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SELF-PROPELLED ROUGH-TERRAIN SCISSOR LIFTS
OPERATOR’S MANUAL
with Maintenance Information
( For JCPT2223RTA )
Part Number: SM0117123
Zhejiang Dingli Machinery Co., Ltd. First Edition, September 2017
WARNINGTHE MANUFACTURER SHALL NOT BE HELD LIABLE IN CASE OF FAULTSOR ACCIDENTS DUE TO NEGLIGENCE, INCAPACITY, INSTALLATION BYUNQUALIFIED TECHNICIANS AND IMPROPER USE OF THE MACHINE
DO NOT OPERATE THIS MACHINE UNTIL YOU READ AND UNDERSTANDALL THE DANGERS,WARNINGS AND CAUTIONS IN THIS MANUAL
OPERATOR’S MANUAL with Maintenance Information
Version of the Record
1
OPERATOR’S MANUAL with Maintenance Information
Version of the Record
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Version of the RecordVersion Number Create Date
SM01117123_Rev1.0 ………………………………………………………………………… 2017-09
OPERATOR’S MANUAL with Maintenance Information
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ImportantRead, understand and obey these safety rulesand operating instructions before operatingthis machine.
Only trained and authorized personnel shall bepermitted to operate this machine. Thismanual should be considered a permanentpart of your machine and should remain withthe machine at all times. If you have anyquestions, please call DINGLI Machinery.
ContentsPage
Safety Rules 1
Legend 8
Decals 9
Specifications 13
Control panel 14
Pre-operation Inspection 18
Workplace Inspection 20
Function Tests 21
Operating Instructions 27
Transport and Lifting Instructions 34
Maintenance 37
Schematic 64
Inspection and Repair Log 68
Owners, Users and operators:We appreciate your choice of our machine foryour application. Our number one priority isuser safety, which is best achieved by our jointefforts. We feel that you make a majorcontribution to safety if you, as the equipmentusers and operators:
1 Comply with employer, job site andgovernmental rules.
2 Read, understand and follow theinstructions in this and other manualssupplied with this machine.
3 Use good safe work practices in acommonsense way.
4 Only have trained / certified operators,directed by informed and knowledgeablesupervision, running the machine.
If there is anything in this manual that is notclear or which you believe should be added,please contact us.
Contact us:
Zhejiang Dingli Machinery Co., Ltd.
1255 Baiyun South Road. Leidian Town.Deqing Zhejiang
China
Tel: +86-572-8681688
Fax: +86-572-8681690
Web: www.cndingli.com
E-mail:market@cndingli.com
OPERATOR’S MANUAL with Maintenance Information
Safety Rules
1
Danger
Failure to obey the instructions andsafety rules in this manual willresult in death or serious injury.
Do Not Operate Unless:√ You learn and practice the principles of
safe machine operation contained in thisoperator's manual.
1 Avoid hazardous situations.
Know and understand the safety rulesbefore going on to the next section.
2 Always perform a pre-operationinspection.
3 Always perform function tests prior touse.
4 Inspect the workplace.
5 Only use the machine as it wasintended.
√ You read, understand and obey themanufacturer's instructions and safetyrules— safety and operator's manuals andmachine decals.
√ You read, understand and obey employer'ssafety rules and worksite regulations.
√ You read, understand and obey allapplicable governmental regulations.
√ You are properly trained to safely operatethe machine.
Decal LegendDINGLI product decals use symbols, colorcoding and signal words to identify thefollowing:
Safety alert symbol—used to alertpersonnel to potential personal injury hazards.Obey all safety messages that follow thissymbol to avoid possible injury or death.
Red—used to indicate thepresence of an imminently hazardous situationwhich, if not avoided, will result in death orserious injury.
Orange—used to indicate thepresence of a potentially hazardous situationwhich, if not avoided, could result in death orserious injury.
Yellow with safety alertsymbol—used to indicate the presence of apotentially hazardous situation which, if notavoided, may cause minor or moderate injury.
Blue without safety alertsymbol—used to indicate the presence of apotentially hazardous situation which, if notavoided, may result in property damage.
OPERATOR’S MANUAL with Maintenance Information
Safety Rules
2
The relevant conditions of usingthe equipmentThe surface of work ground should be flat andhard with no obstacles in air and the safetydistance between the equipment andhigh-tension line is adequate.
The environment temperature should be within-20~40; Height above sea level ≤1000m.
The environment humidity ≤ 90%.
Electrical power: AC 110~230V±10%,50~60Hz.
