SELF-PROPELLED VERTICAL LIFTS

OPERATOR’S MANUAL
with Maintenance Information
For AMWP8-1200/AMWP9.5-1200

WARNING
THE MANUFACTURER SHALL NOT BE HELD LIABLE IN CASE OF FAULTS
OR ACCIDENTS DUE TO NEGLIGENCE, INCAPACITY, INSTALLATION BY
UNQUALIFIED TECHNICIANS AND IMPROPER USE OF THE MACHINE

DO NOT OPERATE THIS MACHINE UNTIL YOU READ AND UNDERSTAND

ALL THE DANGERS,WARNINGS AND CAUTIONS IN THIS MANUAL

Part Number: SM0519111

Zhejiang Dingli Machinery Co., Ltd. Fourth Edition, November 2019 Printing
 OPERATOR’S MANUAL with Maintenance Information
Version of the Record

Version of the Record

Version Number Create Date

SM0519111_Rev1.0 …………………………………………………………………………… 2019-11

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 OPERATOR’S MANUAL with Maintenance Information

Important Owners, Users and operators:

Dingli appreciates your choice of our machine
Read, understand and obey these safety rules
for your application. User’s safety is our priority,
and operating instructions before operating
so we hope you can:
this machine.
1 Comply with employer, job site and
Only trained and authorized personnel shall be
governmental rules.
permitted to operate this machine. This
manual should be considered a permanent 2 Read, understand and follow the
part of your machine and should remain with instructions in this and other manuals
the machine at all times. If you have any supplied with this machine.
questions, please call DINGLI Machinery.
3 Use good safe work practices in a
commonsense way.

4 Only have trained / certified operators,

directed by informed and knowledgeable
supervision, running the machine.

If there is anything in this manual that is not

clear or which you believe should be added,
please contact us.

Contents
Page

Safety Rules 1

Legend 7

Decals 8

Specifications 11

Control panel 13

Pre-Operating Instructions 16
Contact us:

Workplace Inspection 18 Zhejiang Dingli Machinery Co., Ltd.

Function Tests 19 1255 Baiyun South Road. Leidian Town.

Deqing Zhejiang
Operating Instructions 24
China
Transport and Lifting Instructions 50
Tel: +86-572-8681688
Maintenance 52
Fax: +86-572-8681690
Schematic 72 Web: www.cndingli.com
Inspection and Repair Log 75 E-mail:[email protected]

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 OPERATOR’S MANUAL with Maintenance Information
Safety Rules

Danger Decal Legend

Failure to obey the instructions and DINGLI product decals use symbols, color
safety rules in this manual will coding and signal words to identify the
following:
result in death or serious injury.

Safety alert symbol — used to alert

Do Not Operate Unless: personnel to potential personal injury hazards.
√ You learn and practice the principles of Obey all safety messages that follow this
symbol to avoid possible injury or death.
safe machine operation contained in this
operator's manual.
Red — used to indicate the
1 Avoid hazardous situations. presence of an imminently hazardous situation
which, if not avoided, will result in death or
Know and understand the safety rules
serious injury.
before going on to the next section.

2 Always perform a pre-operation Orange — used to indicate

inspection. the presence of a potentially hazardous
situation which, if not avoided, could result in
3 Always perform function tests prior to
death or serious personal injury.
use.

4 Inspect the workplace. Yellow with safety alert

5 Only use the machine as it was symbol — used to indicate the presence of a
intended. potentially hazardous situation which, if not
avoided, may cause minor or moderate
√ You read, understand and obey the personal injury.
manufacturer's instructions and safety
rules— safety and operator's manuals and Blue without safety alert
machine decals. symbol — used to indicate the presence of a
potentially hazardous situation which, if not
√ You read, understand and obey employer's
avoided, may result in property damage.
safety rules and worksite regulations.

√ You read, understand and obey all

applicable governmental regulations.

√ You are properly trained to safely operate

the machine.

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OPERATOR’S MANUAL with Maintenance Information
Safety Rules

Intended Use Keep away from the machine if it contacts

energized power lines. Personnel on the
This machine is intended to be used only to lift
ground or in the platform must not touch or
personnel, along with their tools and materials
operate the machine until energized power
to an aerial work site.
lines are shut off.

This machine is intended to be used Do not use the machine as a ground for
INDOORS ONLY, and must not be used welding.
outdoors as wind forces may make it unstable.

Tip-over Hazard
Safety Sign Maintenance Occupants, equipment and materials must not
Replace any missing or damaged safety signs. exceed the maximum platform capacity or the
Keep operator safety in mind at all times. Use maximum capacity of the platform extension.
mild soap and water to clean safety signs. Do
not use solvent-based cleaners because they This machine is intended to be used
may damage the material of safety sign. INDOORS ONLY, and must not be used
outdoors as wind forces may make it unstable.

Maximum capacity
Electrocution Hazard
Model load occupants
This machine is not
electrically insulated AMWP8-1200 159kg 1
and will not provide AMWP9.5-1200 136kg 1
protection from contact
with or proximity to
Do not drive or elevate unless the
electrical current.
extension deck is retract.
Maintain safe
distances from electrical power lines and
apparatus in accordance with applicable Work Area Safety
governmental regulations and the following Do not raise the platform unless the machine
chart. is on a firm, level surface.
Minimum Safe Do not drive over 1.1km/h with the platform
Voltage
Approach Distance raised.
Phase to Phase
Meters
0 to 300V Avoid Contact
300V to 50kV 3.05
50kV to 200kV 4.60
200kV to 350kV 6.10
350kV to 500kV 7.62
Do not depend on the tilt alarm as a level
500kV to 750kV 10.67
indicator. The tilt alarm sounds on the chassis
750kV to 1000kV 13.72 and in the platform only when the machine is

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 OPERATOR’S MANUAL with Maintenance Information
Safety Rules

on a slope.

If the tilt alarm sounds: Do not place loads outside the platform
perimeter.
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.

Do not use the platform controls to free a

platform that is caught, snagged or otherwise
prevented from normal motion by an adjacent
structure. All personnel must be removed from
the platform before attempting to free the Do not place ladders or scaffolds in the
platform using the ground controls. platform or against any part of this machine.

Use extreme care and slow speeds while Do not transport tools and materials unless
driving the machine in the stowed position they are evenly distributed and can be safely
across uneven terrain, debris, unstable or handled by person(s) in the platform.
slippery surfaces and near holes and Do not use the machine on a moving or mobile
drop-offs. surface or vehicle.
Do not drive the machine on or near uneven Be sure all tires are in good condition, and lug
terrain, unstable surfaces or other hazardous standard parts are properly tightened.
conditions with the platform raised.
Do not alter or disable machine components
that in any way affect safety and stability.

Do not replace items critical to machine

stability with items of different weight or
specification.

Do not use batteries that weigh less than the

original equipment. Batteries are used as
Do not push off or pull toward any object counterweight and are critical to machine
outside of the platform. stability. Each battery must weigh 28 kg.

Do not modify or alter an aerial work platform

Maximum allowable manual force 200N without prior written permission from the
manufacturer. Mounting attachments for
Do not use the machine as a crane.
holding tools or other materials onto the
Do not place or attach fixed or overhanging platform, toe boards or guard rail system can
loads to any part of this machine. increase the weight in the platform and the
Do not push the machine or other objects with surface area of the platform or the load.
the platform. Crushing Hazard
Do not contact adjacent structures with the Keep hands and limbs out of scissors.
platform.
Keep the normal judgment and planned
Do not alter or disable the limit switches. operation while operating the machine by
Do not tie the platform to adjacent structures. ground control box.

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OPERATOR’S MANUAL with Maintenance Information
Safety Rules

Maintain safe distance between operators, the Collision Hazard

machine and fixed objects.

Operation on Slopes Hazard

Do not drive the machine on a slope that
exceeds the slope and side slope rating of the
machine.

Slope rating applies to machines only in the Be aware of limited sight distance and blind
stowed position. spots when driving or operating.

Be aware of the extend platform’s position

Maximum Maximum side
slope rating slope rating when driving.
Model
stowed stowed Check the work area for overhead obstructions
position position
or other possible hazards.
AMWP8-1200 25% 10%

AMWP9.5-1200 25% 10%

Note: Slope rating is subject to ground

conditions and adequate traction.

Fall Hazard
The guard rail
Be aware of crushing hazards when grasping
system
the platform guard rail.
provides fall
protection. Operators must comply with employer, job site
During operation, occupants in the platform and governmental rules regarding use of
must wear a full body harness with a lanyard personal protective equipment.
attached to an authorized lanyard anchorage
Observe and use color-coded direction arrows
point. Attach only one (1) lanyard per lanyard on the platform controls and platform decal
anchorage point. plate for drive and steer functions.
Do not sit, stand or Do not operate a machine in the path of any
climb on the platform crane or moving overhead machinery unless
guard rails. Maintain a the controls of the crane have been locked out
firm footing on the and/or precautions have been taken to prevent
platform floor at all any potential collision.
times.
No stunt driving or horseplay while operating a
machine.
Do not climb down from the platform when Do not lower the platform unless the area
raised. below is clear of personnel and obstructions.
Keep the platform floor clear of debris.
Limit travel speed according to the condition of
Close the entry gate before operating. the ground surface, congestion, slope, location
Do not enter or exit the platform unless the of personnel, and any other factors which may
machine is in the stowed position. cause collision.

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 OPERATOR’S MANUAL with Maintenance Information
Safety Rules

Component Damage Hazard Battery Safety

Do not use any battery or charger greater than Burn Hazard
24V.
Do not use the machine as a ground for
welding.

Explosion and Fire Hazard

Batteries contain acid. Always wear protective
Do not operate the machine or charge the clothing and eye wear when working with
battery in hazardous locations or locations batteries.
where potentially flammable or explosive
Avoid spilling or contacting battery acid.
gases or particles may be present.
Neutralize battery acid spills with baking soda
and water.

Damaged Machine Hazard Explosion Hazard

Do not use a damaged or malfunctioning
machine.

Conduct a thorough pre-operation inspection

of the machine and test all functions before
each work shift. Immediately tag and remove
from service a damaged or malfunctioning
machine. Keep sparks, flames and lighted tobacco away
from batteries. Batteries emit explosive gas.
Be sure all maintenance has been performed
as specified in this manual Do not contact the battery terminals or the
cable clamps with tools that may cause
Be sure all decals are in place and legible.
sparks.
Be sure the manuals are complete, legible and
Component Damage Hazard
in the storage container located in the platform.
Do not use any battery charger greater than
24V to charge the batteries.
Bodily Injury Hazard
Electrocution/ Burn Hazard
Do not operate the machine with a hydraulic oil
Connect the battery charger
or air leak. An air leak or hydraulic leak can
to a grounded, AC 3-wire
penetrate and/or burn skin.
electrical outlet only.
Improper contact with components under any
Inspect daily for damaged
cover will cause serious injury. Only trained
cords, cables and wires.
maintenance personnel should access
Replace damaged items
compartments. Access by the operator is only
before operating.
advised when performing a pre-operation
inspection. All compartments must remain Avoid electrical shock from contact with
closed and secured during operation. battery terminals. Remove all rings, watches
and other jewelry.

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OPERATOR’S MANUAL with Maintenance Information
Safety Rules

Tip-over Hazard
Do not use batteries that weigh less than the
original equipment. Batteries are used as
counterweight and are critical to machine
stability. Each battery must weigh 28 kg.

Lifting Hazard
Use the appropriate number of people and
proper lifting techniques when lifting batteries.

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 Chock the wheels.

5 Charge the batteries.

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 OPERATOR’S MANUAL with Maintenance Information
Legend

Legend

13
1

12

11

3
10

4
9

1 Platform entry mid rail 9 Motor/Pump/Reservoir Unit

（located under the cover, and not
2 Platform controls displayed）

3 Platform extension 10 Ground Control

4 Main Platform 11 Cover

5 Front Wheel 12 Masts Assembly

6 Chassis 13 Platform guard rails

7 Pothole device

8 Rear Wheel

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OPERATOR’S MANUAL with Maintenance Information
Decals

Decal Inspection
Use the pictures on the next page to verify that all decals are legible and in place.
Below is a numerical list with quantities and descriptions.

