red Emergency Stop button
Push in the red Emergency Stop button to the off position to stop all functions. Pull out the red
Emergency Stop button to the on position to operate the machine.

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4.5 Security Configuration

Calibration steps that need to be redone after replacing parts
Replaced Part
MC PCU Angle Sensor Load Pin
Calibration
Model selection √

Tilt calibration √

Height calibration √ √

Load sensing √ √ √

Precautions for replacing MC:

①After the new controller is installed on the machine, please select the model & the number
of cylinders first (2.1. Machine Type & 2.10. Lowering Cylinder).
②Calibration: 3. Tilt Sensor → 4. Angle Sensor → 5. OL Descent High → (7. Down Limit)
→ 6. Up Limit → (8. Outdoor Limit Height) → (10. Level 1 Speed High) → (11. Level 2 Speed
High) → 1. No load Sensing → 2. Full Load Sensing

4.5.1 Motor Controller

ECU, Drive MC, Pump MC, and tilt sensor are assembled in 1 unit.
Lifting Motor Controller - 3
Chassis descent switch: 0
Chassis enable switch: 0
Left pothole protect switch: 0
Right pothole protect switch: 0
X-axis: -0.5°
Y-axis: 0.8°
Calibration:
1. Drive the machine to a level ground (make sure that the tilt value of the machine in both the
X-axis and Y-axis directions are 0°);
2. Get into setting interface, select “3. Tilt Sensor”, then press and hold “Enter” button for
several seconds to calibrate tilt sensor.

3. Tilt Sensor

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4.5.2 Angle Potentiometer

The controller determines the actual height of the platform based on the voltage value output
from the angle potentiometer.
Lifting Motor Controller - 2
Battery voltage: 30.1V
Platform weighing 1: 1981mV
Platform weighing 2: 1869mV
Fork angle sensor 1: 4328mV
Fork angle sensor 2: 696mV
Chassis lifting switch: 0
Calibration:
1. Drive the machine to a level ground, and lower down the machine;
2. Get into setting interface, select “4. Angle Sensor”, then press and hold “Enter” button for
several seconds to calibrate angle sensor;

4. Angle Sensor

3. In calibration interface, select “5. OL Descent High”, then press “Enter” button;

OL descent high
Set Value: 4300
Current Value: 4300

Press “Enter” to set value

4. In calibration interface, select “6. Up Limit”, then press “Enter” button;

Up Limit Up Limit
Set Value: 1200 Lift to max height Set Value: 1200
Current Value: 4300 (Lower down a little to Current Value: 1200
reduce cylinder wear)
Press “Enter” to set value
5. Optional: In calibration interface, select “8. Outdoor Limit Height”, then press “Enter”
button.
1008AC+: 1412AC+: 1612AC+: 1614AC+:
6.1m 8.5m 7.0m 9.0m
After lifting to the corresponding height, press “Enter” button.

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4.5.3 Load System

The load-system consists of an angle-potentiometer and a load-pin. When doing a load
calibration, the system will record the load signals at different heights. Based on these signals, the
system will determine if the load on the platform is overloaded.

Load pin Load pin

0807~1008 AC+ 1212~1614 AC+

Lifting Motor Controller - 2

Battery voltage: 30.1V
Platform weighing 1: 1981mV
Platform weighing 2: 1869mV
Fork angle sensor 1: 4328mV
Fork angle sensor 2: 696mV
Chassis lifting switch: 0

The reference value of sensors at different heights

S0808AC+ Angle 1 Angle 2 Load 1 Load 2

1340 3527
1601 1661
highest
1527 3338 1558 1599

1992 2883 1507 1538

2495 2387 1486 1513

No-load 3008 1876 1488 1510

3519 1389 1526 1555

3732 1178
1558 1594
descent delay
3980 936 1618 1666
4243 672
971 979
stowed

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Calibration:
1. Enable the load function;

7. Load Sensing

2. Drive the machine to a level ground, lower down the machine, and there is no load on
platform;
3. Get into setting interface, select “1. No load Sensing”, then press and hold “Enter” button
for several seconds to start the no load calibration (machine will lift up and lower down for 3
times);

1. No load Sensing

4. Put rated load on platform (see nameplate), then get into setting interface again, select “2.
Full Load Sensing”, press and hold “Enter” button for several seconds to start the full load
calibration (machine will lift up and lower down for 3 times).

2. Full load Sensing

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4.5.4 Limit Switches

Lifting Motor Controller

Chassis descent switch: 0
Chassis enable switch: 0
Left pothole protect switch: 0
Right pothole protect switch: 0
X-axis: -0.5°
Pothole limit switch Down limit switch Y-axis: 0.8°
Anti pinch switch: 1
Lifting limit walking switch: 0
Spare0: 0%

Status of limit switches:

Stowed Raised
Pothole limit switch 0 1
Down limit switch 1 0

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4.5.5 Beacon & Buzzers

When the controller of the machine has an output command, the beacon will flash at a certain
frequency.
At the same time, with the buzzers on ground control panel and PCU, it can also play a role in
reminding others to prevent accidents.

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4.6 Drive System

The drive-system consists of 2 drive-motors and a steer-actuator.

