Ballymore SM0114113, Operator'S Manual

Page 1: ...Machinery Co Ltd Second Edition January 2016 Printing WARNING THE MANUFACTURER SHALL NOT BE HELD LIABLE IN CASE OF FAULTS OR ACCIDENTS DUE TO NEGLIGENCE INCAPACITY INSTALLATION BY UNQUALIFIED TECHNIC...

Page 2: ...OPERATOR S MANUAL with Maintenance Information Version of the Record i Version of the Record Version Number Create Date SM0114113_Rev1 0 2014 12 SM0114113_Rev2 0 2015 10...

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Page 4: ...pection and Repair Log 67 Owners Users and operators We appreciate your choice of our machine for your application Our number one priority is user safety which is best achieved by our joint efforts We...

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Page 6: ...understand and obey all applicable governmental regulations You are properly trained to safely operate the machine Decal Legend BALLYMORE DINGLI product decals use symbols color coding and signal wor...

Page 7: ...e Minimum Safe Approach Distance 0 to 300V Avoid Contact 300V to 50kV 10ft 3 05m 50kV to 200kV 15ft 4 60m 200kV to 350kV 20ft 6 10m 350kV to 500kV 25ft 7 62m 500kV to 750kV 35ft 10 67m 750kV to 1000kV...

Page 8: ...exposed to the wind will decrease machine stability 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 pe...

Page 9: ...e platform toe boards or guard rail system can increase the weight in the platform and the surface area of the platform or the load Do not place ladders or scaffolds in the platform or against any par...

Page 10: ...or exit the platform unless the machine is in the stowed position Collision Hazard Be aware of limited sight distance and blind spots when driving or operating Be aware of extended platform position s...

Page 11: ...tenance has been performed as specified in this manual Be sure all decals are in place and legible Be sure the operator s manual is complete legible and in the storage container located in the platfor...

Page 12: ...contact with battery terminals Remove all rings watches and other jewelry Tip over Hazard Do not use batteries that weigh less than the original equipment Batteries are used as counterweight and are c...

Page 13: ...e point 5 Platform guard rails 6 Platform extension release pedal 7 Main Platform 8 Platform entry gate 9 Scissor Arms 10 Lift Cylinder 11 Ground controls on opposite side of machine 12 Entry ladder 1...

Page 14: ...137 Danger Safety rules 1 3 9414103 Danger Tip over hazard 1 4 9314015 Instructions Platform controller normal position 1 5 9314013 Instructions Refer the operator to the instructions for use 2 6 9114...

Page 15: ...11421 Instructions Wheel load 2948 lbs 4 No Part No Description Qty Remark 20 9311105 Notice Main power switch operation 1 21 9411041 Warning Tip over hazard 1 22 9411011 Danger Explosion burn hazard...

Page 16: ...OPERATOR S MANUAL with Maintenance Information Decals 11 1 2 3 5 6 7 8 9 10 11 7 7 7 9 10 11 12 13 15 14 15 14 16 17 18 26 18 17 16 19 20 22 19 17 18 17 18 14 23 5 19 19 24 25 27 8 4 21...

Page 17: ...OPERATOR S MANUAL with Maintenance Information Decals 12...

Page 18: ...s 12V 300 Ah Controls Proportional AC outlet in platform Standard Maximum hydraulic pressure functions 3000 psi 207 bar System voltage 24 V Tire size 15 5 in 381 127 mm Airborne noise emissions 70 dB...

Page 19: ...ine will be off Turn the key switch to the base position and the ground controls will operate 2 Platform up down switch Move the switch up and the platform will raise Move the switch down and the plat...

Page 20: ...Panel 1 Thumb rocker switch for steer functions 2 Drive function select button 3 Drive speed button 4 Red Emergency Stop button 5 LED 6 Horn button 7 Lift function select button 8 Proportional contro...

Page 21: ...ton Press this button to activate the lift function 8 Proportional control handle 9 Function enable switch for lift and drive functions Lift function Press and hold the function enable switch to enabl...

Page 22: ...iscover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are requi...