No. Part No. Description Qty. Remark

1 09440227 Decal, Danger-Tip-over hazard, tilt-alarm 1

09440213 Decal, Label-Capacity 150kg 1 AMWP8-1200

2
09440214 Decal, Label-Capacity 136kg 1 AMWP9.5-1200

09310294 Decal, Instructions-Maximum wheel load 425kg 4

3
09310296 Decal, Instructions-Maximum wheel load 500kg 4

4 09540001 Decal, Label-CE 2

5 09540002 Decal, Label-IPAF 2

6 09310003 Decal, Instructions-Tie down point 4

7 09420017 Decal, Danger-Do not stand 1

8 09430026 Decal, Warning-Crushing hazard 1

Decal, Instructions-Refer the operator to the

9 09340003 2
instructions for use
10 09440011 Decal, Label-Lanyard anchorage point 2

11 09340016 Decal, Instructions-Open/close 1

12 09440233 Decal, Warning-Tip-over hazard 1

13 09440235 Decal, Warning-Crushing hazard/ Falling hazard 1

14 09440231 Decal, Warning-Use indoors only 1

15 09440066 Decal, Caution-Max. manual force 200N 1

16 09440229 Decal, Danger-Electrocution hazard 1

17 09310001 Decal, Instructions-Forklift pockets 2

18 09310004 Decal, Instructions-Emergency lower 1

19 09410001 Decal, Danger-Explosion/burn hazard 1

20 09310006 Decal, Notice-Main power switch operation 1

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 OPERATOR’S MANUAL with Maintenance Information
Decals

2
10

11

8
7

13

12

3
4
5
3
6

14
20
15

19 16

17
6

5
6
4
18
3
6
17

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OPERATOR’S MANUAL with Maintenance Information
Decals

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 OPERATOR’S MANUAL with Maintenance Information
Specifications

AMWP8-1200

Height, working maximum 8.0m Driving wheels Φ323×100mm

Height, platform maximum 6.0m Airborne noise emissions <70dB

Height, stowed maximum 1.99m Maximum sound level at normal operating

workstations (A-weighted)
Height, guard rails 1.1m
Vibration value does not exceed 2.5m/s2
Width 0.80m
Maximum slope rating
25%
Length, platform retracted 1.39m Stowed position

Platform dimensions Maximum side slope rating

0.74×0.80m 10%
Platform length × width Stowed position

Maximum load capacity 159kg Note: Slope rating is subject to ground

conditions and adequate traction.
Maximum wind speed 0m/s
Maximum working slope X-1.5°,Y-3°
Wheelbase 1.07m
Drive speeds
Turning radius (outside) 1.55m
Stowed, maximum 4.0km/h
Turning radius (inside) 0m
Platform raised, maximum 1.1km/h
Ground clearance 6cm
Floor loading information
Ground clearance 1.4cm
Pothole guards deployed Tire load, maximum 425kg

Weight （See Serial Label） Tire contact pressure 8.1kg/cm2

793.8kPa
Machine weights vary with option configurations
Occupied floor pressure 1150kg/m2
Power source 2×12V 100Ah 11.27kPa

Note: Floor loading information is approximate

Controls Proportional
and does not incorporate different option
AC outlet in platform Standard configurations. It should be used only with
adequate safety factors.
Maximum hydraulic
180bar Continuous improvement of our products is a
pressure (functions)
DINGLI policy. Product specifications are
System voltage 24V subject to change without notice or obligation.

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OPERATOR’S MANUAL with Maintenance Information
Specifications

AMWP9.5-1200

Height, working maximum 9.5m Driving wheels Φ323×100mm

Height, platform maximum 7.5m Airborne noise emissions <70dB

Height, stowed maximum 1.99m Maximum sound level at normal operating

workstations (A-weighted)
Height, guard rails 1.1m
Vibration value does not exceed 2.5m/s2
Width 0.80m
Maximum slope rating
25%
Length, platform retracted 1.44m Stowed position

Platform dimensions Maximum side slope rating

0.74×0.80m 10%
Platform length × width Stowed position

Maximum load capacity 136kg Note: Slope rating is subject to ground

conditions and adequate traction.
Maximum wind speed 0m/s
Maximum working slope X-1.5°,Y-3°
Wheelbase 1.12m
Drive speeds
Turning radius (outside) 1.58m
Stowed, maximum 4.0km/h
Turning radius (inside) 0m
Platform raised, maximum 1.1km/h
Ground clearance 6cm
Floor loading information
Ground clearance 1.4cm
Pothole guards deployed Tire load, maximum 500kg

Weight （See Serial Label） Tire contact pressure 10.5kg/cm2

1028.0kPa
Machine weights vary with option configurations
Occupied floor pressure 1489kg/m2
Power source 2×12V 100Ah 14.59kPa

Note: Floor loading information is approximate

Controls Proportional
and does not incorporate different option
AC outlet in platform Standard configurations. It should be used only with
adequate safety factors.
Maximum hydraulic
180bar Continuous improvement of our products is a
pressure (functions)
DINGLI policy. Product specifications are
System voltage 24V subject to change without notice or obligation.

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 OPERATOR’S MANUAL with Maintenance Information
Control Panel

Ground Control Panel

1 2 3 4 5 6

1 LED readout screen 4 Red Emergency Stop button

Diagnostic readout 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
2 Platform up / down switch
to operate the machine.
Move the switch up and the platform will raise.

Move the switch down and the platform will 5 Alarm

lower.

6 Key switch
3 Overload indicator light
Turn the key switch to the platform position
Light on indicates when overloaded.
and the platform controls will operate. Turn the
key switch to the off position and the machine
will be off. Turn the key switch to the ground
position and the ground controls will operate.

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OPERATOR’S MANUAL with Maintenance Information
Control Panel

Platform Control Panel

1 2 3 4 5 6 7

6 Drive function select button

1 Function enable switch
7 Drive speed button
2 Thumb rocker switch
8 LED readout screen
3 Proportional control handle
9 Red Emergency Stop button
4 Horn button
5 Lift function select button

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 OPERATOR’S MANUAL with Maintenance Information
Control Panel

Platform Control Panel

1 Function enable switch 4 Horn Button

Press and hold the function enable switch Press this button and the horn will sound.
to enable the drive/lift function. Release the button and the horn will stop.
2 Thumb rocker switch 5 Lift function select button
Press the thumb rocker switch in either Press this button to activate the lift
direction to activate steer function. function.
3 Proportional control handle 6 Drive function select button
Lift function: Press and hold the function Press this button to activate the drive
enable switch to enable the lift function on function.
the platform control handle. Move the
7 Drive speed button
control handle in the direction indicated by
the blue arrow and the platform will raise. Press this button to activate the drive
Move the control handle in the direction function.
indicated by the yellow arrow and the 8 LED readout screen
platform will lower. The descent alarm
should sound while the platform is Diagnostic read out and battery charge
indicator.
lowering.
9 Red Emergency Stop button
Drive function: Press and hold the function
enable switch to enable the drive function Push in the red Emergency Stop button to
on the platform control handle. Move the the off position to stop all functions. Pull
control handle in the direction indicated by out the red Emergency Stop button to the
the blue arrow on the control panel and the on position to operate the machine.
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.

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OPERATOR’S MANUAL with Maintenance Information
Pre-operation Inspection

Do Not Operate Unless: Fundamentals

√ You learn and practice the principles of It is the responsibility of the operator to
perform a pre-operation inspection and routine
safe machine operation contained in this
maintenance.
operator's manual.
The pre-operation inspection is a visual
1 Avoid hazardous situations.
inspection performed by the operator prior to
2 Always perform a pre-operation each work shift. The inspection is designed to
inspection. discover if anything is apparently wrong with a
Know and understand the pre-operation machine before the operator performs the
inspection before going on to the next function tests.
section. The pre-operation inspection also serves to
3 Inspect the workplace. determine if routine maintenance procedures
are required. Only routine maintenance items
4 Always perform function tests prior to
specified in this manual may be performed by
use.
the operator.
5 Only use the machine as it was
Refer to the list on the next page and check
intended.
each of the items.

If damage or any unauthorized variation from

factory delivered condition is discovered, the
machine must be tagged and removed from
service.

Repairs to the machine may only be made by

a qualified service technician, according to the
manufacturer's specifications. After repairs are
completed, the operator must perform a
pre-operation inspection again before going on
to the function tests.

Scheduled maintenance inspections shall be

performed by qualified service technicians,
according to the manufacturer's specifications
and the requirements listed in this manual.

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 OPERATOR’S MANUAL with Maintenance Information
Pre-operation Inspection

Pre-operation Inspection
 Be sure that the operator’s manual are Check entire machine for:
complete, legible and in the storage
 Cracks in welds or structural
container located in the platform.
components
 Be sure that all decals are legible and in
 Dents or damage to machine
place. See Decals section.
 Be sure that all structural and other
 Check for hydraulic oil leaks and proper
critical components are present and
oil level. Add oil if needed. See
all associated fasteners and pins are
Maintenance section.
in right place and properly tightened.
 Check for battery fluid leaks and proper
fluid level. Add distilled water if needed.
See Maintenance section.

Check the following components or areas for

damage, improperly installed or missing parts
and unauthorized modifications:

 Electrical components, wiring and

electrical cables

 Hydraulic hoses, fittings, cylinders

and manifolds

 Battery pack and connections

 Drive motors

 Rollers and slide blocks on masts

 Tires and wheels

 Lifting chains and idler wheels

 Mast and mast braces

 Limit switches, alarms and horn

 Nuts, bolts and other fasteners

 Platform entry gate and guard rail

 Alarms and beacons

 Platform extension

 Platform Control Panel

 Pothole guard

 Wire

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OPERATOR’S MANUAL with Maintenance Information
Workplace Inspection

Do Not Operate Unless: Fundamentals

√ You learn and practice the principles of The workplace inspection helps the operator
determine if the workplace is suitable for safe
safe machine operation contained in this
machine operation. It should be performed by
operator's manual.
the operator prior to moving the machine to the
1 Avoid hazardous situations. workplace.
2 Always perform a pre-operation It is the operator's responsibility to read and
inspection. remember the workplace hazards, then watch
3 Inspect the workplace. for and avoid them while moving, setting up
and operating the machine.
Know and understand the workplace
inspection before going on to the next
section.
Workplace Inspection
4 Always perform function tests prior to
Be aware of and avoid the following hazardous
use.
situations:
5 Only use the machine as it was
- Drop-offs or holes
intended.
- Bumps, floor obstructions or debris

- Sloped surfaces

- Unstable or slippery surfaces

- Overhead obstructions and high voltage

conductors

- Hazardous locations

- Inadequate surface support to withstand all

load forces imposed by the machine

- The presence of unauthorized personnel

- Other possible unsafe conditions

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 OPERATOR’S MANUAL with Maintenance Information
Function Tests

Do Not Operate Unless: Fundamentals

√ You learn and practice the principles of The function tests are designed to discover
safe machine operation contained in this any malfunctions before the machine is put
operator's manual. into service.

1 Avoid hazardous situations. The operator must follow the step-by-step

instructions to test all machine functions.
2 Always perform a pre-operation
A malfunctioning machine must never be used.
inspection.
If malfunctions are discovered, the machine
3 Inspect the workplace. must be tagged and removed from service.
4 Always perform function tests prior Repairs to the machine may only be made by
to use. a qualified service technician, according to the
manufacturer's specifications.
Know and understand the function tests
before going on to the next section. After repairs are completed, the operator must
perform a pre-operation inspection and
5 Only use the machine as it was
function tests again before putting the machine
intended.
into service.

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OPERATOR’S MANUAL with Maintenance Information
Function Tests

1 Select a test area that is firm, level and 9 Turn the key switch to off or platform
free of obstruction. position.
2 Be sure the battery pack is connected. 10 Move up and hold the platform up / down
switch.
3 Pull out the main power switch to “on”
position. ⊙ Result: No function should operate.

At the Ground Controls 11 Turn the key switch to ground control

position.
4 Pull out the platform and ground red
Emergency Stop buttons to the on 12 Move up and hold the platform up / down
position. switch.

5 Turn the key switch to ground control. ⊙ Result: The platform should raise.

6 Observe the LED readout screen on the 13 Move down and hold the platform up /
ECU window. down switch.

⊙ Result: The LED should look like the picture ⊙ Result: The platform should lower. The
at underside descent alarm should sound while the
platform is lowering. The platform stop at
the height is approximately 1.3m from the
ground. The descent delay alarm will
sound.

Note: Be sure the area below the platform is

clear of personnel and obstructions before
continuing.
Test Emergency Stop 14 Move down and hold the platform up /
7 Push in the ground red Emergency Stop down switch.
button to the off position. ⊙ Result: The platform should lower to end.
⊙ Result: No functions should operate. The descent delay alarm should sound
while the platform is lowering.
8 Pull out the red Emergency Stop button to
the on position. Test the Emergency Lowering

Test Up/Down Functions 15 Activate the up function and raise the

platform approximately 60 cm.
A buzzer with different sound frequency is
controlled in central system. The descent 16 Pull the emergency lowering knob.
alarm sounds at 60 beeps per minute. The ⊙ Result: The platform should lower. The
descent delay alarm sounds at 120 beeps per descent alarm will not sound.
minute. The alarm that goes off when the
17 Turn the key switch to platform control.
pothole guards have not deployed sounds at
180 beeps per minute. The alarm that goes off
when the machine is not level sounds at 180
beeps per minute. An optional
automotive-style horn is also available.

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 OPERATOR’S MANUAL with Maintenance Information
Function Tests

At the Platform Controls platform is lowering.

Test Emergency Stop Test the Steering

18 Push in the platform red Emergency Stop Note: When performing the steer and drive
button to the off position. function tests, stand in the platform facing the
steer end of the machine.
⊙ Result: No functions should operate.
28 Press the drive function select switch. The
19 Pull the red Emergency Stop button out to indicator light should turn on.
the on position.
29 Press and hold the function enable switch
⊙ Result: The LED indicator light should on the control handle.
come on.
30 Depress the thumb rocker switch on top of
Test the Horn the control handle in the direction identified
by the blue left arrow on the control panel.
20 Push the horn button.
⊙ Result: The steer wheels should turn in the
⊙ Result: The horn should sound.
direction that the blue left arrow points on
Test Function Enable and Up/Down the control panel.
Functions 31 Depress the thumb rocker switch in the
21 Do not hold the function enable switch on direction identified by the yellow right
the control handle. arrow on the control panel.

22 Slowly move the control handle in the ⊙ Result: The steer wheels should turn in the
direction indicated by the blue arrow, then direction that the yellow right arrow points
in the direction indicated by the yellow on the control panel.
arrow.
Test Drive and Braking
⊙ Result: No functions should operate.
32 Press the drive function select button. The
23 Press the lift function select button. indicator light should turn on.

24 Press and hold the function enable switch 33 Press and hold the function enable switch
on the control handle. on the control handle.

25 Slowly move the control handle in the 34 Slowly move the control handle in the
direction indicated by the blue arrow. direction indicated by the blue arrow on the
control panel until the machine begins to
⊙ Result: The platform should raise. The
move, then return the handle to the center
pothole guards should deploy.
position.
26 Release the control handle.
⊙ Result: The machine should move in the
⊙ Result: The platform should stop raising. direction that the blue arrow points on the
control panel, then come to an abrupt stop.
27 Press and hold the function enable switch.
Slowly move the control handle in the 35 Press and hold the function enable switch
direction indicated by the yellow arrow. on the control handle.