Work cycleThe life of designed work cycle is no more than40000 times.
Intended UseThis machine is intended to be used only to liftpersonnel, along with their tools and materialsto an aerial work site.
Safety Sign MaintenanceReplace any missing or damaged safety signs.Keep operator safety in mind at all times. Usemild soap and water to clean safety signs. Donot use solvent-based cleaners because theymay damage the safety sign material.
OperatorOnly the trained and qualified are permitted tooperate this machine. Always use safety beltand helmet when aerially working.
If you are subject to dizziness or seizures, orare bothered by heights, you must not operatethis type of machinery.
An operator must not use drugs or alcohol thatcan change his/her alertness or coordination.
An operator on prescription orover-the-counter drugs needs medical adviceon whether or not he/she can safely operatemachines.
Electrocution HazardThis machine is not electrically insulated andwill not provide protection from contact with orproximity to electrical current.
Maintain safe distances from electrical powerlines and apparatus in accordance withapplicable governmental regulations and thefollowing chart.
VoltagePhase to Phase
Minimum SafeApproach Distance
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
500kV to 750kV 10.67
750kV to 1000kV 13.72
Allow for platform movement, electrical linesway or sag and beware of strong or gustywinds.
Keep away from the machine if it contactsenergized power lines. Personnel on theground or in the platform must not touch oroperate the machine until energized powerlines are shut off.
OPERATOR’S MANUAL with Maintenance Information
Safety Rules
3
Do not operate the machine during lightning orstorms.
Do not use the machine as a ground forwelding.
Tip-over HazardOccupants, equipment and materials must notexceed the maximum platform capacity or themaximum capacity of the platform extension.
Maximum capacity – JCPT2223RTA
Maximum occupants 4
Models with one extension deck
Platform allowable maximum load 750kg
Extension deck allowable maximum load 500kg
Only Only
Extension platform
deck500kg 250kg
Work Area SafetyDo not raise the platform unless the machineis on a firm, level surface.
Do not drive over 0.5km/h with the platformraised.
Do not depend on the tilt alarm as a levelindicator. The tilt alarm sounds on the chassisand in the platform when the machine is on aslope.
If the tilt alarm sounds:
Lower the platform. Move the machine to a
firm, level surface. If the tilt alarm soundswhen the platform is raised, use extremecaution to lower the platform.
For outdoor use machine, Do not raise theplatform when wind speeds may exceed 12.5m/s. If wind speeds exceed 12.5 m/s when theplatform is raised, lower the platform and donot continue to operate the machine.
Do not operate the machine in strong or gustywinds. Do not increase the surface area of theplatform or the load. Increasing the areaexposed to the wind will decrease machinestability.
Do not use the platform controls to free aplatform that is caught, snagged or otherwiseprevented from normal motion by an adjacentstructure. All personnel must be removed fromthe platform before attempting to free theplatform using the ground controls.
Use extreme care and slow speeds whiledriving the machine in the stowed positionacross uneven terrain, debris, unstable orslippery surfaces and near holes anddrop-offs.
Do not drive the machine on or near uneventerrain, unstable surfaces or other hazardousconditions with the platform raised.
Do not push off or pull toward any objectoutside of the platform.
OPERATOR’S MANUAL with Maintenance Information
Safety Rules
4
Maximum allowable manual force
Model Applicationmanualforce
Maximumoccupants
JCPT2223RTAOutdoor 400N 4
Indoor 400N 4
Do not use the machine as a crane.
Do not place or attach fixed or overhangingloads to any part of this machine.
Do not push the machine or other objects withthe platform.
Do not contact adjacent structures with theplatform.
Do not alter or disable the limit switches.
Do not tie the platform to adjacent structures.
Do not place loads outside the platformperimeter.
Do not alter or disable machine componentsthat in any way affect safety and stability.
Do not replace items critical to machinestability with items of different weight orspecification.
Do not modify or alter an aerial work platformwithout prior written permission from themanufacturer. Mounting attachments forholding tools or other materials onto theplatform, toe boards or guard rail system canincrease the weight in the platform and thesurface area of the platform or the load.
Do not place ladders or scaffolds in theplatform or against any part of this machine.
Do not transport tools and materials unlessthey are evenly distributed and can be safely
handled by person(s) in the platform.
Do not use the machine on a moving or mobilesurface or vehicle.
Be sure all tires are in good condition, air-filledtires are properly inflated and lug nuts areproperly tightened.
Crushing Hazard
Keep hands and limbs out of scissors.