Page 23: ...lds Battery pack and connections Drive motors Wear pads Tires and wheels Ground strap Limit switches alarms and horn Nuts bolts and other fasteners Platform overload components Platform entry gate Bea...

Page 24: ...if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the...

Page 25: ...machine as it was intended Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service The operator must follow the step by step instructions to te...

Page 26: ...also available 8 Turn the key switch to off or platform position 9 Move up and hold the platform up down switch Result No function should operate 10 Turn the key switch to ground control position 11 M...

Page 27: ...row on the control panel Result The steer wheels should turn in the direction that the white right arrow points on the control panel Test Drive and Braking 30 Press and hold the function enable switch...

Page 28: ...The pothole guards should automatically deploy when the platform is raised The pothole guards activate another limit switch which allows the machine to continue to function If the pothole guards do no...

Page 29: ...ound level and can be used to reach work areas located above and over machinery or equipment The Operating Instructions section provides instructions for each aspect of machine operation It is the ope...

Page 30: ...on 2 Press and hold the lift function enable switch on the control handle 3 Move the control handle according to the markings on the control panel To Steer 1 Press the drive function select button 2 P...

Page 31: ...wood run and multiply by 100 Example Run 12 ft 3 6 m Rise 12 in 0 3 m 12 in 144 in 0 083 100 8 3 0 3 m 3 6 m 0 083 100 8 3 If the slope exceeds the maximum slope or side slope rating the machine must...

Page 32: ...ep or the ground 9 From the rear step or from the ground remove the right rear main deck wire lock pins 10 Fold down the right rail assembly Keep hands clear of pinch points 11 Replace the removed pin...

Page 33: ...atform Left Turn Switch ON at power up Message Diagnostic Message Only 43 Platform Right Turn Switch ON at power up Message Diagnostic Message Only 46 Platform Joystick Enable Switch ON at power up Fa...

Page 34: ...Lifting and Driving 72 Motor Controller Over Voltage Fault Controller Dependent 73 Motor Controller Thermal Cutback Fault Controller Dependent 74 Motor Controller Motor Fault Controller Dependent 75...

Page 35: ...Platform Joystick Enable Switch ON at power up Fault Ensure that nothing is holding the Enable switch closed Also check the neutral zone parameters If OK consider replacing the Joystick or PCU 47 Plat...

Page 36: ...he ECU and PCU 69 High Neutral Current The MC is sensing current in the motors when there should not be This could occur anytime the MC thinks the brakes are on and the motors are still turning This m...

Page 37: ...ure they are tight Check the Motor for a short 80 Over 80 Load Warning Platform is getting close to its limit of weight Consider not adding more load 81 Right Drive Motor Short Fault Check the Motor c...

Page 38: ...o cover the plates Do not overfill prior to the charge cycle 6 Replace the battery vent caps 7 Connect the battery charger to a grounded AC circuit 8 The charger will indicate when the battery is full...

Page 39: ...rakes Do not allow the rails to fall when the snap pins are removed Maintain a firm grasp on the rails when the rails are lowered Do not drive the machine on a slope that exceeds the slope or side slo...

Page 40: ...or Trailer for Transit Always chock the machine wheels in preparation for transport Retract and secure the extension deck s Turn the key switch to the off position and remove the key before transporti...

Page 41: ...rklift Be sure the extension deck controls and component trays are secure Remove all loose items on the machine Fully lower the platform The platform must remain lowered during all loading and transpo...

Page 42: ...ve all loose items on the machine Determine the center of gravity of your machine using the table and the picture on this page Attach the rigging only to the designated lifting points on the machine T...

Page 43: ...h type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance...

Page 44: ...all be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in this manual Instructions Use the operator s manual on your machine The P...

Page 45: ...remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist A Y N R A 1 Inspect the manuals...

Page 46: ...re 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 ma...

Page 47: ...A 3 Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage...

Page 48: ...he sight of hydraulic oil level from the side of the hydraulic oil tank Result The hydraulic oil level should be as marked on the tank 2 Add oil if necessary Do not overfill Hydraulic oil specificatio...