4.6.1 Drive Motor

0807AC+ 0808~1614AC+
Model SNR0.5-4-0391 SNR0.87-4-0394
Power 0.50 kW 0.87 kW
Rated Speed 4300 rpm 3530 rpm
Rated Torque 1.85 N·m 2.40 N·m

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4.6.2 Steer Actuator

Service Conditions
Stroke 129 mm
Rated Force 12 kN
Nominal Speed 40 mm/s
Supply Voltage 24V
Environment Temperature -20 ~ +50 ℃
Motor
Rated Power 600 W
Rated Speed 3600 rpm
Rated Torque 1.6 N·m
Encoder Hall Element

CAN bus
Not used control

Power -

Power +

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4.7 Lift System

SV 2 SV 1
M

SV1: Switch valve

When the pump is idle, the valve shall not be energised, so that the hydraulic oil can flow
directly back to the tank, reducing the burden on the hydraulic system.

SV2: Lift valve

① When lifting, both valves are energised at the same time and hydraulic oil flows into the
lifting cylinder(s).
② When Lowering, both valves are energised at the same time and the hydraulic oil drives
the pump, causing the pump motor to charge the battery.

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4.8 Emergency system

4.8.1 Emergency Lowering

Emergency
lowering knob

Emergency lowering:
By pulling the emergency lowering knob, the descending oil circuit of the lift-cylinder will be
opened; if the machine is a dual-cylinder model, the hydraulic oil in the upper oil cylinder will also
flow out because of the relief valve, thus realizing the emergency lowering of the platform.
Note: When performing emergency descent in this way, the decent delay function will be
invalid.

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4.8.2 Brake Release

Method 1:
1) Chock the wheels to prevent the machine from rolling.
2) Pull out the red Emergency Stop button on both the ground and platform controls to the ON
position.
3) Get into setting interface: Press & hold the “Enter” button and turn the key switch to ground
control, then enter password of “0000”.

1. Brake Release

4) Select “4. Special Mode” → “1. Brake Release”.

Special Mode
1. Brake Release

Towing the AC Model is not recommended. If the machine must be towed, do not exceed
4.0km/h.

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Method 2:
Chock the wheels to prevent the machine from rolling.
0807AC+:

brake release screw

fastening screw

Unscrew the 5 fastening screws and 2 brake release screws with a 4mm Allen key. Then
remove the cover. Screw in 2 brake release screws, this will separate the brake disc from the
motor.
0808 ~ 1614AC+:

Use 5mm Allen key to remove the plug, then use 4mm Allen key to screw in the internal
screw.

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4.8.3 Emergency Steering

When the machine cannot be turned through the joystick, it can be turned by emergency
methods.
Method 1:

Remove the cover of the motor, turn 180°, and connect with the motor shaft. Steering wheels
can be controlled by rotating the cover-plate.
Method 2:

Pin 1 (red)
Pin 2 (black)

Power -

Power +

Under the premise that "Power +" and "Power -" are energized, if "Pin 1" is connected with
24V electricity, the electric actuator can be extended and the machine can turn left; If "Pin 2" is
connected with 24V electricity, the push rod can be retracted and the machine can turn right.

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Record of Repair

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Fault Code

5 Fault Code
5.1 Machine Code
The LED readout screen displays fault codes that provide information about
the machine operating status and about malfunctions. The fault codes listed in the
following charts describe malfunctions and can aid in troubleshooting the machine
by pinpointing the area or component affected.
List of Fault Codes

Code Description Lift Reaction Failure reason & solution

System initialization failure, the system will
prohibit all actions.
System Initialization Disables All
01 Solution:
Fault Motion
1. Try to power on again;
2. Replace main controller.
The CAN bus communication of the main
controller and PCU is faulty, and the system will
prohibit all actions.
Solution:
System Disables All 1. The PCU is faulty, replace the PCU;
02
Communication Fault Motion 2. Check the wiring at the PCU 6-hole connector;
3. The main controller may be faulty, replace it;
4. Measure whether the battery voltage is
correct;
5. Check whether the power relay is energized.
Invalid Option Setting Disables All Get into setting interface, and check
03
Fault Motion corresponding options.
1. The angle sensor calibration fails, it may be
that the angle sensor analog output changes
too little or no change during the calibration
process. Check whether the angle sensor is
firmly fixed, whether the power supply and
wiring are normal, or replace the angle sensor.
04 Calibration Fault Warning Only
2. No-load/full-load calibration fails, it may be
that the load-pin and angle sensor analog
output changes too little or no change during
the calibration process, or the machine is not
in a horizontal state.
3. Replace the main controller.
Disable Lifting
06 Collision Trigger
and Driving
1. Try to restart the power supply, or replace key
Disables All
08 Key Switch Error switch;
Motion
2. Replace the main controller.

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Code Description Lift Reaction Failure reason & solution

The built-in GPS module or external GPS

module communication failure, only alarm.
Solution:
GPS Communication 1. Check whether the connection between the
09 Warning Only
Fault CAN communication bus of the external GPS
module and the CAN bus of the machine is
normal;
2. Replace the main controller.
Disable Lifting Check the wires between main controller and
10 MC Lost
and Driving display, or replace the main controller.