Keep hands clear when folding rails.
Use common sense and planning whenoperating the machine with the controller fromthe ground. Maintain safe distances betweenthe operator, the machine and fixed objects.
Maintain a firm grasp on the platform rail whenremoving the rail pins. Do not allow theplatform guard rails to fall.
Operation on Slopes Hazard
Do not drive the machine on a slope thatexceeds the slope and side slope rating of themachine.
Slope rating applies to machines only in thestowed position.
ModelMaximum
slope ratingstowed position
Maximumside slope ratingstowed position
JCPT2223RTA 30% (17°) 25% (14°)
Note: Slope rating is subject to groundconditions and adequate traction.
Fall Hazard
The guard rail system provides fall protection.During operation, occupants in the platformmust wear a full body harness with a lanyardattached to an authorized lanyard anchoragepoint. Attach only one (1) lanyard per lanyardanchorage point.
OPERATOR’S MANUAL with Maintenance Information
Safety Rules
5
Do not sit, stand or climb on the platform guardrails. Maintain a firm footing on the platformfloor at all times.
Do not climb down from the platform whenraised.
Keep the platform floor clear of debris.
Close the entry gate before operating.
Do not operate the machine unless the guardrails are properly installed and the entry issecured for operation.
Do not enter or exit the platform unless themachine is in the stowed position.
Collision Hazard
Be aware of limited sight distance and blindspots when driving or operating.
Be aware of extended platform position(s)when moving the machine.
Check the work area for overhead obstructionsor other possible hazards.
Be aware of crushing hazards when graspingthe platform guard rail.
Operators must comply with employer, job siteand governmental rules regarding use ofpersonal protective equipment.
Observe and use color-coded direction arrowson the platform controls and platform decalplate for drive and steer functions.
Do not operate a machine in the path of anycrane or moving overhead machinery unlessthe controls of the crane have been locked outand/or precautions have been taken to preventany potential collision.
No stunt driving or horseplay while operating amachine.
Do not lower the platform unless the areabelow is clear of personnel and obstructions.
Limit travel speed according to the condition ofthe ground surface, congestion, slope, locationof personnel, and any other factors which maycause collision.
Component Damage HazardDo not use any battery or charger greater than12V to jump-start the engine.
Do not use the machine as a ground forwelding.
Explosion and Fire HazardDo not start the engine if you smell or detectliquid petroleum gas (LPG), gasoline, dieselfuel or other explosive substances.
OPERATOR’S MANUAL with Maintenance Information
Safety Rules
6
Do not refuel the machine with the enginerunning.
Refuel the machine and charge the batteryonly in an open, well-ventilated area awayfrom sparks, flames and lighted tobacco.
Do not operate the machine in hazardouslocations or locations where potentiallyflammable or explosive gases or particles maybe present.
Do not spray ether into engines equipped withglow plugs.
Damaged Machine HazardDo not use a damaged or malfunctioningmachine.
Conduct a thorough pre-operation inspectionof the machine and test all functions beforeeach work shift. Immediately tag and removefrom service a damaged or malfunctioningmachine.
Be sure all maintenance has been performedas specified in this manual. Be sure all decalsare in place and legible.
Be sure the operator’s manual is complete,legible and in the storage container located inthe platform.
Bodily Injury HazardAlways operate the machine in awell-ventilated area to avoid carbon monoxidepoisoning.
Do not operate the machine with a hydraulic oilor air leak. An air leak or hydraulic leak canpenetrate and/or burn skin.
Improper contact with components under anycover will cause serious injury. Only trainedmaintenance personnel should accesscompartments. Access by the operator is only
advised when performing a pre-operationinspection. All compartments must remainclosed and secured during operation.
Outrigger SafetyDo not lower the outriggers unless themachine is on a firm surface. Avoid drop-offs,holes, unstable or slippery surfaces and otherpossible hazardous conditions.
When the auto level function is not being usedand the outriggers are being loweredindividually, the steer-end outriggers must belowered first.
Do not raise the platform unless the machineis level. Do not set the machine up on asurface where it cannot be leveled using onlythe outriggers.
Do not raise the platform unless all fouroutriggers are properly lowered, the footpadsare in firm contact with the ground and themachine is level.
Do not adjust the outriggers while the platformis raised.
Do not drive while the outriggers are lowered.
Battery Safety
Burn Hazard
Batteries contain acid. Always wear protectiveclothing and eye wear when working withbatteries.
Avoid spilling or contacting battery acid.Neutralize battery acid spills with baking sodaand water.