⊙ Result: The platform should lower. The 36 Slowly move the control handle in the
descent alarm should sound while the direction indicated by the yellow arrow on

21
OPERATOR’S MANUAL with Maintenance Information
Function Tests

the control panel until the machine begins The platform controls LED readout should
to move, then return the handle to the display “LL”.
center position.
43 Press the drive function select button.
⊙ Result: The machine should move in the 44 Press and hold the function enable switch
direction that the yellow arrow points on the on the control handle.
control panel, then come to an abrupt stop.
45 Move the drive control handle in the
Note: The brakes must be able to hold the direction indicated by the blue up arrow,
machine on any slope that is able to then move the drive control handle in the
climb. direction indicated by the yellow arrow.
Test Limited Drive Speed ⊙ Result: The drive function should not work
37 Press the lift function select button. The in either direction.
indicator light should turn on. Press and 46 Lower the platform and drive the machine
hold the function enable switch. Raise the off the block.
platform approximately 2 m from the
ground. Test the Pothole Guards

⊙ Result: The pothole guards should deploy. Note: The pothole guards should automatically
deploy when the platform is raised. The
38 Press the drive function select button. The pothole guards activate another limit switch
indicator light should turn on. which allows the machine to continue to
39 Press and hold the function enable switch function. If the pothole guards do not deploy,
on the control handle. Slowly move the an alarm sounds and the machine will not
control handle to the full drive position. drive and lift.

⊙ Result: The maximum achievable drive 47 Raise the platform.

speed with the platform raised should not ⊙ Result: When the platform is raised
exceed 20 cm/s. approximately 2m from the ground, the
¤ Result: If the drive speed with the platform pothole guards should deploy.
raised exceeds 20 cm/s, immediately tag 48 Press on the pothole guards on one side,
and remove the machine from service. and then the other side.
Test the Tilt Sensor Operation ⊙ Result: The pothole guards should not
Note: Perform this test from the ground with move.
the platform controller. Do not stand in the 49 Lower the platform.
platform.
⊙ Result: The pothole guards should return to
40 Fully lower the platform. the stowed position.
41 Place a 3×10cm or similar piece of wood 50 Place a 5x10cm or similar piece of wood
under both wheels on one side and drive under a pothole guard. Raise the platform.
the machine up onto them.
⊙ Result: When the platform is raised
42 Raise the platform at least 2 m.
approximately 2m from the ground, the
⊙ Result: The platform should stop and the tilt pothole alarm will sound at 180 beeps per
alarm will sound at 180 beeps per minute. minute, and the platform controls LED

22
 OPERATOR’S MANUAL with Maintenance Information
Function Tests

screen readout should display “58”.

51 Press the drive function select button.

52 Press and hold the function enable switch

on the control handle.

53 Move the control handle in the direction

indicated by the blue arrow, and then
move the control handle in the direction
indicated by the yellow arrow.

⊙ Result: The drive function should not work

in either direction.

54 Press and hold the function enable switch

on the control handle.

55 Depress the thumb rocker switch on top of

the control handle in the direction identified
by the blue and yellow arrow on the control
panel.

⊙ Result: The steer function should not work

in either direction.

56 Lower the platform and remove the 5x10

wood block.

23
OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Do Not Operate Unless: The Operating Instructions section provides

instructions for each aspect of machine
√ You learn and practice the principles of operation.
safe machine operation contained in this
It is the operator's responsibility to follow all
operator's manual.
the safety rules and instructions in the
1 Avoid hazardous situations. operator's, safety and responsibilities
2 Always perform a pre-operation manuals.
inspection. Using the machine for anything other than
3 Inspect the workplace. lifting personnel, along with their tools and
materials, to an aerial work site is unsafe and
4 Always perform function tests prior to
dangerous.
use.
5 Only use the machine as it was Only trained and authorized personnel should
intended. be permitted to operate a machine. If more
than one operator is expected to use a
machine at different times in the same work
Fundamentals shift, they must all be qualified operators and
are all expected to follow all safety rules and
This machine is a self-propelled hydraulic lift instructions in the operator's, safety and
equipped with a work platform on the Vertical responsibilities manuals. That means every
mechanism. Vibrations emitted by these new operator should perform a pre-operation
machines are not hazardous to an operator in inspection, function tests, and a workplace
the work platform. The machine can be used inspection before using the machine.
to position personnel with their tools and
supplies at position above ground level and
can be used to reach work areas located
above and over machinery or equipment.

A full and detailed implementation of EN ISO

13849-1/2 is correctly applied on our MEWP
design. SISTEMA, a software tool for PL
Calculation Tool, is also used to perform some
relatively straightforward calculations on
subsystem to determine the overall PL of the
system. Reliability data, diagnostic coverage
[DC], the system architecture [Category],
common cause failure and, where relevant,
requirements for software are used to assess
the PL to comply with PLr of SRP/CS in
Clause 5.11 of EN 280.

24
 OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Emergency Stop 3 Move the control handle according to the

markings on the control panel.
Push in the red Emergency Stop button to the
off position at the ground controls or the To Steer
platform controls to stop all machine functions. 1 Press the drive function select button.
Repair any function that operates when either 2 Press and hold the function enable switch
red Emergency Stop button is pushed in. on the control handle.

3 Turn the steer wheels with the thumb

rocker switch located on the top of the
Emergency Lowering
control handle.
1 Pull the emergency lowering knob to lower
To Drive
the platform.
1 Press the drive function select button.

2 Press and hold the function enable switch

Operation from Ground on the control handle.
1 Turn the key switch to ground control. 3 Increase speed: Slowly move the control
2 Pull out both ground and platform red handle off center.
Emergency Stop buttons to the on Decrease speed: Slowly move the control
position. handle toward center.
3 Be sure the battery pack is connected Stop: Return the control handle to center or
before operating the machine. release the function enable switch.
To Position Platform Use the color-coded direction arrows on the
1 Move the up/down switch according to the platform controls and on the platform to
markings on the control panel. identify the direction the machine will travel.

Drive and steer functions are not available Machine travel speed is restricted when the
from the ground controls. platform is raised.

Battery condition will affect machine

performance. Machine drive speed and
Operation from Platform function speed will drop when the battery level
indicator is flashing.
1 Turn the key switch to platform control.

2 Pull out the ground and platform red To select drive speed
Emergency Stop buttons to the on The drive controls can operate in two different
position. drive speed modes. When the drive speed
3 Be sure the battery pack is connected button light is on, slow drive speed mode is
before operating the machine. active. When the button light is off, fast drive
speed mode is active.
To Position Platform
Press the drive speed button to select the
1 Press the lift function select button. desired drive speed.
2 Press and hold the function enable switch Note：When the platform is elevated, the drive
on the control handle.

25
OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

speed button light is always on, indicating Operation from Ground with
elevated drive speed.
Controller
Driving on a slope
Maintain safe distances between operator,
Determine the slope and side slope ratings for machine and fixed objects.
the machine and determine the slope grade.
Be aware of the direction the machine will
Maximum slope rating, stowed position 25%, travel when using the controller.
Maximum side slope rating, stowed position
10%

Note: Slope rating is subject to ground Battery Level Indicator

conditions and adequate traction.

Press the drive speed button to the fast drive

speed mode.
Full Low
To determine the slope grade
Use the LED readout screen to determine the
Measure the slope with a digital inclinometer battery level.
OR use the following procedure.

You will need:

Carpenter’s level
To Extend and Retract Platform
Straight piece of wood, at least 1m long 1 Pull and turn the platform lock pin handle
on the extension deck.
Tape measure
2 Push the platform extension guardrail to
Lay the piece of wood on the slope.
extend the platform.
At the downhill end, lay the level on the top
3 Turn the handle and push the platform lock
edge of the piece of wood and lift the end until
pin to the socket on the extension deck.
the piece of wood is level.
4 Reverse the above steps to retract
While holding the piece of wood level,
platform.
measure the distance from the bottom of the
piece of wood to the ground. NOTE：Do not stand on the platform extension
while trying to extend and retract it.
Divide the tape measure distance (rise) by the
length of the piece of wood (run) and multiply
by 100.

Example:

Run = 3.6 m

Rise = 0.3 m

0.3 m ÷ 3.6 m = 0.083 x 100 = 8.3%

If the slope exceeds the maximum slope or

side slope rating, the machine must be
winched or transported up or down the slope.
See Transport and Lifting section.
26
 OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

WARNING CODE DESCRIPTION

warning
Warning Description Denied motion
code
51 ECU ALARM ALL

52 PCU ALARM ALL

53 TM1 ALARM ALL

54 PRESS SENSOR ERROR ALL

Machine traction & steering (cage-up
55 LOCK TRACTION IF CAGE UP
traction speed must be 0）

56 LEVEL SENSOR ERROR cage lifting

OL MACHINE OVERLOAD cage lifting & vehicle traction

58 POTHOLE SWITCH FAULT cage lifting & vehicle traction

59 HIGH POSTION LIMIT cage lifting

60 OUTDOOR 2.5M HEIGHT LIMIT cage lifting

61 LOW POSITION LIMIT Cage descent

62 TILT CYLIDER OUT cage steering & vehicle traction

LL TILTING X OVER THRESHOLD cage lifting & vehicle traction

LL TILTING Y OVER THRESHOLD cage lifting & vehicle traction

Cage descent. to release joystick or

63 ANTI-HAND CLAMP STOP
toggle switch and redo the motion
64 CAGE NOT ALLOWED EXTENDED Cage platform extension

65 CAGE EXTENDED Cage descent.

Cage lifting, turtle/rabbit speed traction.

66 LOW BATTERY LEVEL
“cage-up” speed traction is allowed
67 OBSTACLE UNDER CAGE Cage descent

68 CAGE DOOR OPEN cage lifting & vehicle traction

70 POTHOLE SWITCH FAULT cage lifting & vehicle traction

71 CAGE SIDE OPEN vehicle traction

72 CHAIN LOOSE vehicle traction & cage descent

73 FRONT RADAR vehicle traction

74 ANTI COLLISION Cage lifting（for scissor only）

75 Rental Locked

27
OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

warning
Warning Description Denied motion
code
76 GPS LOCKER

80 RenewRental 1 month

81 RenewRental 3 month

82 RenewRental 6 month

83 RenewRental 12 month
TRACTION MOTOR RIGHT SIDE
88 NONE. Warning only
OVERLOAD
TRACTION MOTOR LEFT SIDE
89 NONE. Warning only
OVERLOAD
90 TM1 PCB HIGH TEMPERATURE NONE. Warning only

91 TM1 RADIATOR HIGH TEMPERATURE NONE. Warning only

92 TM1 PARAMETER OVER LIMIT NONE. Warning only

93 TM has not software parameters NONE. Warning only

94 PUMP MOTOR OVERLOAD NONE. Warning only

95 EMPTY CALIBRATION FAULT NONE. Warning only

96 LADEN CALIBRATION FAULT NONE. Warning only

CAGE LIFTING FUNCTION IS

97 NONE. Warning only
OVERRIDED
98 VEHICLE BRAKE RELEASED NONE. Warning only

VEHICLE BYPASS FUNCTION

99 NONE. Warning only
ENGAGED

28
 OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

ALARM CODE DESCRIPTION

Alarm Denied
Alarm Description
code motion
101 ECU E2PROM ALARM ALL

102 ECU WATCHDOG FAULT ALL

103 LMI OverLoad_Start

104 ECU Thermal Calib.

105 Init. Data Logger

106 E2P Save On Err

107 TMParameter Modified

108 Password Inserted

109 LMI OverLoad_End

110 PCU CPU0 CANBUS TIMEOUT1 ALL

111 PCU CPU0 CANBUS TIMEOUT2 ALL

112 PCU CPU1 CANBUS TIMEOUT1 ALL

113 PCU CPU1 CANBUS TIMEOUT2 ALL

114 TM1 CANBUS TIMEOUT ALL

116 PRESSURE SENSOR REDUNDANT CHECK FAULT ALL

117 ANALOG SCISSOR ANGLE SENSOR REDUNDANT CHECK FAULT ALL

118 TILT-X REDUNDANT CHECK FAULT ALL

119 TILT-Y REDUNDANT CHECK FAULT ALL

120 KEY SWITCH INPUT CHECK FAULT ALL

121 TOGGLE SWITCH INPUT CHECK FAULT ALL

122 ECU PIN29, INP00 REDUNDANT CHECK FAULT ALL

123 ECU PIN30, INP01 REDUNDANT CHECK FAULT ALL

124 ECU PIN32, INP02 REDUNDANT CHECK FAULT ALL

125 ECU PIN33, INP03 REDUNDANT CHECK FAULT ALL

126 ECU PIN06, INP04 REDUNDANT CHECK FAULT ALL

127 ECU PIN34, INP05 REDUNDANT CHECK FAULT ALL

128 ECU PIN45, INP10 REDUNDANT CHECK FAULT ALL

129 ECU PIN46, INP11 REDUNDANT CHECK FAULT ALL

130 ECU PIN47, INP12 REDUNDANT CHECK FAULT ALL

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OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Alarm Denied
Alarm Description
code motion
131 ECU PIN48, INP13 REDUNDANT CHECK FAULT ALL