Lithium battery BMS CAN bus communication

failure.
BMS Communication Disable Lifting Solution:
11 1. Check whether the CAN bus communication
Fault and Driving
between the lithium battery and the machine
is normal;
2. Replace the lithium battery.
Chassis Up or Down Disable Ground control panel lift buttons failure, ground
12
Switch ON Chassis Control control operation is prohibited.
Disables All
13 Foot Pedal Fault
Motion
Disable All
14 Brake Release
Motion
1. Check the status of the pothole plates and
pothole switches after platform is lifted, and
whether there is any foreign matter stuck.
Pothole Guard Fault
Disable Lifting 2. Check the status of the angle potentiometer
18 or down limit switch
and Driving and down limit switch after the platform is
Fault
lowered, and calibrate the angle sensor if
necessary.
3. Replace the main controller.
Outdoor limit fault Disable Lifting
19
(optional) and Driving
1. If the load-pin is not installed, check if the load
function is turned on;
Pressure Sensor Disables All 2. Check the load-pin power supply and its
31
Fault Motion wiring;
3. Check the signal in display;
4. Replace the main controller.

1. Check the angle sensor power supply and its

Disable Lifting wiring;
32 Angle Sensor Fault
and Driving 2. Check the signal in display;
3. Replace the main controller.

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Code Description Lift Reaction Failure reason & solution

Disable Lifting
33 Lift Is Locked and Drive
speed limit
1. If the load-pin is not installed, check if the load
function is turned on;
Pressure Sensor 2 Disables All 2. Check the load-pin power supply and its
35
Fault Motion wiring;
3. Check the signal in display;
4. Replace the main controller.
It indicates that the current battery power is low.
In order to prevent the battery from
Drive speed over-discharging, the system will prohibit the
36 Low Battery Limp lifting function and limit the driving speed.
limit
Solution:
The battery needs to be charged in time.
Disables All
37 Battery Sleep
Motion
Platform Left Button It is reminded that when the system is powered
42 Warning Only
ON on and self-checked, the joystick buttons are
Platform Right Button triggered.
43 Warning Only Solution:
ON
1. Operate the machine 3s after the system is
Disable
Platform Enable powered on;
46 Platform
Button ON 2. Replace the joystick.
Control
It is reminded that when the system is powered
Joystick Not In Disables All
47 on and self-checked, the joystick is not in the
Neutral Motion
neutral position.
48 Horn Coil Fault Warning Only
49 Meter Coil Fault Warning Only
50 Beacon Coil Fault Warning Only
51 Spare Coil Fault Warning Only
Drive Forward Coil Disable Lifting Drive forward / reverse solenoid valve open
52
Fault and Driving circuit failure.
Drive Reverse Coil Disable Lifting 1. Set the correct model for the machine;
53 2. Replace the main controller.
Fault and Driving
The platform lifting solenoid valve has open
circuit failure, and the lifting and driving functions
are prohibited.
Disable Lifting
54 Lift Up Coil Fault Solution:
and Driving
1. Check the solenoid valve coil and its wiring at
the valve block;
2. Replace the main controller.

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Fault Code

Code Description Lift Reaction Failure reason & solution

1. Check the lowering solenoid valve coil and its

Disable Lifting
55 Lift Down Coil Fault wiring at the valve block of the lifting cylinder;
and Driving
2. Replace the main controller.
Disable Lifting
56 Steer Right Coil Fault
and Driving
/
Disable Lifting
57 Steer Left Coil Fault
and Driving
General Brake Coil Disable Lifting
58
Fault and Driving
Disable Lifting
59 Parallel Coil Fault /
and Driving
It is reminded that the current battery power is
lower than the preset value, and the machine
Disables All
68 Battery Low Voltage needs to be charged in time to protect the
Motion
battery from over-discharge and damage. At this
time, the control system will prohibit all actions.

80 Platform Load is over Warning Only

80% Prompt that the load of the current platform
90 Platform Load is over Warning Only exceeds 80% / 90% / 99% of the rated load, only
90% an alarm does not limit the action.
99 Platform Load is over Warning Only
99%
PCU: It prompts that the machine is in a tilted state and
LL exceeds the set alarm angle value. Lifting and
Disable Lifting
Machine Inclined driving operations are prohibited.
ECU: and Driving
You need to descend to the lower limit and drive
100 to a solid level road to work at heights.
Prohibition of
lifting and
It prompts that the current platform load exceeds
PCU: driving; The the rated load. In order to ensure the safe use of
platform is
OL the equipment, the system will prohibit the lifting
Platform Overloaded forbidden to
ECU: and driving functions at this time, and it is
descend after forbidden to descend above the overloaded
101 exceeding the
descending height.
"overload
descent height"
Restore Parameters
102 Warning Only /
to Default
103 Battery is draining Warning Only /

Check whether the wiring of the motor controller

104 Motor Controller Fault Warning Only
is normal, otherwise replace the motor controller.

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Fault Code

Code Description Lift Reaction Failure reason & solution

The lithium battery management system has an

Prohibit lifting,
alarm, and the control system will prohibit the
105 BMS Alarm limit driving
lifting function and limit the driving speed at this
speed
time

Lithium battery management system fails, in

Disable All
106 BMS Fault order to ensure safety, the control system will
Motion
prohibit all actions

Disable Lifting
107 GPS Actively Lock
and Driving

Disable Lifting
108 GPS Passive Lock
and Driving

GPS Temporary
109 Warning Only
Unlock

PCU:
n1, Right Drive Motor Controller
Motor controller processing
ECU: Controller Fault Dependent
1xxx
PCU:
Left Drive Motor Controller
n2, Motor controller processing
Controller Fault Dependent
ECU:
PCU:
2xxx
n3, Pump Motor Controller
Motor controller processing
ECU: Controller Fault Dependent
3xxx
PCU:
n4, BMS
BMS Fault
ECU: Dependent
4xxx
code
PCU： Platform up limit The system prompts that the platform has
Warning Only
UP position reached the upper limit and only gives an alarm.