OPERATOR’S MANUAL with Maintenance Information
Safety Rules
7
Explosion Hazard
Keep sparks, flames and lighted tobacco awayfrom batteries. Batteries emit explosive gas.
Electrocution/ Hazard
Avoid contact with electrical terminals.
pollute Hazard
Dispose of old battery must comply with jobsite and governmental rules.
Lockout after Each Use1 Select a safe parking location - firm level
surface, clear of obstructions and traffic.
2 Lower the platform.
3 Turn the key switch to the off position andremove the key to secure fromunauthorized use.
4 Chock the wheels.
OPERATOR’S MANUAL with Maintenance Information
Legend
8
Legend
15
6
1
342
5
7
8
9
10
11
12
14
17
13
16
1 Platform entry gate 10 Lift Cylinder
2 Main Platform 11 Engine(behind cover)
3 Lanyard anchorage point 12 Outrigger
4 Platform guard rails 13 Front wheel
5 Platform extensions 14 Hydraulic tanks、Fuel tanks (behind cover)
6 Manual storage containers 15 Ground controls
7 Platform controls 16 Rear wheel
8 Scissor Arms 17.Entry ladder
9. Safety arm
OPERATOR’S MANUAL with Maintenance Information
Decals
9
Decal InspectionUse 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 9334011 Notice – Operator’s Manual Storage 1
2 9414101 Danger – Safety Rules 1
3 9414119 Danger – Tip-over Hazard 1
4 9314013 Instructions – Refer the operator to the instructionsfor use 2
5 9114013 Label – Platform Console Panel 1
6 9414123 Label – Lanyard Anchorage 6
7 9914025 Cosmetic – Warning 1
8 9414063 Label – Capacity 750kg 1
9 9914023 Cosmetic – Warning 1
10 9514011 Cosmetic – Mark 2
11 9414107 Caution – Max. Manual Force: 400N 2
12 9614091 Cosmetic – JCPT2223RTA 2
13 9514105 Cosmetic – Mark 1
14 9914021 Cosmetic – Warning 1
15 9514051 Cosmetic – Mark 1
16 9914019 Cosmetic – Warning 1
17 9413017 Warning – Crushing Hazard 7
18 9413015 Danger – Safety Arm 2
19 9411015 Danger – Tip-over hazard 1
20 9311557 Instructions – Maximum wheel load: 4030kg 4
21 9432013 Warning – Crushing Hazard 4
22 9331013 Instructions – Tie Down Point 4
OPERATOR’S MANUAL with Maintenance Information
Decals
10
No. Part No. Description Qty. Remark
23 9331011 Instructions – Lift Point 4
24 9211011 Decal – Manufacturer’s Plate 1
25 9311143 Instructions – Outrigger load: 4030kg 4
26 9411019 Warning – Crushing Hazard 4
27 9311105 Notice – Main power switch operation 1
28 9514301 Cosmetic – IPAF 2
29 9514201 Cosmetic – CE 2
30 9411011 Danger – Explosion/Burn Hazard 1
31 9911023Instructions – JCPT2223RTA 4×4
SELF-PROPELLED ROUGHTERRAIN SCISSOR LIFTS
2
32 9411021 Warning – Injection Hazard 1
33 9311109 Instructions – Emergency 1
34 9411013 Warning – Inspected and operating properly 1
35 9332013 Instructions – Hydraulic Oil 1 On the HydraulicOil Tank
36 9332017 Instructions – Lowest Hydraulic Oil Level 2 On the HydraulicOil Tank andDiesel Tank37 9332015 Instructions – Highest Hydraulic Oil Level 2
389111011 Label – Ground Console Panel 1
9111013 Label – Ground Console Panel 1
39 9332011 Instructions – Diesel 1 On the DieselTank
OPERATOR’S MANUAL with Maintenance Information
Decals
11
27
21
2322
2426
2829
3031
2322
19
13
14
1516
1717
1717
12
11
10
18
34
3332
21
2322
26
2322
21
21
3536
37
38
39
3736
4
26
26
25
20
20
25
25
25
20
20
2829
31
12
34 5
66666666
7
8
9
12
11
10
17
18
1717
OPERATOR’S MANUAL with Maintenance Information
Decals
12
OPERATOR’S MANUAL with Maintenance Information
Specifications
13
Model JCPT2223RTA
Height, working maximum 22m
Height, platform maximum 20m
Height, drive maximum 12 m
Height, stowed maximumRails up 3.68m
Height, stowed maximumRails folded 2.9m
Width 2.35m
Length, platform retracted 4.9m
Platform dimensionsPlatform length x width 4.35m×1.85m
Platform extension length 2.0m
Maximum load capacity 750kg
Maximum wind speed 12.5m/s
Wheelbase 3.13m
Turning radius (outside) 4.6m
Turning radius (inside) 2.1m
Ground clearance 30cm
Weight See Serial Label
Machine weights vary with option configurations
Controls Proportional
AC outlet in platform Standard
Maximum hydraulic pressure(functions)
240bar
Tire size 355/55D625
Airborne noise emissions <80 dB
Maximum sound level at normal operatingworkstations (A-weighted)
Vibration value does not exceed 2.5m / s2
Maximum slope rating ,Stowed position 30%
Maximum side slope ratingStowed position 25%
Note: Slope rating is subject to groundconditions and adequate traction.