132 ECU PIN49, INP14 REDUNDANT CHECK FAULT ALL

133 ECU PIN50, INP15 REDUNDANT CHECK FAULT ALL

134 ECU PIN19, INP RELAY REDUNDANT CHECK FAULT ALL

135 ECU PIN20, INP BRAKE REDUNDANT CHECK FAULT ALL

136 ECU PIN23, INP M1 REDUNDANT CHECK FAULT ALL

137 ECU PIN24, INP M2 REDUNDANT CHECK FAULT ALL

138 PRESSURE SENSOR N.1 OPEN CIRCUIT OR SHORT TO GND ALL

139 PRESSURE SENSOR N.1 SHORT CIRCUIT TO PWR ALL

140 PRESSURE SENSOR N.1 VALUE LOWER THAN THRESHOLD MIN. ALL

141 PRESSURE SENSOR N.1 VALUE GREATER THAN THRESHOLD MAX. ALL

142 PRESSURE SENSOR N.2 OPEN CIRCUIT OR SHORT TO GND ALL

143 PRESSURE SENSOR N.2 SHORT CIRCUIT TO PWR ALL

144 PRESSURE SENSOR N.2 VALUE LOWER THAN THRESHOLD MIN. ALL

145 PRESSURE SENSOR N.2 VALUE GREATER THAN THRESHOLD MAX. ALL
ANALOG SCISSOR ANGLE CHANNEL A: OPEN CIRCUIT OR SHORT TO
146 ALL
GND
147 ANALOG SCISSOR ANGLE CHANNEL A: SHORT CIRCUIT TO PWR ALL
ANALOG SCISSOR ANGLE CHANNEL A: ANGLE VALUE LOWER THAN
148 ALL
MIN.
ANALOG SCISSOR ANGLE CHANNEL A: ANGLE VALUE GREATER THAN
149 ALL
MAX.
ANALOG SCISSOR ANGLE CHANNEL B: OPEN CIRCUIT OR SHORT TO
150 ALL
GND
151 ANALOG SCISSOR ANGLE CHANNEL B: SHORT CIRCUIT TO PWR ALL
ANALOG SCISSOR ANGLE CHANNEL B: ANGLE VALUE LOWER THAN
152 ALL
MIN.
ANALOG SCISSOR ANGLE CHANNEL B: ANGLE VALUE GREATER THAN
153 ALL
MAX.
154 .ADXL Open Circuit ALL

160 ECU PIN01 OUT00 SHORT TO +VB ALL

161 ECU PIN01 OUT00 INTERNAL FAULT ALL

162 ECU PIN01 OUT00 CHECK FAULT ALL

30
 OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Alarm Denied
Alarm Description
code motion
163 ECU PIN01 OUT00 OPEN CIRCUIT ALL

164 ECU PIN01 OUT00 SHORT CIRCUIT ALL

165 ECU PIN02 OUT01 SHORT TO +VB ALL

166 ECU PIN02 OUT01 INTERNAL FAULT ALL

167 ECU PIN02 OUT01 CHECK FAULT ALL

168 ECU PIN02 OUT01 OPEN CIRCUIT ALL

169 ECU PIN02 OUT01 SHORT CIRCUIT ALL

170 ECU PIN04 OUT02 SHORT TO +VB ALL

171 ECU PIN04 OUT02 INTERNAL FAULT ALL

172 ECU PIN04 OUT02 CHECK FAULT ALL

173 ECU PIN04 OUT02 OPEN CIRCUIT ALL

174 ECU PIN04 OUT02 SHORT CIRCUIT ALL

175 ECU PIN05 OUT03 SHORT TO +VB ALL

176 ECU PIN05 OUT03 INTERNAL FAULT ALL

177 ECU PIN05 OUT03 CHECK FAULT ALL

178 ECU PIN05 OUT03 OPEN CIRCUIT ALL

179 ECU PIN05 OUT03 SHORT CIRCUIT ALL

180 ECU PIN08 OUT04 SHORT TO +VB ALL

181 ECU PIN08 OUT04 INTERNAL FAULT ALL

182 ECU PIN08 OUT04 CHECK FAULT ALL

183 ECU PIN08 OUT04 OPEN CIRCUIT ALL

184 ECU PIN08 OUT04 SHORT CIRCUIT ALL

185 ECU PIN09 OUT05 SHORT TO +VB ALL

186 ECU PIN09 OUT05 INTERNAL FAULT ALL

187 ECU PIN09 OUT05 CHECK FAULT ALL

188 ECU PIN09 OUT05 OPEN CIRCUIT ALL

189 ECU PIN09 OUT05 SHORT CIRCUIT ALL

190 ECU PIN11 OUT06 SHORT TO +VB ALL

191 ECU PIN11 OUT06 INTERNAL FAULT ALL

192 ECU PIN11 OUT06 CHECK FAULT ALL

31
OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Alarm Denied
Alarm Description
code motion
193 ECU PIN11 OUT06 OPEN CIRCUIT ALL

194 ECU PIN11 OUT06 SHORT CIRCUIT ALL

195 ECU PIN13 OUT07 SHORT TO +VB ALL

196 ECU PIN13 OUT07 INTERNAL FAULT ALL

197 ECU PIN13 OUT07 CHECK FAULT ALL

198 ECU PIN13 OUT07 OPEN CIRCUIT ALL

199 ECU PIN17 OUT07 SHORT CIRCUIT ALL

200

201 Pump Current Offset error ALL

202 Traction motor 1 Current Offset error ALL

203 Traction motor 2 Current Offset error ALL

204 TM1 HW Parameter Loading error ALL

205 TM1 Parameter Loading error ALL

210 TM Power Over Range ALL

211 TM Power Relay Stuck ALL

212 TM Precharge Undone ALL

213 TM Power Relay Open ALL

214 Traction motor1 Short Circuit ALL

215 Traction motor2 Short Circuit ALL

216 Pump Short Circuit ALL

217 Excitation circuit in short circuit (for TM2 SepEx. only) ALL
220 Pump Over Current ALL

221 Traction motor1 Over Current ALL

222 Traction motor2 Over Current ALL

223 TM Capacitor Over Voltage ALL

224 TM Capacitor Low Voltage ALL

225 TM PCB high temperature alarm ALL

226 TM Radiator high temperature alarm ALL

227 TM OUT1 Over Current ALL

228 TM OUT2 Over Current ALL

32
 OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Alarm Denied
Alarm Description
code motion
229 TM OUT3 Over Current ALL

230 TM WatchDog Error ALL

231 TM WatchDog Validity Error ALL

232 TM Pump Open Circuit ALL

233 Tractor Motor1 Open circuit ALL

234 Tractor Motor2 Open circuit ALL

235 Traction Motor1 Wiring Error ALL

236 Traction Motor2 Wiring Error ALL

237 TM Excitation Open Circuit ALL

238 TM Excitation Wiring Error ALL

239 Vehicle Battery Under Voltage ALL

240 Excitation circuit over current (for TM2 SepEx. only) ALL

241 Field Open Circuit （After Reboot） ALL

260 Tilt OverLimit_start

261 Tilt OverLimit_end

262 Batt.Charging Start

263 Batt.Charging End

280 AL_PCU_INITCHECK

281 PCU cpu0 fault ALL

282 PCU cpu1 fault ALL

300 ECU OUT08 SHORT TO +VB ALL

301 ECU OUT08 INTERNAL FAULT ALL

302 ECU OUT08 CHECK FAULT ALL

303 ECU OUT08 OPEN CIRCUIT ALL

304 ECU OUT08 SHORT CIRCUIT ALL

305 ECU OUT09 SHORT TO +VB ALL

306 ECU OUT09 INTERNAL FAULT ALL

307 ECU OUT09 CHECK FAULT ALL

308 ECU OUT09 OPEN CIRCUIT ALL

309 ECU OUT09 SHORT CIRCUIT ALL

33
OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Alarm Denied
Alarm Description
code motion
310 ECU OUT10 SHORT TO +VB ALL

311 ECU OUT10 INTERNAL FAULT ALL

312 ECU OUT10 CHECK FAULT ALL

313 ECU OUT10 OPEN CIRCUIT ALL

314 ECU OUT10 SHORT CIRCUIT ALL

315 ECU RELAY OUTPUT SHORT TO +VB ALL

316 ECU RELAY OUTPUT INTERNAL FAULT ALL

317 ECU RELAY OUTPUT CHECK FAULT ALL

318 ECU RELAY OUTPUT OPEN CIRCUIT ALL

319 ECU RELAY OUTPUT SHORT CIRCUIT ALL

320 ECU OUTPUT BRAKE1 SHORT TO +VB ALL

321 ECU OUTPUT BRAKE1 INTERNAL FAULT ALL

322 ECU OUTPUT BRAKE1 CHECK FAULT ALL

323 ECU OUTPUT BRAKE1 OPEN CIRCUIT ALL

324 ECU OUTPUT BRAKE1 SHORT CIRCUIT ALL

325 ECU OUTPUT BRAKE2 P SHORT TO +VB ALL

326 ECU OUTPUT BRAKE2 INTERNAL FAULT ALL

327 ECU OUTPUT BRAKE2 CHECK FAULT ALL

328 ECU OUTPUT BRAKE2 OPEN CIRCUIT ALL

329 ECU OUTPUT BRAKE2 SHORT CIRCUIT ALL

34
 OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Troubleshooting chart

Code Possible failure reason Suggested operation

OL Vehicle is overloaded Reduce the vehicle load

The vehicle tilting level is greater than the Bring the vehicle to leveled ground, or to
threshold setting. descend the platform to minimum position
LL Check the system or to calibrate the ECU
If you are certain the ground is well leveled tilting sensor (see the sensor calibration
chapter)
Refer to the alarm code description for
51 System failures
detailed information
Refer to the alarm code description for
52 Joystick PCU failure
detailed information
Refer to the alarm code description for
53 TM traction module failures
detailed information
Refer to the alarm code description for
54 Pressure transducer failures
detailed information
“Traction Lock” input is high level therefore Descend the platform in order to unlock
55 the traction function is cut off traction function
“Traction Lock” input is short circuited Check the “traction lock” switch
When the platform is off minimum position,
Check the pothole switch electric signal
the pothole switch is still “low-level” signal.
58
When the platform is off minimum position,
Check the pothole mechanical system
the pothole mechanical system is stuck.

The platform reaches the maximum position Descend the platform

59
The max. position micro switch is open circuit Check the max. position micro switch (if
(if applicable) applicable)
Turn off the “outdoor 2.5mt height” function
Outdoor 2.5mt height limit function
or to descend the platform
60
“Outdoor 2.5mt height “ micro switch is open
Check the micro switch
circuit
61 The platform reaches the lowest position Lifting the platform

62 Rear axle leveling limit switch activation reset the cylinder

the platform stops descending for Release the joystick or toggle switch, then
63
“anti-hand-clamp” purpose operate again for platform descent
Platform extended at the height of
64 reset the platform
“anti-hand-clamp”
Platform extended and fall to the height of
65 reset the platform
“anti-hand-clamp”
Low battery level ( less than 15% ) Recharge the vehicle battery
66 Recharge the vehicle and reset the system
Wrong battery level calculation
power

35
OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Code Possible failure reason Suggested operation

There is obstacle under the vehicle platform Remove the obstacle

67
“ultrasonic” input failure Check the ultrasonic sensor

The platform safety door is open Close the platform safety door
68
Platform safety door switch failure Check the safety door micro switch
When the platform is at minimum position,
Check the pothole switch electric signal
the pothole switch is “high level” signal
70 When the platform is at minimum position,
the pothole mechanical system does not Check the pothole mechanical system
retract
The platform lateral extension is not retracted Retract the platform lateral extension
71 The platform lateral extension micro switch
Check the micro switch
failure
The platform chain is loosed (if applicable) Check the chain
72 The platform chain micro switch is short
Check the micro switch
circuited
There is obstacle in front of the vehicle Remove the obstacle
73
Vehicle “front radar” sensor is short circuited Check the sensor
Vehicle “anti-collision” input has “high level” Check your working surrounding and
74 signal regulate the position of platform
The “anti collision” switch is short circuited Check the micro switch
-- Stop vehicle translation and control the
wheel status;
88 Traction motor right side is in overload -- Vehicle is probably travel on abrupt ramp
uphill. Stop vehicle periodically for cooling
down the motor.
-- Stop vehicle translation and control the
wheel status;
89 Traction motor left side is in overload -- Vehicle is probably travel on abrupt ramp
uphill. Stop vehicle periodically for cooling
down the motor.
Stop using the vehicle and cool down the
Traction module internal temperature is high
traction module
90
Change the working location or reduce the
The working surrounding of vehicle is too hot
location temperature
Stop using the vehicle and cool down the
Traction module internal temperature is high
traction module
91 Change the working location or reduce the
The working surrounding of vehicle is too hot
location temperature
Wrong installation of the TM radiator Check the TM radiator installation
There is at least 1 TM parameter is out of the Contact the assistance for checking the TM
92
allowed range parameter setting

36
 OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Code Possible failure reason Suggested operation

There is too much load in the cage.
94 Pump motor is in overload
Reduce the weight.
The empty load calibration of LMI function
95 Redo the empty load calibration
does not finish successfully
The laden load calibration of LMI function
96 Redo the empty load calibration
does not finish successfully
The cage lifting stop is override. It won’t stop
97 Pay attention when use this function.
until reach the cylinder end of stroke.
The vehicle traction brake is manually To engage the vehicle brake, cycle the
98
released system power
The vehicle bypass (override) function is To disengage the function, cycle the
99
engaged system power
Go to the operation menu and execute
ECU SW is updated
101 “saving” procedure
ECU internal failure Contact assistance, or replace ECU unit