For more information, please consult the appropriate Dingli Service Dept.

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Fault Code

5.2 Motor-controller Code

1xxx represents the right drive motor controller, 2xxx represents the left drive motor
controller, 3xxx represents the pump motor controller.

Code Fault name Solution

1. Contactor stuck
2. The large wire of contactor is short-circuited to the
X037 CONTACTOR CLOSED
positive terminal
3. The motor controller is broken
1. Contactor is broken
2. The wire of contactor is not in good contact
X038 CONTACTOR OPEN
3. Big fuse is broken
4. The motor controller is broken
1. Check +B/-B if there are other loads causing leakage or
short circuit
X060 CAPACITOR CHARGE
2. Whether the power supply of the key switch is leaking
3. The motor-controller is broken

1. Wait to cool down

X062 TH. PROTECTION 2. If the actual temperature is not high, the hardware is
damaged, replace the motor controller

X065 MOTOR TEMPERAT. Wait for the motor to cool down

X070 Vkey Fault
X071 5V Power Fault
X072 Hardware Overload
X073 Current CL Fault
X074 Opposite Comm. Fault
X075 Opposite Fault
X076 MOSFET Fault
1. The encoder is broken
X153 ENCODER ERROR XX 2. Motor stuck more than a certain time
3. Replace the motor controller
1. The encoder is broken
X175 SPEED FB. ERROR 2. Motor stuck more than a certain time
3. Replace the motor controller
1. Check if the brake wiring is short circuit
X177 COIL SHOR. EB.
2. Replace the motor controller
1. Whether the motor temperature is actually too high
X178 MOTOR TEMP. STOP 2. Whether the motor temperature sensor wiring open circuit
3. Replace the motor controller

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Fault Code

Code Fault name Solution

1. Problem with motor/encoder wiring

2. The machine collides or shakes violently
X180 OVERLOAD
3. The parameter debugging is not perfect, contact ZAPI
engineer

1. Check whether the wiring of the motor is normal, whether

X196 MOT.PHASE SH. there is leakage or water inflow
2. Replace the motor controller

1. Check the battery

X200 VDC OFF SHORTED
2. Replace the motor controller

1. Check for abnormal regenerative braking

X202 VDC LINK OVERV. 2. One of the external capacitors is damaged
3. Replace the motor controller

X207 Motor Phase Open

1. Whether the machine is driving on an slope

X211 STALL ROTOR
2. Motor mechanical problem

X212 Parameter Error

1.Check if the brake is open circuit

X216 EB. COIL OPEN
2. Replace the motor controller

1. The actual temperature is too high, waiting for cooling

X218 SENS MOT TEMP KO
2. The motor temperature sensor problem or wiring problem

1. Check the battery

X220 VKEY OFF SHORTED
2. Replace the motor controller

1. Contactor coil short circuit

2. The coil of the contactor (to motor controller) is
X223 Contactor Coil Short
short-circuited with the main circuit
3. The motor controller is broken
X227 Current Sensor Fault
X229 HW FAULT
X230 Contactor Coil Open

1.Interference problem, check CAN resistance setting,

interference level
X248 NO CAN MSG.
2.For other software setting problems, you need to contact
ECU and ZAPI engineers

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Fault Code

5.3 BMS Code

List of Fault Codes (Battery BMS)

Display Description Lift Reaction

4001 Low charging temperature 2 Lift and Drive speed limit

4002 Low charging temperature 3 Disables All Motion

4003 High charging temperature 2 Lift and Drive speed limit

4004 High charging temperature 3 Disables All Motion

4005 Low discharging temperature 2 Lift and Drive speed limit

4006 Low discharging temperature 3 Disables All Motion

4007 High discharging temperature 2 Lift and Drive speed limit

4008 High discharging temperature 3 Disables All Motion

4009 Temperature imbalance 2 Lift and Drive speed limit

4010 Temperature imbalance 3 Disables All Motion

4011 Pad Temperature high 2 Lift and Drive speed limit

4012 Pad Temperature high 3 Disables All Motion

4013 Low SOC 2 Lift and Drive speed limit

4014 Low SOC 3 Disables All Motion

4015 High SOC 2 Lift and Drive speed limit

4016 High SOC 3 Disables All Motion

4017 Discharge total voltage high 2 Lift and Drive speed limit

4018 Discharge total voltage high 3 Disables All Motion

4019 Discharge total voltage low 2 Lift and Drive speed limit

4020 Discharge total voltage low 3 Disables All Motion

4021 Charge total voltage high 2 Lift and Drive speed limit

4022 Charge total voltage high 3 Disables All Motion

4023 High charge current 2 Lift and Drive speed limit

4024 High charge current 3 Disables All Motion

80
 TRAINING MANUAL

Fault Code

List of Fault Codes (Battery BMS)