Maximum working slope X-2°, Y-3°
Drive speeds
Stowed, maximum 6.6 km/h
Platform raised, maximum 0.5 km/h
Floor loading information
Tire load, maximum 4030kg
Outrigger load, maximum 4030kg
Tire contact pressure 740kPa
Occupied floor pressure 11.8kPa
Note: Floor loading information is approximateand does not incorporate different optionconfigurations. It should be used only withadequate safety factors.
Continuous improvement of our products is aDINGLI policy. Product specifications aresubject to change without notice or obligation.
OPERATOR’S MANUAL with Maintenance Information
Control Panel
14
Ground Control Panel
1 LED readout screen 8 Red Emergency Stop button
2 Idle select button 9 Platform down button
3 Overload indicator light 10 Lift function enable button
4 Engine start/flameout button 11 Standby
5 Engine RPM display button 12 Platform up button
6 Hour meter 13 Standby
7 Key switch for platform / off / ground controlselection
6 7 8
1
2
3
4
5
13
12
11
10
9
OPERATOR’S MANUAL with Maintenance Information
Control Panel
15
Ground Control Panel1 LED
Diagnostic readout
2 Idle select button
Press this button to select the engine idlesetting. Light on indicates high idle isselected. Light off indicates low idle isselected.
3 Overload indicator light
Light on indicates when overloaded.
4 Engine start/flameout button
Press this button to start/flameout theengine.
5 Engine RPM display button
Press this button to show the engineRPM.
6 Hour meter
The hour meter displays the number ofhours the machine has operated.
7 Key switch for platform / off / ground Turnthe key switch to the platform position andthe platform controls will operate.
Turn the key switch to the off position andthe machine will be off. Turn the keyswitch to the base position and the groundcontrols will operate.
8 Red Emergency Stop button
Push in the red Emergency Stop button tothe off position to stop all functions. Turnthe red Emergency Stop button clockwiseto the on position to operate the machine.
9 Platform down button
Press this button and the platform willlower
10 Lift function enable button
Press this button to activate the liftfunction.
11 Standby
12 Platform up button
13 Standby
OPERATOR’S MANUAL with Maintenance Information
Control Panel
16
Platform Control Panel
1 Red Emergency Stop button 9 Steer mode select button
2 Drive function select button 10 LED
3 Platform retractable enable button 11 Engine start / flameout button
4 Engine high speed idle select button 12 Engine lower speed Idle select button
5 Horn button 13 Lift function select button
6 Differential lock enable button 14 Proportional control handle
7 Outrigger control button 15 Thumb rocker switch for steer function
8 Outrigger auto level button 16 Function enable button
7 7 9 10
16
15
14
13
12
11
1
2
3
4
5
6
7
8
7
OPERATOR’S MANUAL with Maintenance Information
Control Panel
17
Platform Control Panel1 Red Emergency Stop button
Push in the red Emergency Stop button tothe off position to stop all functions. Pull outthe red Emergency Stop button to the onposition to operate the machine.
2 Drive function select button
Press this button to activate the drivefunction.
3 Platform retractable enable button
Press and hold this button to activate theplatform retractable function.
4 Engine high speed idle select button
Press this button to select the engine idlesetting. Light on indicates high idle isselected.
5 Horn button
Press this button and the horn will sound.
Release the button and the horn will stop.
6 Differential lock enable button
Press and hold this button to activate thedifferential lock function.
7 Outrigger control button
Press this button to activate the individualoutrigger up/down function.
8 Outrigger auto level button
Press this button to activate the auto levelfunction.
9 Steer mode select button
Press this button to select steer mode :FSmode (Front Steer mode), AS mode (Allwheel Steer mode), CS mode (Crab Steermode).