ECU watchdog check failure Check the harness and ECU connection
102
ECU internal failure Contact assistance, or replace ECU unit
Joystick PCU CAN bus communication Check the harness and connection, or
110
failure replace the PCU unit
Joystick PCU CAN bus communication Check the harness and connection, or
111
failure replace the PCU unit
Joystick PCU CAN bus communication Check the harness and connection, or
112
failure replace the PCU unit
Joystick PCU CAN bus communication Check the harness and connection, or
113
failure replace the PCU unit
Traction module TM CAN bus Check the harness and connection, or
114
communication failure replace the TM unit
Pressure difference between pressure
transducer n.1 & n.2 is greater than allowed Check the harness and connection
tolerance (if applicable)
116
Pressure transducer n.1 failure Replace pressure transducer

Pressure transducer n.1 failure (if applicable) Replace pressure transducer

Scissor angle potentiometer has redundant

Check the harness and connection
signal failure (if applicable)
117 Scissor angle potentiometer open circuit / Check the harness and connection, or
short circuit replace potentiometer
Scissor angle potentiometer internal failure Replace potentiometer

ECU Tilt sensor X axis value failure Redo vehicle 0° level calibration
118 Replace ECU, or redo vehicle 0° level
ECU tilt sensor internal failure
calibration

37
OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Code Possible failure reason Suggested operation

ECU Tilt sensor Y axis value failure Redo vehicle 0° level calibration
119 Replace ECU, or redo vehicle 0° level
ECU tilt sensor internal failure
calibration
Check the ECU key switch signal
ECU key switch failure
120 (diagnostic screen)
ECU internal failure Contact assistance, or replace ECU
Check the ECU toggle switch signal
ECU toggle switch failure
121 (diagnostic screen)
ECU internal failure Contact assistance, or replace ECU

ECU pin n.29 (IN 00) failure Contact assistance, or replace ECU
122
ECU internal failure Contact assistance, or replace ECU

ECU pin n.30 (IN 01) failure Contact assistance, or replace ECU
123
ECU internal failure Contact assistance, or replace ECU

ECU pin n.32 (IN 02) failure Contact assistance, or replace ECU
124
ECU internal failure Contact assistance, or replace ECU

ECU pin n.33 (IN 03) failure Contact assistance, or replace ECU
125
ECU internal failure Contact assistance, or replace ECU

ECU pin n.06 (IN 04) failure Contact assistance, or replace ECU
126
ECU internal failure Contact assistance, or replace ECU

ECU pin n.34 (IN 05) failure Contact assistance, or replace ECU
127
ECU internal failure Contact assistance, or replace ECU

ECU pin n.45 (IN 10) failure Contact assistance, or replace ECU
128
ECU internal failure Contact assistance, or replace ECU
ECU pin n.46 (IN 11) failure Contact assistance, or replace ECU
129
ECU internal failure Contact assistance, or replace ECU

ECU pin n.47 (IN 12) failure Contact assistance, or replace ECU
130
ECU internal failure Contact assistance, or replace ECU

ECU pin n.48 (IN 13) failure Contact assistance, or replace ECU
131
ECU internal failure Contact assistance, or replace ECU

ECU pin n.49 (IN 14) failure Contact assistance, or replace ECU
132
ECU internal failure Contact assistance, or replace ECU

ECU pin n.19 (IN RELAY) failure Contact assistance, or replace ECU
133
ECU internal failure Contact assistance, or replace ECU

38
 OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Code Possible failure reason Suggested operation

ECU pin n.20 (IN BRAKE) failure Contact assistance, or replace ECU
134
ECU internal failure Contact assistance, or replace ECU

ECU pin n.23 (IN M1) failure Contact assistance, or replace ECU
135
ECU internal failure Contact assistance, or replace ECU

ECU pin n.24 (IN M2) failure Contact assistance, or replace ECU
136
ECU internal failure Contact assistance, or replace ECU

ECU pin n.29 (IN 00) failure Contact assistance, or replace ECU
137
ECU internal failure Contact assistance, or replace ECU

Pressure transducer n.1 open circuit Check harness and connection

138
Pressure transducer n.1 internal failure Replace pressure transducer

Pressure transducer n.1 short circuit Check harness and connection

139
Pressure transducer n.1 internal failure Replace pressure transducer
Pressure transducer n.1 has low pressure Contact assistance, check the pressure
140
value transducer parameter setting
Pressure transducer n.1 has high pressure Contact assistance, check the pressure
141 value transducer parameter setting
Pressure transducer n.1 internal failure Replace pressure transducer
Pressure transducer n.2 open circuit (if
Check harness and connection
applicable)
142
Pressure transducer n.2 internal failure (if
Replace pressure transducer
applicable)
Pressure transducer n.2 short circuit (if
Check harness and connection
applicable)
143
Pressure transducer n.2 internal failure (if
Replace pressure transducer
applicable)
Pressure transducer n.2 has low pressure Contact assistance, check the pressure
144
value (if applicable) transducer parameter setting
Pressure transducer n.2 has high pressure Contact assistance, check the pressure
value (if applicable) transducer parameter setting
145
Pressure transducer n.2 internal failure (if
Replace pressure transducer
applicable)
Scissor angle potentiometer n.1 open circuit Check harness and connection
146 Scissor angle potentiometer n.1 internal
Replace potentiometer
failure
Scissor angle potentiometer n.1 short circuit Check harness and connection
147 Scissor angle potentiometer n.1 internal
Replace potentiometer
failure

39
OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Code Possible failure reason Suggested operation

Scissor angle potentiometer n.1 converted Contact assistance, check the
148
value too low potentiometer parameter setting
Scissor angle potentiometer n.1 converted Contact assistance, check the
value too high potentiometer parameter setting
149
Scissor angle potentiometer n.1 internal
Replace potentiometer
failure
Scissor angle potentiometer n.1 open circuit Check harness and connection
150 Scissor angle potentiometer n.1 internal
Replace potentiometer
failure
Scissor angle potentiometer n.1 short circuit Check harness and connection
151 Scissor angle potentiometer n.1 internal
Replace potentiometer
failure
Scissor angle potentiometer n.1 converted Contact assistance, check the
152
value too low potentiometer parameter setting
Scissor angle potentiometer n.1 converted Contact assistance, check the
value too high potentiometer parameter setting
153
Scissor angle potentiometer n.1 internal
Replace potentiometer
failure
ECU pin n.01 (OUT 00) is short to power
Check harness and connection
160 +VB
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.01 (OUT 00) internal failure Contact assistance, or replace ECU unit
161
ECU internal failure Contact assistance, or replace ECU unit

ECU watchdog failure ( internal short circuit ) replace ECU unit

162
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.01 (OUT 00): external load is
Check harness and connection
163 open circuit
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.01 (OUT 00): external load is
Check harness and connection
164 short circuit
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.02(OUT 01) is short to power +VB Check harness and connection
165
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.02 (OUT 01) internal failure Contact assistance, or replace ECU unit
166
ECU internal failure Contact assistance, or replace ECU unit

ECU watchdog failure ( internal short circuit ) replace ECU unit

167
ECU internal failure Contact assistance, or replace ECU unit

40
 OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Code Possible failure reason Suggested operation

ECU pin n.02 (OUT 01): external load is
Check harness and connection
168 open circuit
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.02 (OUT 01): external load is
Check harness and connection
169 short circuit
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.04(OUT 02) is short to power +VB Check harness and connection
170
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.04 (OUT 02) internal failure Contact assistance, or replace ECU unit
171
ECU internal failure Contact assistance, or replace ECU unit

ECU watchdog failure ( internal short circuit ) replace ECU unit

172
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.04 (OUT 02): external load is
Check harness and connection
173 open circuit
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.04 (OUT 02): external load is
Check harness and connection
174 short circuit
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.05(OUT 03) is short to power +VB Check harness and connection
175
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.05 (OUT 03) internal failure Contact assistance, or replace ECU unit
176
ECU internal failure Contact assistance, or replace ECU unit

ECU watchdog failure ( internal short circuit ) replace ECU unit

177
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.05 (OUT 03): external load is
Check harness and connection
178 open circuit
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.05 (OUT 03): external load is
Check harness and connection
179 short circuit
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.08(OUT 04) is short to power +VB Check harness and connection
180
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.08 (OUT 04) internal failure Contact assistance, or replace ECU unit
181
ECU internal failure Contact assistance, or replace ECU unit

41
OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Code Possible failure reason Suggested operation

ECU watchdog failure ( internal short circuit ) replace ECU unit

182
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.08 (OUT 04): external load is
Check harness and connection
183 open circuit
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.08 (OUT 04): external load is
Check harness and connection
184 short circuit
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.09(OUT 05) is short to power +VB Check harness and connection
185
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.09 (OUT 05) internal failure Contact assistance, or replace ECU unit
186
ECU internal failure Contact assistance, or replace ECU unit

ECU watchdog failure ( internal short circuit ) replace ECU unit

187
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.09 (OUT 05): external load is
Check harness and connection
188 open circuit
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.09 (OUT 05): external load is
Check harness and connection
189 short circuit
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.11(OUT 06) is short to power +VB Check harness and connection
190
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.11 (OUT 06) internal failure Contact assistance, or replace ECU unit
191
ECU internal failure Contact assistance, or replace ECU unit

ECU watchdog failure ( internal short circuit ) replace ECU unit

192
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.11 (OUT 06): external load is open
Check harness and connection
193 circuit
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.11 (OUT 06): external load is short
Check harness and connection
194 circuit
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.13(OUT 07) is short to power +VB Check harness and connection
195
ECU internal failure Contact assistance, or replace ECU unit

42
 OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Code Possible failure reason Suggested operation

ECU pin n.13 (OUT 07) internal failure Contact assistance, or replace ECU unit
196
ECU internal failure Contact assistance, or replace ECU unit

ECU watchdog failure ( internal short circuit ) replace ECU unit

197
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.13 (OUT 07): external load is
Check harness and connection
198 open circuit
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.13 (OUT 07): external load is
Check harness and connection
199 short circuit
ECU internal failure Contact assistance, or replace ECU unit

201 Traction module TM internal failure Replace TM unit

202 Traction module TM internal failure Replace TM unit

203 Traction module TM internal failure Replace TM unit

Traction module TM internal chip EEPROM
Replace TM unit
204 failure
Traction module TM internal failure Replace TM unit
Traction module TM internal chip EEPROM
Replace TM unit
205 failure
Traction module TM internal failure Replace TM unit
Check the battery voltage, or replace the
Vehicle battery failure
vehicle battery
210 Battery charger is not disconnected when
Check the battery charger
power on the system
Low battery voltage Charge the battery, or replace the battery

Main power contactor is stuck Check or replace the main power contactor
211
“+Batt” of TM connected to battery “+” side Check harness and connection

Low battery voltage Charge the battery, or replace the battery

212 “+Batt” of TM short to “-Batt” of TM Check harness and connection

Traction module TM internal failure Replace TM unit

Check harness and connection, check the
Main power contactor is open circuit
ECU output to main contactor
213 Main power contactor coil failure Replace main power contactor

No power supply to the main power contactor Check harness and connection

43
OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Code Possible failure reason Suggested operation

M1(right side) traction motor harness short
Check harness and connection
circuit
M1(right side) traction motor internal short
214 Replace traction motor
circuit
Check TM parameter “Trac. Short R.
Wrong TM1 parameter setting
Setting”
M2(left side) traction motor harness short
Check harness and connection
circuit
M2(left side) traction motor internal short
215 Replace traction motor
circuit
Check TM parameter “Trac. Short R.
Wrong TM1 parameter setting
Setting”
Pump motor harness short circuit Check harness and connection

216 Pump motor internal short circuit Replace traction motor

Check TM parameter “Pump Short R.
Wrong TM1 parameter setting
Setting”
Traction motor harness in short circuit Check harness and motor connection;
217
TM2 hardware failure Replace TM;
Check the pump load, harness, connection
Pump motor overload
& hydraulic system
220 Pump motor failure Replace pump motor

TM internal failure Replace TM

Check the traction motor load, harness,
M1(right side) traction motor overload
connection
221 traction motor failure Replace traction motor

TM internal failure Replace TM

Check the traction motor load, harness,
M2(left side) traction motor overload
connection
222 traction motor failure Replace traction motor

TM internal failure Replace TM

Check harness, connection, replace
Capacitor group of TM is over voltage
223 vehicle battery or TM
Vehicle brakes roughly
Check harness, connection, replace
Capacitor group of TM is under voltage
vehicle battery or TM
224
Check the main contactor or ECU, check
The main power contactor is open circuit
harness/connection

44
 OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Code Possible failure reason Suggested operation

Stop using the vehicle and cool down the
Traction module internal temperature is high
traction module
225 Change the working location or reduce the
The working surrounding of vehicle is too hot
location temperature
TM internal failure Replace TM
Stop using the vehicle and cool down the
Traction module internal temperature is high
traction module
226 Change the working location or reduce the
The working surrounding of vehicle is too hot
location temperature
Wrong installation of the TM radiator Check the TM radiator installation

External load is too high Check the external load and harness
227
The pin out1 of TM is short to GND Check harness and connection

External load is too high Check the external load and harness
228
The pin out2 of TM is short to GND Check harness and connection

External load is too high Check the external load and harness
229
The pin out3 of TM is short to GND Check harness and connection
Check harness and connection, check
TM or ECU CAN bus communication failure
230 CAN line terminal resistance, check ECU
TM internal failure Replace TM
Check harness and connection, check
TM or ECU CAN bus communication failure
231 CAN line terminal resistance, check ECU
ECU internal failure Replace ECU
Pump motor is not connected, or harness is
Check harness and connection
open circuit
232 Pump motor is connected to “-Pump” and
Check the connection drawing
“-Batt” of TM
Wrong pump motor connection Check connection
M1 motor is not connected, or harness is
Check harness and connection
233 open circuit
TM internal failure Replace TM
M2 motor is not connected, or harness is
Check harness and connection
234 open circuit
TM internal failure Replace TM