Display Description Lift Reaction

4025 High discharge current 2 Lift and Drive speed limit

4026 High discharge current 2 Disables All Motion

4027 Discharge cell voltage high 2 Lift and Drive speed limit

4028 Discharge cell voltage high 3 Disables All Motion

4029 Discharge cell voltage low 2 Lift and Drive speed limit

4030 Discharge cell voltage low 3 Disables All Motion

4031 Charge cell voltage low 2 Lift and Drive speed limit

4032 Charge cell voltage low 3 Disables All Motion

4033 Cell voltage imbalance 2 Lift and Drive speed limit

4034 Cell voltage imbalance 3 Disables All Motion

4035 Main relay adhesion 2 Lift and Drive speed limit

4036 Main relay adhesion 3 Disables All Motion

4037 Heating relay adhesion 2 Lift and Drive speed limit

4038 Heating relay adhesion 3 Disables All Motion

4039 High monomer 2 Lift and Drive speed limit

4040 High monomer 3 Disables All Motion

4041 Low monomer 2 Lift and Drive speed limit

4042 Low monomer 3 Disables All Motion

4043 High temperature 2 Lift and Drive speed limit

4044 High temperature 3 Disables All Motion

81
 TRAINING MANUAL

Fault Code

5.4 PCU & Steer Code

5xxx represents the PCU, 6xxx represents the steer-actuator.
Display Description

5129, 6129 Communication error with IC

5130, 6130 Encoder failure

5131, 6131 Power input over voltage

5132, 6132 Power input low voltage

5133, 6133 Motor over heat

5134, 6134 MOSFET over temperature

5135, 6135 MOSFET over current

5138, 6138 CAN bus communication timeout

5139, 6139 NV storage read error

5140, 6140 NV storage write error

5141, 6141 MOSFET Error

5142, 6142 Auto-calibrati

5143, 6143 Motor blocked Error

5144, 6144 Motor blocked warning

5145, 6145 Actuator unwanted movement

5146, 6146 Encoder auto-calibration error

5147, 6147 Motor run in wrong direction

5148, 6148 Encoder calibration data warning

5149, 6149 Encoder error

5150, 6150 Encoder calibration timeout

5151, 6151 Encoder sensor IIC error

5152, 6152 Encoder IC communication error

5153, 6153 Encoder sensor IIC warning

5154, 6154 Encoder IC communication warning

82
 TRAINING MANUAL

Fault Code

Display Description

5155, 6155 Motor speed too high

5156, 6156 CAN peripheral failure

5157, 6157 CAN systick failure

5158, 6158 CAN wrong PDO

5159, 6159 CAN status frame lost

5160, 6160 CAN command frame lost

5161, 6161 CAN wrong Node ID

5162, 6162 CAN PDO not correct

5163, 6163 CAN wrong frame values

5164, 6164 STO signal is invalid

5165, 6165 Communication between MCU1 and MCU2 error

5166, 6166 Redundancy STO signal is invalid

83
TRAINING MANUAL

Electrical Schematic

6 Electrical Schematic
6.1 S0807AC+
7 GY(18) 7
6 OR(18) 6
PCU
FU2 10A Joystick
SB1 002A RD(16) KM1 Display
RD(5) RD(5) RD(5) SB2
Power Switch PW-IN1 GN(18) 4 GN(18) 4 Drive Enable
FU1 250A Contactor E-Stop
Battery 3-005 RD(18) Pw Out RD(18) 3 RD(18) 3
Power(BMS) GND Lift Enable
M A26 BU(18) 1-GND1 WH(18) 1 WH(18) 1
D Power 102 BN(20) CANH
Activate CANH YE(18) 2 YE(18) 2 Drive speed
F

002B RD(16)
101 BN(20) CANL
V-CANH CANL BU(18) 5 BU(18) 5
K V-CANL
V-CANH YE(20) 4 6-CANH YE(20)
L V-CANL GN(20) 5 6-CANL GN(20) Joystick Deadman
C-CANH
GB1
E C-CANL 10 A26 BU(18)
C C-GND
HA1
Alarm
B 9 3-005 RD(18)
C-12V
A GND BK(14)

4
3

5
6
7
BK(5)

1
C-12V RD(20) 3 B+ RD(18) SQ4 SQ5
+ - C-GND BK(20) FU4 1A Anti-collision Switch (Option)
L C-CANL GN(20) 7 SQ6 SQ7
N C-CANH YE(20) KA2 2-005 RD(18) A 007 RD(18)
2 PW-IN3 PK(18) S1
PE P18 WH(20) B P18 WH(20) Pothole Switch SQ1
1-007 RD(20)
100~240V Input Charger 1 FootSwitch (Option)