Page 49: ...the Steer Yokes BALLYMORE DINGLI requires that this procedure be performed every 100 hours of operation Regular application of lubrication to the steer yokes is essential to good machine performance a...

Page 50: ...connections are tight 5 Fully charge the batteries Allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize Models without maintenance free or seale...

Page 51: ...ery charger d quick disconnect All models 13 Check each battery pack and verify that the batteries are wired correctly 14 Inspect the battery charger plug and pigtail for damage or excessive insulatio...

Page 52: ...power unit module tray Battery pack module tray Platform controls 3 Turn the red Emergency Stop button clockwise to the on position at both the ground and platform controls 4 Raise the platform appro...

Page 53: ...m Bolt torque lubricated 27 9 ft lbs 37 8Nm B 4 Test the Emergency Stop BALLYMORE DINGLI requires that this procedure be performed every 250 hours or quarterly whichever comes first A properly functio...

Page 54: ...orm 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 th...

Page 55: ...button clockwise to the on position at both the ground and platform controls 3 Lower the platform to the stowed position 4 Press the drive function select button a a drive function select button 5 Ch...

Page 56: ...use when crossing the start and finish lines 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 7 Contin...

Page 57: ...est the Slow Drive Speed BALLYMORE DINGLI requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation Th...

Page 58: ...BALLYMORE DINGLI requires that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and...

Page 59: ...eed to step 3 Note When checking for positive tank cap venting air should pass freely through the cap 3 Using a mild solvent carefully wash the cap venting system Dry using low pressure compressed air...

Page 60: ...rm cable from the ECU cable at the 6 pin Deutsch connector under the chassis deck 8 Securely install the platform control box harness plug into the 6 pin Deutsch connector of the ECU cable 9 Open the...

Page 61: ...arm to the stowed position 27 Lower the platform to the stowed position Pothole Limit Switches 28 Move the machine onto a grade which exceeds the rating of the level sensor Refer to the serial label o...

Page 62: ...performed every 250 hours or quarterly whichever comes first Maintaining the limit switches is essential to safe operation and good machine performance Operating the machine with a faulty limit switch...

Page 63: ...tch and a tilt sensor The overload pressure switch which is adjustable and located at the barrel end of the lift cylinder is used to determine when the hydraulic lift cylinder requires too much pressu...

Page 64: ...owed position 13 Securely connect the wires of the up limit switch 14 Fully raise the platform Release the toggle switch Result The alarm should not sound The system is functioning correctly Result Th...

Page 65: ...ydraulic 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 ca...

Page 66: ...cross tube and the chassis deck at the ground controls side of the non steer end of the machine Refer to illustration below Result The measurement is 1 34 in 34mm or more Proceed to step 2 Result The...

Page 67: ...may cause severe burns The hydraulic tank return filter is mounted on the bracket between the function manifold and the hydraulic power unit 1 Clean the area around the oil filter Remove the filter wi...

Page 68: ...ry 2 Open the power unit module tray 3 Tag and disconnect the hydraulic tank return line from the hydraulic filter head and remove the line from the tank Cap the fitting on the filter head 4 Tag and d...

Page 69: ...ting onto the hydraulic filter head and torque 14 Fill the tank with hydraulic oil until the fluid is full in the hydraulic tank Do not overfill 15 Activate the pump to fill the hydraulic system with...

Page 70: ...OR S MANUAL with Maintenance Information Schematic 65 DSL 40 L RV5 CV4 SV5 Platform Overload Sensor Upper Lift Cylinder Lower Lift Cylinder Steer Cylinder SV1 S1 S2 L P T M RV1 ORF2 ORF1 FRRV1 SV2 L C...

Page 71: ...6 BU RD 16 010 5 RD BU 16 010 5 RD BU 16 SB2 4 3 5 2 1 Platform E STOP B1 B4 Buzzer Right Pothole Switch GND 3 BK 16 GND 2 BK 16 3A BN 18 010A 2 YE 16 010A BN RD 16 SS1 Left Pothole Switch GND 1 BK 1...

Page 72: ...OPERATOR S MANUAL with Maintenance Information Inspection and Repair Log 67 Inspection and Repair Log Date Comments...