Connection error of M1 traction motor Check harness and connection

235
TM internal failure Replace TM

Connection error of M2 traction motor Check harness and connection

236
TM internal failure Replace TM

45
OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Code Possible failure reason Suggested operation

In the excitation circuit, there is no traction
motor connected or traction motor is open Check traction motor connection, check
237 circuit harness
[valid for Separate Excitation TM only]
Defective TM Replace TM
Wrong excitation circuit connection:
Check the TM and motor connection
238 [valid for Separate Excitation TM only]
Defective TM Replace TM

Low battery voltage Charge the vehicle battery

239
Battery terminal is oxidized or corrupted Replace battery, or harness
Stop the vehicle for cooling down the
Excessive load in the excitation circuit
motor. If alarm persist, contact assistance;
240 Traction motor has issue in excitation circuit Check traction motor or replace motor

TM2 internal failure Replace TM2;

CAN bus failure Cycle the system power

281
Joystick PCU failure Replace PCU

CAN bus failure Cycle the system power

282
Joystick PCU failure Replace PCU

ECU pin n.17(OUT 08) is short to power +VB Check harness and connection
300
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.17 (OUT 08) internal failure Contact assistance, or replace ECU unit
301
ECU internal failure Contact assistance, or replace ECU unit

ECU watchdog failure ( internal short circuit ) replace ECU unit

302
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.17 (OUT 08): external load is
Check harness and connection
303 open circuit
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.17 (OUT 08): external load is
Check harness and connection
304 short circuit
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.18(OUT 09) is short to power +VB Check harness and connection
305
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.18 (OUT 09) internal failure Contact assistance, or replace ECU unit
306
ECU internal failure Contact assistance, or replace ECU unit

46
 OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Code Possible failure reason Suggested operation

ECU watchdog failure ( internal short circuit ) replace ECU unit

307
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.18 (OUT 09): external load is
Check harness and connection
308 open circuit
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.18 (OUT 09): external load is
Check harness and connection
309 short circuit
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.21(OUT 10) is short to power +VB Check harness and connection
310
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.21 (OUT 10) internal failure Contact assistance, or replace ECU unit
311
ECU internal failure Contact assistance, or replace ECU unit

ECU watchdog failure ( internal short circuit ) replace ECU unit

312
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.21 (OUT 10): external load is
Check harness and connection
313 open circuit
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.21 (OUT 10): external load is
Check harness and connection
314 short circuit
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.22(OUT TM RELAY) is short to
Check harness and connection
315 power +VB
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.22 (OUT TM RELAY) internal
Contact assistance, or replace ECU unit
316 failure
ECU internal failure Contact assistance, or replace ECU unit

ECU watchdog failure ( internal short circuit ) replace ECU unit

317
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.22 (OUT TM RELAY): external
Check harness and connection
318 load is open circuit
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.22 (OUT TM RELAY): external
Check harness and connection
319 load is short circuit
ECU internal failure Contact assistance, or replace ECU unit

47
OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

Code Possible failure reason Suggested operation

ECU pin n.25(OUT BRAKE 1) is short to
Check harness and connection
320 power +VB
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.25 (OUT BRAKE 1) internal failure Contact assistance, or replace ECU unit
321
ECU internal failure Contact assistance, or replace ECU unit

ECU watchdog failure ( internal short circuit ) replace ECU unit

322
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.25 (OUT BRAKE 1): external load
Check harness and connection
323 is open circuit
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.25 (OUT BRAKE 1): external load
Check harness and connection
324 is short circuit
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.26(OUT BRAKE 2) is short to
Check harness and connection
325 power +VB
ECU internal failure Contact assistance, or replace ECU unit

ECU pin n.26 (OUT BRAKE 2) internal failure Contact assistance, or replace ECU unit
326
ECU internal failure Contact assistance, or replace ECU unit

ECU watchdog failure ( internal short circuit ) replace ECU unit

327
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.26 (OUT BRAKE 2): external load
Check harness and connection
328 is open circuit
ECU internal failure Contact assistance, or replace ECU unit
ECU pin n.26 (OUT BRAKE 2): external load
Check harness and connection
329 is short circuit
ECU internal failure Contact assistance, or replace ECU unit

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

48
 OPERATOR’S MANUAL with Maintenance Information
Operating Instructions

8 Check the battery acid level when the

Battery and Charger Instructions charging cycle is complete. Replenish
with distilled water to the bottom of the fill
Observe and Obey: tube. Do not overfill.

√ Do not use an external charger or booster

battery.
Dry Battery Filling and Charging
√ Charge the battery in a well-ventilated area. Instructions
√ Use proper AC input voltage for charging 1 Remove the battery vent caps and
as indicated on the charger. permanently remove the plastic seal from
the battery vent openings.
√ Use only a Dingli authorized battery and
charger. 2 Fill each cell with battery acid (electrolyte)
until the level is sufficient to cover the
plates.

To Charge Battery Do not fill to the maximum level until the

battery charge cycle is complete. Overfilling
1 Be sure the battery is connected before can cause the battery acid to overflow during
charging. charging. Neutralize battery acid spills with
Maintenance - free battery baking soda and water.

2 Connect the battery charger to a 3 Install the battery vent caps.

grounded AC circuit. 4 Charge the battery.
3 The charger will indicate when the battery 5 Check the battery acid level when the
is fully charged. charging cycle is complete. Replenish
Standard Battery with distilled water to the bottom of the fill
tube. Do not overfill.
4 Remove the battery vent caps and check
the battery acid level. If necessary, add
only enough distilled water to cover the
plates. Do not overfill prior to the charge
cycle.

5 Replace the battery vent caps.

6 Connect the battery charger to a

grounded AC circuit.

7 The charger will indicate when the battery

is fully charged.

49
OPERATOR’S MANUAL with Maintenance Information
Transport and Lifting Instructions

Observe and Obey: Brake Release Operation

√ Common sense and planning must be 1 Chock the wheels to prevent the machine
applied to control the movement of the from rolling.
machine when lifting it with a crane or 2 Pull out the red Emergency Stop button on
forklift. both the ground and platform controls to
the on position.
√ Only qualified aerial lift operators should 3 Press the brake release switch to on
move the machine on or off the truck. position.
4 Press and hold lift switch to “down”
√ The transport vehicle must be parked on a
position in ground control, meanwhile turn
level surface.
on the key switch to the "Ground" position.
√ The transport vehicle must be secured to The brake will be released after Alarm
prevent rolling while the machine is being alerts.
loaded. 5 If you want to close the brake release, just
turn off the key switch in “ground” position.
√ Be sure the vehicle capacity, loading 6 Push the red Emergency stop button on
surfaces and chains or straps are sufficient both the ground and platform controls to
to withstand the machine weight. See the the off position.
serial label for the machine weight. The machine must be towed, do not exceed
√ The machine must be on a level surface or 4km/h.
secured before releasing the brakes.

√ Only qualified forklift operators should lift

the machine with a forklift.

√ Be sure the crane capacity, loading

surfaces and straps or lines are sufficient to
withstand the machine weight. See the
serial plate for the machine weight.

50
 OPERATOR’S MANUAL with Maintenance Information
Transport and Lifting Instructions

Securing to Truck or Trailer for Lifting the Machine with a

Transit Forklift
Always chock the machine wheels in Be sure the extension deck, controls and
preparation for transport. component trays are secure. Remove all loose
items on the machine.
Retract and secure the extension deck(s).
Fully lower the platform. The platform must
Turn the key switch to the off position and
remain lowered during all loading and
remove the key before transporting.
transport procedures.
Inspect the entire machine for loose or
Use the forklift pockets located on both sides
unsecured items.
of the driving wheels.
Use the tie-down points on the chassis for
Position the forklift forks in position with the
anchoring down to the transport surface.
forklift pockets.
Use a minimum of four chains or straps.
Drive forward to the full extent of the forks.
Use chains or straps of ample load capacity.
Raise the machine 6 in / 15 cm and then tilt the
forks back slightly to keep the machine secure.

Be sure the machine is level when lowering

the forks.

Lifting the machine from the

side can result in component damage.

51
OPERATOR’S MANUAL with Maintenance Information
Maintenance

Observe and Obey: Pre-delivery Preparation Report

The pre-delivery preparation report contains
√ Only routine maintenance items specified in
checklists for each type of scheduled
this manual shall be performed by the
inspection.
operator.
Make copies of the Pre-delivery Preparation
√ Scheduled maintenance inspections shall report to use for each inspection. Store
be completed by qualified service completed forms as required.
technicians, according to the manufacturer's
specifications and the requirements
specified in this manual.
Maintenance Schedule
There are five types of maintenance
inspections that must be performed according
Maintenance Symbols Legend to a schedule— daily, quarterly, semi-annually,
annually, and two year. The Scheduled
The following symbols have Maintenance Procedures Section and the
been used in this manual to help communicate Maintenance Inspection Report have been
the intent of the instructions. When one or divided into five subsections—A, B, C, D, and
more of the symbols appear at the beginning E. Use the following chart to determine which
of a maintenance procedure, it conveys the group(s) of procedures are required to perform
meaning below. a scheduled inspection.

Inspection Checklist
Indicates that tools will be required to Daily or every 8 hours A
perform this procedure.
Quarterly or every 250 hours A+B
Semi-annually or every 500 hours A+B+C
Indicates that new parts will be
required to perform this procedure. Annually or every 1000 hours A+B+C+D
Two year or every 2000 hours A+B+C+D+E
Indicates that dealer service will be
required to perform this procedure.
Maintenance Inspection Report
The maintenance inspection report contains
checklists for each type of scheduled
inspection.
Make copies of the Maintenance Inspection
Report to use for each inspection. Maintain
completed forms for a minimum of 4 years or
in compliance with your employer, jobsite and
governmental regulations and requirements.
52
 OPERATOR’S MANUAL with Maintenance Information
Maintenance

Pre-delivery Preparation Report

Fundamentals Instructions
It is the responsibility of the dealer to perform Use the operator’s manual on your machine.
the Pre-delivery Preparation.
The Pre-delivery Preparation consists of
The Pre-delivery Preparation is performed completing the Pre-operation Inspection, the
prior to each delivery. The inspection is Maintenance items and the Function Tests.
designed to discover if anything is apparently
Use this form to record the results. Place a
wrong with a machine before it is put into
check in the appropriate box after each part is
service.
completed. Follow the instructions in the
A damaged or modified machine must never operator’s manual.
be used. If damage or any variation from
If any inspection receives an N, remove the
factory delivered condition is discovered, the
machine from service, repair and re-inspect it.
machine must be tagged and removed from
After repair, place a check in the R box.
service.

Repairs to the machine may only be made by Legend

a qualified service technician, according to the Y = yes, completed
manufacturer’s specifications. N = no, unable to complete
Scheduled maintenance inspections shall be R = repaired
performed by qualified service technicians,
according to the manufacturer’s specifications Comments
and the requirements listed in this manual.

Pre-Delivery Preparation Y N R
Pre-operation inspection
completed
Maintenance items
completed
Function tests completed

Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company

53
OPERATOR’S MANUAL with Maintenance Information
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 Function tests
Machine owner
Perform after 40 hours:
Inspected by (print)
A-4 30 day service
Inspector signature
Perform every 100 hours:
Inspector title
A-5 Grease steer yokes
Inspector company
Checklist B Y N R
Instructions
B-1 Batteries
• Make copies of this report to use for each
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 B-5 Lifting Chains
□ A
Inspection:
B-6 Clean and Lubricate the
Quarterly or 250 hours Columns
□ A+ B
Inspection:
B-7 Test the up limit switches
Semi-annually or 500
□ A+B+C
hours Inspection: B-8 Key switch
Annually or 1000 hours B-9 Horn
□ A+B+C+D
Inspection:
B-10 Drive brakes
• Place a check in the appropriate box after
B-11 Drive speed - stowed
each inspection procedure is completed.
B-12 Drive speed - raised
• Use the step-by-step procedures in this
section to learn how to perform these B-13 Hydraulic oil analysis
inspections. B-14 Tank venting system

• If any inspection receives an “N”, tag and B-15 wire ropes system
remove the machine from service, repair and Checklist C Y N R
re-inspect it. After repair, place a check in the
“R’ box. C-1 Platform overload

C-2 Breather cap - models with

Legend
optional oil
Y = yes, acceptable
Checklist D Y N R
N = no, remove from service
R = repaired D-1 Hydraulic oil

54
 OPERATOR’S MANUAL with Maintenance Information
Maintenance

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

1 Check to make sure that the operator

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 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.
3 Open the operator’s manual to the decals
inspection section. Carefully and
thoroughly inspect all decals on the
machine for legibility and damage.

55
OPERATOR’S MANUAL with Maintenance Information
Maintenance

A-2 A-3
Perform Pre-operation Inspection Perform Function Tests
Completing a Pre-operation Inspection is Completing the function tests is essential to
essential to safe machine operation. The safe machine operation. Function tests are
Pre-operation Inspection is a visual inspection designed to discover any malfunctions before
performed by the operator prior to each work the machine is put into service. A
shift. The inspection is designed to discover if malfunctioning machine must never be used. If
anything is apparently wrong with a machine malfunctions are discovered, the machine
before the operator performs the function tests. must be tagged and removed from service.
The Pre-operation Inspection also serves to
Complete information to perform this
determine if routine maintenance procedures
procedure is available in the appropriate
are required.
operator’s manual. Refer to the Operator’s
Complete information to perform this Manual on your machine.
procedure is available in the appropriate
operator’s manual. Refer to the Operator’s
Manual on your machine.