002B RD(16)
P07 WH(20) Pothole Switch SQ2

102 BN(20)
GS1 Relay P07 WH(20) C 2-007 RD(20)
001B RD(20) 8

101 BN(20)
FU3 3A Charger Protection GS1 4 Ultrasonic
001A RD(20) 12 001A RD(14) K 001A RD(14) 3 Sensor
2-001 RD(20) 11 2-001 RD(14) G 2-001 RD(14) U1
1 (Option)
1-P29 WH(20) P29 WH(20) HL1
J
KA1 Beacon

001B RD(18)
7-GND1 BK(16) S GND7 BK(20)
SQ3 Lift Down Limit Switch
Power P17 WH(20) H P17 WH(20) 3-007 RD(20)
Relay

Potentiometer
P15 WH(20) E P15 WH(20)

3-GND1 BK(18)

BK(5)
3-P26 PK(20)

005 RD(16)
L 3-P26 PK(20)
10 P14 WH(20) D P14 WH(20)
Display Control Power In
P27 WH(20) F P27 WH(20)
Button
3-GND2 BK(20) R 3-GND2 BK(20)
MC Buzzer
8 8-005 RD(16)
RP1

Chassis/Platform Control P19 P19 WH(20) 7

6 1-CANL GN(20) 5-CANL GN(20)
5 1-CANH YE(20) 5-CANH YE(20)
U1 11 PW IN WH(18) Control Power Out PW-IN2 WH(20)
1 9-GND1 BK(16)
Chassis Panel 2 Hourmeter
B+ RD(18) B- B+
9-005 RD(20)
Contactor A26 A26 BU(18)
Relay P32 P32 WH(20) Temperature A32 PK(20)
A32
Relay Feedback A4 A04 OR(20) P22 BU(20) A24
Brake+ A24 WH(18)
MC A25 A25 BK(20)

Hourmeter
Lift Down Switch P17 P17 WH(20) Brake-

Power On

LOCK_H

LOCK_L

Ground
Ground

Ground
Rotation- A7 A07 GN(20)

Brake+R RD(20)
CANL
CANH
Power

KEY

Brake+L RD(20)
Left Pothole Switch P18 P18 WH(20) A20 OR(20)
Cos- A20 LT-B GY(20)
Right Pothole Switch P7 P07 WH(20) Rotation+ A18 A18 YE(20)
Connector

10
11
12
Cos+

4
2

6
3

7
8
9
A8 A08 BN(20)

1
Beacon P29 P29 WH(20)
Sin- A31 A31 BU(20)
Potentiometer Power P26 P26 PK(20) Sin+ A19 WH(20)
A19
Potentiometer 1 P14 P14 WH(20)
Zero Potentiometer P27 P27 WH(20) 3 45 1 2 6 8 7 10 9
LOCK L P22 P22 BU(20)
Motor Encoder
LOCK H P11 P11 RD(20) U2 RD(7)

Brake
Potentiometer 2 P15 P15 WH(20) V2 WH(7) M3 Left Motor
TIME WH(20) W2 BU(7)
Temperature Sensor
Platform E-Stop P16 P16 GY(18)
Platform E-Stop P5 P05 OR(18)
Power P23 P23 RD(18)
Temperature A22 A22 PK(20)
Power P34 P34 RD(18)
Power P35 P35 RD(18) Brake- A27 A27 BK(20)
Rotation- A17 A17 GN(20) RT-B GY(20)
Power A01 A01 RD(18) Cos- A10 OR(20)
A10
Rotation+ A29 A29 YE(20)
CAN_Shied A5 Cos+ A33 A33 BN(20)
CAN_H A16 A16 YE(20) Sin- A21 A21 BU(20)
CAN_L A15 A15 GN(20) Sin+ A9 A09 WH(20)

2-P26 PK(20) J RD(20) 3 45 1 2 6 8 7 10 9

Load Cell
Load Cell 1 P1 P01 WH(20) P01 WH(20) K GN(20) Motor Encoder
U1 RD(7)

Brake
Load Cell 2 P13 P13 WH(20) P13 WH(20) L WH(20) V1 WH(7) M2Right Motor
Lift Up Valve P30 P30 WH(16) 1-P30 WH(18)
SV2
12-GND1 BK(18) 2-GND2 BK(20) M BK(20) DC- BK(12) W1 BU(7)
Temperature Sensor
SV1 Lift Up Valve DC+ RD(12)
2-P30 WH(18) 10-GND1 BK(18)
10-005 RD(20) RD(20)
M4
Emergency Switch Valve G Module
SQ4 CAN_Shied A5 A05 BK(18)
High Limit Switch P10 High Limit Switch (Option) Motor
P10 WH(20) P10 WH(20) H BU(20) Temperature A12 A12 WH(20)
GND A6 A06 GY(20)

PR-B BK(20)
VCC+ A30 A30 PK(20)
Cos+ A23 A23 YE(20)
Lift Down Valve P31 P31 WH(18) P31 WH(18) RD(20) SV3
A 4-CANH YE(20) 3 Cos- A35 A35 GN(20)
Lift Down Valve
Sin+ A34 A34 BN(20)
8-GND1 BK(18) B BU(20) 4-CANL GN(20) 4 Sin- A11 WH(20)
A11
FootSwitch P9 P09 WH(20) P09 WH(20) C 1 23456 2 1