56
 OPERATOR’S MANUAL with Maintenance Information
Maintenance

A-4 A-5
Perform 30 Day Service Grease the Steer Yokes

The 30 day maintenance procedure is a one DINGLI requires that this procedure be
time procedure to be performed after the first performed every 100 hours of operation.
30 days or 40 hours of usage. After this Regular application of lubrication to the steer
interval, refer to the maintenance tables for yokes is essential to good machine
continued scheduled maintenance. performance and service life. Continued use of
1 Perform the following maintenance an insufficiently greased steer yoke will result
procedures: in component damage.

• B-3 Inspect the Tires and Wheels. 1 Open the steer yoke cover.

2 Locate the grease add hole on the top of

the steer yoke.

3 Pump multipurpose grease into the steer

yoke until the steer yoke is full and grease
is being forced past the bearings.

4 Install the cover.

5 Repeat this step for the other steer yoke.

Grease Specification

Chevron Ultra-duty grease, EP NLGI 1 (lithium

based) or equivalent

57
OPERATOR’S MANUAL with Maintenance Information
Maintenance

Checklist B Procedures
B-1
Inspect the Batteries

DINGLI requires that this procedure be 5 Remove the battery vent caps and check
performed every 250 hours or quarterly, the specific gravity of each battery cell with
whichever comes first. a hydrometer. Note the results.

Proper battery condition is essential to good 6 Check the ambient air temperature and
machine performance and operational safety. adjust the specific gravity reading for each
Improper fluid levels or damaged cables and cell as follows:
connections can result in component damage • Add 0.004 to the reading of each cell for
and hazardous conditions. every 5.5° C above 26.7° C.

Electrocution / burn hazard. • Subtract 0.004 from the reading of each

Contact with electrically charged circuits could cell for every 5.5° C below 26.7° C.
result in death or serious injury. Remove all ⊙ Result: All battery cells display an adjusted
rings, watches and other jewelry.
specific gravity of 1.277 or higher. The
battery is fully charged. Proceed to step 10.
Bodily injury hazard.
Batteries contain acid. Avoid spilling or ¤ Result: One or more battery cells display a
contacting battery acid. Neutralize battery acid specific gravity of 1.217 or below. Proceed
spills with baking soda and water. to step 7.
1 Put on protective clothing and eye wear. 7 Perform an equalizing charge OR fully
charge the batteries and allow the
2 Be sure that the battery cable connections
are free of corrosion. batteries to rest at least 6 hours.

8 Remove the battery vent caps and check

Note: Adding terminal protectors and a
the specific gravity of each battery cell with
corrosion preventative sealant will help
a hydrometer. Note the results.
eliminate corrosion on the battery terminals
and cables. 9 Check the ambient air temperature and
adjust the specific gravity reading for each
3 Be sure that the battery retainers and
cable connections are tight. cell as follows:

• Add 0.004 to the reading of each cell for

4 Fully charge the batteries. Allow the
every 5.5° C above 26.7° C.
batteries to rest 24 hours before
performing this procedure to allow the • Subtract 0.004 from the reading of each
battery cells to equalize. cell for every 5.5° C below 26.7° C.
Models without maintenance-free or sealed ⊙ Result: All battery cells display a specific
batteries: gravity of 1 .277 or greater. The battery is
fully charged. Proceed to step 10.

58
 OPERATOR’S MANUAL with Maintenance Information
Maintenance

¤ Result: The difference in specific gravity B-2

readings between cells is greater than 0.1
Inspect the Electrical Wiring
OR the specific gravity of one or more cells
is less than 1.177. Replace the battery.

10 Check the battery acid level. If needed,

DINGLI requires that this procedure be
replenish with distilled water to 3 mm
performed every 250 hours or quarterly,
below the bottom of the battery fill tube. Do
whichever comes first.
not overfill.
Maintaining electrical wiring in good condition
11 Install the vent caps and neutralize any
is essential to safe operation and good
electrolyte with baking soda and water that
machine performance. Failure to find and
may have spilled.
replace burnt, chafed, corroded or pinched
All models: wires could result in unsafe operating
12 Check each battery pack and verify that conditions and may cause component
the batteries are wired correctly. damage.

13 Inspect the battery charger plug and pigtail Electrocution / burn hazard.
for damage or excessive insulation wear. Contact with electrically charged circuits could
Replace as required. result in death or serious injury. Remove all
14 Connect the battery charger to a properly rings, watches and other jewelry.
grounded 110 - 230V / 50 – 60 Hz single 1 Inspect the underside of the chassis for
phase AC power supply. damaged or missing ground strap(s).
⊙ Result: The charger should operate and 2 Inspect the following areas for burnt,
begin charging the batteries. chafed, corroded and loose wires:
¤ Result: If, simultaneously, the charger alarm • Mast cable
sounds and the LEDs blink, correct the
• Platform controls
charger connections at the fuse and battery.
The charger will then operate correctly and • Power to platform wiring
begin charging the batteries. • Ground control panel
Note: For best results, use an extension of • Hydraulic power unit module tray
adequate size with a length no longer than
3 Turn the key switch to ground control and
15m.
pull out the red Emergency Stop button to
Note: If you have any further questions the on position at both the ground and
regarding the battery charger operation, platform controls.
please contact the DINGLI Service
4 Raise the platform approximately 2 m from
Department.
the ground.

5 Place a lifting strap from an overhead

crane under the platform. Support the
platform. Do not apply any lifting pressure.

59
OPERATOR’S MANUAL with Maintenance Information
Maintenance

Component damage hazard.

B-3
The platform railings can be damaged if they Inspect the Tires and Wheels
are used to lift the platform. Do not attach the (including castle nut torque)
lifting strap to the platform railings.

6 Inspect for a liberal coating of dielectric

grease in the following locations:
DINGLI requires that this procedure be
• Between the ECU and platform controls performed every 250 hours or quarterly,
whichever comes first.
• All wire harness connectors tilt sensor
Maintaining the tires and wheels in good
7 Open the cover.
condition is essential to safe operation and
8 Inspect the battery tray for burnt, chafed good performance. Tire and/or wheel failure
and pinched cables. could result in a machine tip-over. Component
9 Close the battery tray cover. damage may also result if problems are not
discovered and repaired in a timely fashion.
10 Remove the strap from the platform.
1 Check the tire surface and sidewalls for
11 Lower the platform to the stowed position
cuts, cracks, punctures and unusual wear.
and turn the machine off.
2 Check each wheel for damage, bends and
cracks.

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 OPERATOR’S MANUAL with Maintenance Information
Maintenance

B-4 B-5
Test the Emergency Stop Lubricate the Lifting Chains
DINGLI requires that this procedure be
performed every 250 hours or quarterly,
whichever comes first. Lubricated chains are essential to good
A properly functioning Emergency Stop is machine performance and safe operation.
essential for safe machine operation. An Extremely dirty conditions may require that the
improperly operating red Emergency Stop chains be cleaned and lubricated more often.
button will fail to shut off power and stop all The direct result of wearing the transmission
machine functions, resulting in a hazardous chain is to stretch the total length of the chain.
situation. Measure the stretching rate of the used
As a safety feature, selecting and operating transmission chain by eye every three months.
the ground controls will override the platform The mast connected to the elongated chain
controls, except the platform red Emergency would be lower in position so that the top of
Stop button. each mast is obviously uneven in ‘stored’
position. It may lead to damage on guide roller
1 Turn the key switch to ground control and
if the problem is serious.
pull out the red Emergency Stop button to
the on position at both the ground and Every link of the transmission
platform controls. chain is associated with three links of the
masts.
2 Push in the red Emergency Stop button at
the ground controls to the off position. 1 Lower the platform to the stowed position.

⊙ Result: No machine functions should 2 Measure the maximum height of the

operate. machine.

3 Turn the key switch to platform control and ⊙ Result: The machine should be no lower
pull out the red Emergency Stop button to than specification.
the on position at both the ground and ¤ Result: The machine should be lower than
platform controls.
specification.
4 Push down the red Emergency Stop button
The following sketch shows the connection of
at the platform controls to the off position.
the masts and the transmission chain.
⊙ 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.

61
OPERATOR’S MANUAL with Maintenance Information
Maintenance

important safety role; therefore, try to

make both chains as loose or tight as
consistent each other when regulating the
length of the chain. The methods of judge
at site are as follows: Press the two chains
by hands to compare their tautness under
lifting status.

Make sure the chock is in

place during maintenance

When the work platform of a

GTWY needs to be raised for routine servicing
purposes, a captive chock shall be used to
enable the extending structure to be held in
the required position to prevent work platform.

1-next link of the mast；

2-the middle link of the mast；

3-the transmission chain;

4-adjusting bolt；

5-adjusting lock nut；

6-chainwheel；

7-chainwheel shaft；

8-the last link of the mast

3 When regulating the length of the chain,

please select the mast that needs
increasing its height. As shown in the
sketch, regulating the nut 5 tightly makes
the last link of the mast 8 move upwards.
The dual nuts 5 should be connected with
each other tightly after regulating the
length of the chain.

4 The same link of the mast is pulled by two

chains and endures the raised weight
loads at the same time. If one of the chains
loses efficacy, the other will play an

62
 OPERATOR’S MANUAL with Maintenance Information
Maintenance

B-6 B-7
Clean and Lubricate the Columns Test the Up Limit Switch

Clean and properly lubricated columns are Maintaining the limit switches is essential to
essential to good machine performance and safe operation and good machine
safe operation. Extremely dirty conditions may performance.
require that the columns be cleaned and
Operating the machine with a faulty limit switch
lubricated more often.
could result in reduced machine performance
1 Raise the platform to the maximum height. and a potentially unsafe operating condition.
2 Visually inspect the inner and outer Perform these procedures with the machine on
channels of the columns for debris or a firm, level surface that is free of obstructions.
foreign material. If necessary, use a mild
1 Turn the key switch to ground control
cleaning solvent to clean the columns.
2 While raising the platform from the ground
3 The bearing between chain wheel with the
controls, push in the roller of the up limit
shaft is lubricated with the calcium base
switch to activate the limit switch.
grease in raising.
⊙ Result: The platform stops raising. The
4 Lubricate the place between chain wheel
machine is functioning properly.
with chain used grease gun.

5 Lubricate the lead rail with the calcium ¤ Result: The platform continues to raise.
base grease in raising. Adjust or replace the up limit switch.

This procedure will require

the use of additional access equipment. Do
not place ladders or scaffold on or against any
part of the machine. Performing this procedure
without the proper skills and tools may result in
death or serious injury. Dealer service is
strongly recommended.

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OPERATOR’S MANUAL with Maintenance Information
Maintenance

B-8 B-9
Test the Key Switch Test the Automotive-style Horn
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.

Proper key switch action and response is The horn is activated at the platform controls
essential to safe machine operation. The and sounds at the ground as a warning to
machine can be operated from the ground or ground personnel. An improperly functioning
platform controls and the activation of one or horn will prevent the operator from alerting
the other is accomplished with the key switch. ground personnel of hazards or unsafe
Failure of the key switch to activate the conditions.
appropriate control panel could cause a
1 Turn the key switch to platform control and
hazardous operating situation.
pull out the red Emergency Stop button to
Perform this procedure from the ground using the on position at both the ground and
the platform controls. Do not stand in the platform controls.
platform.
2 Push down the horn button at the platform
1 Pull out the red Emergency Stop button to controls.
the on position at both the ground and
⊙ Result: The horn should sound.
platform controls.

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.

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 OPERATOR’S MANUAL with Maintenance Information
Maintenance

B-10
Test the Drive Brakes

DINGLI requires that this procedure be 6 Bring the machine to top drive speed
performed every 250 hours or quarterly, before reaching the test line. Release the
whichever comes first. function enable switch or the joystick when
Proper brake action is essential to safe your reference point on the machine
machine operation. The drive brake function crosses the test line.
should operate smoothly, free of hesitation, 7 Measure the distance between the test line
jerking and unusual noise. and your machine reference point.
Hydraulically-released individual wheel brakes
⊙ Result: The machine stops within the
can appear to operate normally when not fully
operational. specified braking distance. No action
required.
Perform this procedure with the machine on a
firm level surface that is free of obstructions, ¤ Result: The machine does not stop within
with the platform extension deck fully retracted the specified braking distance.
and the platform in the stowed position. Note: The brakes must be able to hold the
1 Mark 2 test lines those are on the ground machine on any slope it is able to climb.
for reference. 8 Replace the brakes and repeat this
2 Turn the key switch to platform control and procedure beginning with step 1.
pull out the red Emergency Stop button to
Braking distance, maximum
the on position at both the ground and
platform controls.
High range on paved surface 61cm±30cm
3 Lower the platform to the stowed position.

4 Press the drive function select button.

a 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.

65
OPERATOR’S MANUAL with Maintenance Information
Maintenance

B-11 B-12
Test the Drive Speed - Stowed Test the Drive Speed - Raised
Position Position

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.
Proper drive functions are essential to safe Proper drive functions are essential to safe
machine operation. The drive function should machine operation. The drive function should
respond quickly and smoothly to operator respond quickly and smoothly to operator
control. Drive performance should also be free control. Drive performance should also be free
of hesitation, jerking and unusual noise over of hesitation, jerking and unusual noise over
the entire proportionally controlled speed the entire proportionally controlled speed
range. range.
Perform this procedure with the machine on a Perform this procedure with the machine on a
firm, level surface that is free of obstructions. firm, level surface that is free of obstructions.
1 Create start and finish lines by marking 1 Create start and finish lines by marking
two lines on the ground 12.2 m apart. two lines on the ground 12.2 m apart.
2 Turn the key switch to platform control and 2 Turn the key switch to platform control and
pull out the red Emergency Stop button to pull out the red Emergency Stop button to
the on position at both the ground and the on position at both the ground and
platform controls. platform controls.
3 Lower the platform to the stowed position. 3 Press the lift function select button.
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 start
and finish lines.
a b
6 Bring the machine to top drive speed
before reaching the start line. Begin timing
when your reference point on the machine
crosses the start line.
a lift function select button
7 Continue at full speed and note the time
b drive function select button
when your reference point on the machine
passes over the finish line. Refer to
specifications.

66
 OPERATOR’S MANUAL with Maintenance Information
Maintenance

4 Press and hold the function enable switch B-13

on the joystick.
Perform Hydraulic Oil Analysis
5 Raise the platform approximately 1.2 m
from the ground.

6 Press the drive function select button.

DINGLI requires that this procedure be
7 Choose a point on the machine; i.e., performed every 250 hours or quarterly,
contact patch of a tire, as a visual whichever comes first.
reference for use when crossing the start
Replacement or testing of the hydraulic oil is
and finish lines.
essential for good machine performance and
8 Bring the machine to top drive speed service life. Dirty oil may cause the machine to
before reaching the start line. Begin timing perform poorly and continued use may cause
when your reference point on the machine component damage. Extremely dirty
crosses the start line. conditions may require oil changes to be
performed more often.
9 Continue at full speed and note the time
when your reference point on the machine Before replacing the hydraulic oil, the oil may
passes over the finish line. Refer to be tested by an oil distributor for specific levels
specifications. of contamination to verify that changing the oil
is necessary.

If the hydraulic oil is not replaced at the two

year inspection, test the oil quarterly. Replace
the oil when it fails the test. See D-1, Test or
Replace the Hydraulic Oil.

67
OPERATOR’S MANUAL with Maintenance Information
Maintenance

B-14 B-15
Inspect the Hydraulic Tank Cap Inspect the system of wire ropes
Venting System Maintaining the system of wire ropes in good
condition can reduce risk effectively after
chains break。
DINGLI requires that this procedure be 1 Raise the platform approximately 2 m
performed quarterly or every 250 hours,
2 Visually inspect condition of every wire
whichever comes first. Perform this procedure
rope and both ends：
more often if dusty conditions exist.

A free-breathing hydraulic tank cap is essential  Excessive corrosion or contamination

for good machine performance and service life.  Untightened wire ropes
A dirty or clogged cap may cause the machine
 Deformed seat plates
to perform poorly. Extremely dirty conditions
may require that the cap be inspected more  Missing or damaged related
often. components

1 Open the cover. 3 Inspect the chain terminations near the

bottom of each column to confirm that
2 Remove the breather cap from the
each seat plate has a lock nut.
hydraulic tank.

3 Check for proper venting.

⊙ Result: Air passes through the breather

cap.

¤ Result: If air does not pass through the cap,

clean or replace the cap. Proceed to step
4.

Note: When checking for positive tank cap

venting, air should pass freely through the cap.

4 Using a mild solvent, carefully wash the

cap venting system. Dry using low
pressure compressed air. Repeat step 3.

5 Install the breather cap onto the hydraulic

tank.

6 Install the cover.

68
 OPERATOR’S MANUAL with Maintenance Information
Maintenance

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

DINGLI requires that this procedure be ⊙ Result: The overload alarm at the platform
performed every 500 hours or six months, controls sound, indicating a normal
whichever comes first or when the machine condition.
occurs overload fault. ¤ Result: The overload alarm at the platform
Testing the platform overload system regularly controls does not sound. Calibrate the
is essential to safe machine operation. platform overload system.
Continued use of an improperly operating
5 Test all machine functions from the
platform overload system could result in the platform controls.
system not sensing an overloaded platform
condition. Machine stability could be ⊙ Result: All platform control functions should
compromised resulting in the machine tipping not operate.
over. 6 Turn the key switch to ground control.

7 Test all machine functions from the ground

Perform this procedure with
controls
the machine on a firm, level surface.
⊙ Result: All ground control functions should
1 Turn the key switch to platform control and
not operate.
pull out the red Emergency Stop button to
the on position at both the ground and 8 Lift the test weight off the platform floor
platform controls. using a suitable lifting device.

2 Determine the maximum platform capacity. ⊙ Result: The overload alarm at the platform
controls should not sound, indicating a
3 Using a suitable lifting device, place an
normal condition.
appropriate test weight equal to the
maximum platform capacity in the center of ¤ Result: The overload alarm at the platform
the platform floor. controls sounds. Calibrate the platform
overload system.
⊙ Result: The overload alarm at the platform
controls should not sound, indicating a 9 Test all machine functions from the ground
normal condition. controls.

¤ Result: The overload alarm at the platform ⊙ Result: All ground control functions should
controls sounds. Calibrate the platform operate.
overload system. 10 Turn the key switch to platform control.
4 Add an additional weight to the platform 11 Test all machine functions from the
not to exceed 10% of the maximum rated platform controls.
load.
⊙ Result: All platform control functions should
operate.
69
OPERATOR’S MANUAL with Maintenance Information
Maintenance

C-2
Replace the Hydraulic Tank Breather
Cap

DINGLI requires that this procedure be

performed every 500 hours or semi-annually,
whichever comes first.

The hydraulic tank is a vented-type tank. The

breather cap has an internal air filter that can
become clogged or, over time, can deteriorate.
If the breather cap is faulty or improperly
installed, impurities can enter the hydraulic
system which may cause component damage.
Extremely dirty conditions may require that the
cap be inspected more often.

1 Open the cover.

2 Remove and discard the hydraulic tank

breather cap.

3 Install a new cap onto the tank.

4 Install the cover

70
 OPERATOR’S MANUAL with Maintenance Information
Maintenance

Checklist D Procedure
D-1
Test or Replace the Hydraulic Oil

DINGLI requires that this procedure be Bodily injury hazard.

performed every 1000 hours or every one year, Spraying hydraulic oil can penetrate and burn
whichever comes first. skin. Loosen hydraulic connections very slowly
Replacement or testing of the hydraulic oil is to allow the oil pressure to dissipate gradually.
essential for good machine performance and Do not allow oil to squirt or spray.
service life. Dirty oil may cause the machine to 8 Clean up any oil that may have spilled.
perform poorly and continued use may cause Properly discard the used oil.
component damage. Extremely dirty
9 Clean the inside of the hydraulic tank using
conditions may require oil changes to be
a mild solvent. Allow the tank to dry
performed more often.
completely.
Before replacing the hydraulic oil, the oil may
10 Install the hydraulic tank and install and
be tested by an oil distributor for specific levels
tighten the hydraulic tank retaining
of contamination to verify that changing the oil
fasteners. Torque to specification.
is necessary.

If the hydraulic oil is not replaced at the two Torque specifications

year inspection, test the oil quarterly. Replace
the oil when it fails the test. Hydraulic tank retaining fasteners, dry 4 Nm

Note: Perform this procedure with the platform Hydraulic tank retaining fasteners,
2.9Nm
in the stowed position. lubricated

1 Disconnect the battery pack from the

11 Install the hydraulic power pack into the
machine.
tray. Install the fitting and hydraulic hoses
2 Fully lower the platform. onto the hydraulic power pack and torque.

Electrocution / burn hazard. 12 Fill the tank with hydraulic oil until the fluid
Contact with electrically charged circuits could is full in the hydraulic tank. Do not overfill.
result in death or serious injury. Remove all 13 Activate the pump to fill the hydraulic
rings, watches and other jewelry. system with oil and bleed the system of air.
3 Remove the cover.
Component damage hazard.
4 Tag and disconnect the hydraulic pump The pump can be damaged if operated without
outlet line and remove the line from the oil. Be careful not to empty the hydraulic tank
pump. Cap the fitting on the pump. while in the process of filling the hydraulic
5 Loose the bolt and remove the hydraulic system. Do not allow the pump to cavitate.
power pack form the tray.
6 Remove the tank.

7 Drain all of the oil into a suitable container.

71
OPERATOR’S MANUAL with Maintenance Information
Schematic

Hydraulic Schematic
AMWP8-1100 AMWP9.5-1100

Upper lift Cylinder

Platform
Overload
(Option) steer Cylinder

SP1

Pump

Filter

Tank

72
 OPERATOR’S MANUAL with Maintenance Information
Schematic

Hydraulic Schematic
AMWP9.5-2100 AMWP11-2100

Upper lift Cylinder Upper lift Cylinder

steer Cylinder

Platform
Overload
(Option)

SP1

Pump

Filter

Tank

73
 PLATFORM CONTROL BOX ECU MC1
PCU 7 SE GM ENT 007 BUVT (16) 14
JS1 DISP LAY 10
JOYSTICK 7 SEGMENT CA N LO W
5 W H/BK (18) 5 1C W H/BK (18) 8C WT/VT (16) 5
SB3(BK) DISPLAY J1
JOYSTICK CA N HIG H 5C BN/BU ( 16) 3
2 B U/W H (18) 2 1B B U/WH (18)
DEADMAN DRIVE SB2( RD) 10B BK (16) 6
S2 4 BU (16) 4
INDICATOR 12A -Z B N/BK ( 16) 7
Schematic

STEER LEFT PLATFO RM EMS

ST EER RIGHT 3 RD ( 16) 3 11C BU/V T (16) 11C-2 BU/V T (16) 4
SB4(BK) K A3
LO W SPEED 1 WT ( 16) 1
7A BN/WT (16) 4
LIFT ENABLE INDICATOR K A2
SB5(BK) S Q5 6C BN/GY (16) 8
DRIVE ENABLE 10C BU/VT (16) 10C-Z BU/VT (16) 5
SB6(BK) LIFT J2
B2 10A GY/BU (16) 10A-Z GY/BU (16) 1
LOW SPEED INDICATO R
SB7( BK) 006 RD (16) 6
BUZZER 005 RD (16) 2
HORN
9A BN/BK (16) 9

G ND- 5 BK ( 16)
4C BU/WT (16) 4

004 RD/WH (16)

J3

003-3 BU/RD (16)

KA 3 K A2
Electrical Schematic

8A BN/BU (16) 6
3B B K ( 16) 010-4 RD/BU (16) 7
010-3 RD/BU (16) 1
008- 1 B U/RD ( 20) 010-1 RD/BU (16) 2
TILT SENSO R
11C-1 BU/V T (20) TILT M OT OR
CO NTROL
HOURMETER MO DULE
S1 LIFT UP
12B BN/WT (16) 8A -1 BN/BU (16) HM GND-2 BK (16) V
002-1 RD (16)
12A BN/G Y (16)
LIF T DOWN H1
10C-1 BU/VT (16)
10A-1 G Y/BU (16)

HO RN
8B BK ( 16) G ND- 13 BK (16)
002-2 RD (14) 2C BU/RD (16)
V RD ( 4)

4A BU/RD (16) YV2 LIFT DO WN VALVE 1 2

6B G Y/BU ( 16) GND-1 BK (16)
010-2 BU/RD (16) 5A BU/RD (16) YB2

003-2 BU/RD (16)

B1 LEFT DRIVE
YV 1 LIF T UP V ALVE LEFT
M3
230VAC BUZZER 6A B U/VT (16) GND- 14 B K (14) MO TOR
9B WT/BK (16) BRAKE
INPUT
SB1(RD) YV 3 STE E R LE FT VA LVE
GRO UND 7B WH/BU (16) GND- 15 B K (14)

003- 5 BU/RD ( 20)

003-4 BU/RD (20)
EMS
YV 4 STE ER RIGHT V ALV E

74
7C WH/B U (16) GND- 16 B K (14)
W1 BK ( 4)

S B8(RD)
W

008 BU/RD ( 16)

12C- 2 B N/BK (16)
PE N L 5B BN/RD (16) GND-17 BK (14)
OPERATOR’S MANUAL with Maintenance Information

KACH BRA KE RELE AS E S WITCH

W2 BK (4)

9C BU/RD (16) 1
CHARGER

003-1 BU/RD (16)

003-8 BU/RD (16)
YB1
M2 RIGHT DRIVE
_ KA1 12C GY /BU (16) MOTOR
RIG HT

+
SA1 LOAD SENSOR
BRAKE
KEY LS1 3C-1 BU/RD (20) 3C BU/RD (16) 11B BU/RD (16)
SWITCH
SQ1 LIF T UP LIMIT SWITCH 2
FU3
10A
U RD (4)

3B- 1 BK ( 16)

009-2 BU/RD (20) 11B -1 B U/RD ( 20)

U
SQ2 LIFT DO WN LIMIT SWITCH
009-3 BU/RD (20) 12C-1 GY /BU (20)

003-6 RD (14)
003-7 RD (14)
002 RD ( 14)
GND-6 BK (14)
SQ3 LE FT PO THOLE P ROTE CT LIMIT S WITCH P- BK (4) P-
001 RD (4) 009-8 BU/RD (20) 10B- 2 B K (16) 10B -1 BK (16)
SQ4
M1 HYDRAULIC
P OW ER 009-9 BU/RD (20) 10B- 3 B K (16) PUMP MOTO R
S A2( RD) RIGHT PO THOLE P ROTE CT LIM IT SW ITCH
SW IT CH
GND-8 BK (20) BF +1 RD (4) B+

7A
B-

FU2
BF+
GND-11 BK (20)

G ND-10 B K ( 20) GND-3 BK (20) GND-12 BK (16)

HL1
001-5 RD (4)
3B-2 BK (16)

FLASHING BEACON
009-7 BU/RD (20) G ND-9 B K ( 20) GND-7 BK (20)

001-1 RD (4)
001-4 RD ( 14)
GB1
BAT TERY
12VDC
GB2 FU1 KM1
001-2 RD ( 4) 001-3 RD ( 4)
BAT TERY 100A DRIVE CONTACTO R
12VDC
GND BK (4)
 OPERATOR’S MANUAL with Maintenance Information
Inspection and Repair Log

Inspection and Repair Log

Date Comments

75