Anti-collision Switch P8 P08 WH(20) P08 WH(20) E Motor Encoder

U3 RD(3)
5-005 RD(20) D V3 RD(3) M1 Pump
W3 RD(3)
6-005 RD(20) F Temperature Sensor
HA2 Buzzer (Option)
Buzzer P28 P28 WH(20) P28 WH(20) R P28 WH(20)
13-GND1 BK(20) S 13-GND1 BK(20)
HL2 Beacon (Option)
11-GND1 BK(20) N 11-GND1 BK(20)
2-P29 WH(20) P 2-P29 WH(20)

84
 TRAINING MANUAL

Electrical Schematic
6.2 S0808AC+ ~ S1614AC+
7 GY(18) 7
6 OR(18) 6
PCU
Joystick
SB1 Display
RD(2) RD(2) RD(2) PW-IN1 GN(18) 4 GN(18) 4 Drive Enable
Power Switch FU1 300A SB2 E-Stop
Battery 002A RD(16) Pw Out RD(18) 3 RD(18) 3
Power(BMS) FU2 10A GND Lift Enable
M Power 2-001 RD(20) 1-GND1 WH(18) 1 WH(18) 1
D Activate 102 BN(20)
CANH YE(18) 2 YE(18) 2
CANH
Drive speed

002B RD(16)
F 101 BN(20) CANL
V-CANH CANL BU(18) 5 BU(18) 5
K V-CANL V-CANH YE(20) 4 6-CANH YE(20)
L V-CANL GN(20) 5 6-CANL GN(20) Joystick Deadman
C-CANH
GB1
E C-CANL
C C-GND HA1
Alarm
B C-12V GND BK(14)
A

4
2

6
3

7
BK(2)

1
C-12V RD(20) B+ RD(18) 3 B+ RD(18) SQ4 SQ5
+ - C-GND BK(20) FU4 1A Anti-collision Switch (Option)
L C-CANL GN(20) 7 SQ6 SQ7
N C-CANH YE(20) 2-005 RD(18) A 007 RD(18)
2 S1
PE
2-001 RD(20) P18 WH(20) B P18 WH(20) Pothole Switch SQ1
1-007 RD(20)
100~240V Input Charger 1 1 FootSwitch (Option)

002B RD(16)
KA2 SQ2
P07 WH(20) Pothole Switch

102 BN(20)
GS1 PW-IN3 PK(18) P07 WH(20) C 2-007 RD(20)
2 001A RD(20) 001B RD(20) 8
FU3 3A 4 Ultrasonic
Relay 3 Sensor

101 BN(20)
U1
1 (Option)
HL1

001B RD(18)
1-P29 WH(20) J P29 WH(20)
KA1 Beacon
7-GND1 BK(16) S GND7 BK(20)
SQ3 Lift Down Limit Switch
Power P17 WH(20) H P17 WH(20) 3-007 RD(20)
KM1

Potentiometer
Relay P15 WH(20) E P15 WH(20)

3-GND1 BK(18)
Contactor

BK(2)
005 RD(16)
3-P26 PK(20) L 3-P26 PK(20)
10 P14 WH(20) D P14 WH(20)
Display Control Power In
P27 WH(20) F P27 WH(20)
Button
3-GND2 BK(20) R 3-GND2 BK(20)
MC Buzzer
8 8-005 RD(16)
RP1

Chassis/Platform P19 P19 WH(20) 7

6 1-CANL GN(20) 5-CANL GN(20)
5 1-CANH YE(20) 5-CANH YE(20)
U1 11 PW IN WH(18) Control Power Out PW-IN2 WH(20)
1 9-GND1 BK(16)
Chassis Panel 2 Hourmeter
B+ RD(18) B- B+
9-005 RD(20)
Contactor A26 A26 BU(18)
Relay P32 P32 WH(20) Temperature A32 PK(20)
A32
Relay Feedback A4 A04 OR(20) P22 BU(20) A24
Brake+ A24 WH(18)
MC A25 BK(20)

Hourmeter
Potentiometer 2 P15 P15 WH(20) Brake- A25

Power On

LOCK_H

LOCK_L

Ground
Ground

Ground
Rotation- A7 A07 GN(20)

Brake+R RD(20)
CANL
CANH

Brake+L RD(20)
Power
Lift Down Switch P17 P17 WH(20)

Key
Cos- A20 A20 OR(20) LT-B GY20)
Left Pothole Switch P18 P18 WH(20) Rotation+ A18 A18 YE(20)
Connector

10
11
12
Cos+

4
2
3

5
6

8
9
7
A8 A08 BN(20)

1
Right Pothole Switch P7 P07 WH(20)
Sin- A31 A31 BU(20)
Beacon P29 P29 WH(20) Sin+ A19 A19 WH(20)
Potentiometer Power P26 P26 PK(20)
3 45 1 2 6 8 7 10 9
Potentiometer 1 P14 P14 WH(20)
Zero Potentiometer P27 P27 WH(20) Motor Encoder
LOCK L P22 BU(20) U2 RD(6)

Brake
P22
LOCK H P11 P11 RD(20) V2 WH(6) M3
TIME WH(20) BU(6)
W2 Temperature Left Motor
Sensor
Platform E-Stop P16 P16 GY(18)
Platform E-Stop P5 P05 OR(18)
Power P23 P23 RD(18)
Power P34 P34 RD(18) Temperature A22 A22 PK(20)
Power P35 P35 RD(18) Brake- A27 A27 BK(20)
Rotation- A17 A17 GN(20) RT-B GY(20)
Power A01 A01 RD(18) 3-005 RD(20)
Cos- A10 A10 OR(20)
Rotation+ A29 A29 YE(20)
CAN_Shied A5 Cos+ A33 A33 BN(20)
CAN_H A16 A16 YE(20) Sin- A21 A21 BU(20)
CAN_L A15 A15 GN(20) Sin+ A9 A09 WH(20)

3 45 1 2 6 8 7 10 9
2-P26 PK(20) J RD(20)

Load Cell
Load Cell 1 P1 P01 WH(20) P01 WH(20) K GN(20) Motor Encoder
U1 RD(6)

Brake
Load Cell 2 P13 P13 WH(20) P13 WH(20) L WH(20) V1 WH(6) M2 Right Motor
Lift Up Valve P30 SV2 DC- BK(12) W1 BU(6)
P30 WH(16) 1-P30 WH(18) 12-GND1 BK(18) 2-GND2 BK(20) M BK(20) Temperature Sensor
SV1 Lift Up Valve Motor DC+ RD(12)
2-P30 WH(18) 10-GND1 BK(18)
10-005 RD(20) RD(20)
M4
Emergency Switch Valve G Module CAN_Shied A5 A05 BK(18)
SQ4 High Limit Switch (Option)
High Limit Switch P10 P10 WH(20) P10 WH(20) H BU(20) Temperature A12 A12 WH(20)
GND A6 A06 GY(20)

PR-B BK(20)
RD(20) SV4 VCC+ A30 A30 PK(20)
Lift Down Valve(For S1212-1614AC+)
Cos+ A23 A23 YE(20)
Lift Down Valve P31 P31 WH(18) P31 WH(18) RD(20) SV3 Cos- A35 A35 GN(20)
A 4-CANH YE(20) 3
Lift Down Valve Sin+ A34 A34 BN(20)
8-GND1 BK(18) B BU(20) 4-CANL GN(20) 4 Sin- A11 A11 WH(20)
FootSwitch P9 P09 WH(20) P09 WH(20) C 1 23456 2 1

Anti-collision Switch P8 P08 WH(20) P08 WH(20) E Motor Encoder

U3 RD(3)
5-005 RD(20) D V3 RD(3) M1 Pump
W3 RD(3)
6-005 RD(20) F Temperature Sensor
HA2 Buzzer (Option)
Buzzer P28 P28 WH(20) P28 WH(20) R P28 WH(20)
13-GND1 BK(20) S 13-GND1 BK(20)
HL2 Beacon (Option)
11-GND1 BK(20) N 11-GND1 BK(20)
2-P29 WH(20) P 2-P29 WH(20)

85
TRAINING MANUAL

Electrical Schematic
6.3 Harness
JCPT 0807 AC+ JCPT 0808~1614 AC+
Platform Control
Limit Switch
Platform Control Box Assembly Limit Switch
(Pothole)
Box Assembly (Pothole)

Limit Switch Limit Switch

(Pothole) (Pothole)

Load Rotary Sensor Load Rotary Sensor

Sensor 3 3
Sensor
Beacon
2 5 Beacon
Coil Coil 2 5
Limit Switch
4 (Lift Down) Limit Switch
4
Coil (Lift Down)

Controller Controller

1 Relay 1 Relay

Relay Relay

Pushbeam Pushbeam
Fuse Fuse
Assembly DC
Assembly
DC Contactor
9 Contactor 10

Power Power
switch switch
7
7 Hydraulic power 8 Hydraulic power
unit unit

8
Motor Motor

Battery 6 Battery 9 6

6 6
Motor Motor

Charger Motor Charger Motor

Controller Controller

86
 TRAINING MANUAL

Hydraulic Schematic

7 Hydraulic Schematic
S0807AC+

SV3

Lift
CV1
cylinder

Lower valve
IN

T P

SV2

SV1

RV1
180Bar

Pump
Motor

Pump unit

Tank

87
TRAINING MANUAL

Hydraulic Schematic

S0808AC+ ~ S1012AC+

SV3

Lift
CV1
cylinder

Lower valve
IN

T P

SV2

SV1

RV1

RV1=130bar (S0808AC+)
RV1=160bar (S1008AC+)
Pump RV1=210bar (S1012AC+)
Motor

Pump unit

Tank

88
 TRAINING MANUAL

Hydraulic Schematic

S1212AC+ ~ S1614AC+

SV4
SV3

RV2
Lift Upper lift
CV1 cylinder
cylinder CV2

Lower valve Lower valve

IN IN

T P

SV2

SV1

RV1

RV1=150bar (S1212AC+)
RV1=190bar (S1412AC+)
RV1=200bar (S1612AC+)
Pump
Motor RV1=210bar (S1614AC+)

Pump unit

Tank

89
Zhejiang Dingli Machinery Co., Ltd.
No.188 Qihang Road. Deqing Zhejiang P.R.
China 313219
Tel: +86-572-8681688
Fax: +86-572-8681690
Web: en.cndingli.com
E-mail: [email protected]