10 LED
Diagnostic readout and steer mode andbattery charge indicator.
11 Engine start / flameout button
Press this button to start/ flameout theengine.
12 Engine lower speed Idle select button
Press this button to select the engineidle setting. Light on indicates high idleis selected.
13 Lift function select button
Press this button to activate the liftfunction.
14 Proportional control handle
Move the control handle control thedrive function, Lift function, and platformretractable function outrigger retractablefunction
15 Thumb rocker switch for steer function
Press the thumb rocker switch in eitherdirection to activate steer function.
16 Function enable switch
Lift function: Press and hold the functionenable switch to enable the lift functionon the platform control handle. Move thecontrol handle in the direction indicatedby the blue arrow and the platform willraise. Move the control handle in thedirection indicated by the yellow arrowand the platform will lower. The descentalarm should sound while the platform islowering.
Drive function: Press and hold thefunction enable switch to enable thedrive function on the platform controlhandle. Move the control handle in thedirection indicated by the blue arrow onthe control panel and the machine willmove in the direction that the blue arrowpoints. Move the control handle in thedirection indicated by the yellow arrowon the control panel and the machinewill move in the direction that the yellowarrow points.
OPERATOR’S MANUAL with Maintenance Information
Pre-operation Inspection
18
Do Not Operate Unless:√ You learn and practice the principles of
safe machine operation contained in thisoperator's manual.
1 Avoid hazardous situations.
2 Always perform a pre-operationinspection.
Know and understand the pre-operationinspection before going on to the nextsection.
3 Inspect the workplace.
4 Always perform function tests prior touse.
5 Only use the machine as it wasintended.
FundamentalsIt is the responsibility of the operator toperform a pre-operation inspection and routinemaintenance.
The pre-operation inspection is a visualinspection performed by the operator prior toeach work shift. The inspection is designed todiscover if anything is apparently wrong with amachine before the operator performs thefunction tests.
The pre-operation inspection also serves todetermine if routine maintenance proceduresare required. Only routine maintenance itemsspecified in this manual may be performed bythe operator.
Refer to the list on the next page and checkeach of the items.
If damage or any unauthorized variation fromfactory delivered condition is discovered, themachine must be tagged and removed fromservice.
Repairs to the machine may only be made bya qualified service technician, according to themanufacturer's specifications. After repairs arecompleted, the operator must perform apre-operation inspection again before going onto the function tests.
Scheduled maintenance inspections shall beperformed by qualified service technicians,according to the manufacturer's specificationsand the requirements listed in this manual.
OPERATOR’S MANUAL with Maintenance Information
Pre-operation Inspection
19
Pre-operation InspectionBe sure that the operator’s manual arecomplete, legible and in the storagecontainer located in the platform.
Be sure that all decals are legible and inplace. See Decals section.
Check for engine oil leaks and proper oillevel. Add oil if needed. See Maintenancesection.
Check for hydraulic oil leaks and proper oillevel. Add oil if needed. See Maintenancesection.
Check for engine coolant leaks and properlevel of coolant. Add coolant if needed.See Maintenance section.
Check for battery fluid leaks and properfluid level. Add distilled water if needed.See Maintenance section.
Check the following components or areas fordamage, improperly installed or missing partsand unauthorized modifications:
Electrical components, wiring andelectrical cables
Hydraulic hoses, fittings, cylinders andmanifolds
Fuel and hydraulic tanks
Drive motors
Wear pads
Tires and wheels
Engine and related components
Limit switches, alarms and horn
Nuts, bolts and other fasteners
Platform overload components
Platform entry gate
Beacon and alarms (if equipped)
Safety arm
Platform extension(s)
Scissor pins and retaining fasteners
Platform control joystick
Oscillate Axle
Differential lock
Outrigger housings and footpads
Check entire machine for:
Cracks in welds or structuralcomponents
Dents or damage to machine
Be sure that all structural and othercritical components are present andall associated fasteners and pins arein place and properly tightened
Note: If the platform must be raised to inspectthe machine, make sure the safety arm is inplace. See Operating Instructions section.
OPERATOR’S MANUAL with Maintenance Information
Workplace Inspection
20
Do Not Operate Unless:√ You learn and practice the principles of
safe machine operation contained in thisoperator's manual.
1 Avoid hazardous situations.
2 Always perform a pre-operationinspection.
3 Inspect the workplace.
Know and understand the workplaceinspection before going on to the nextsection.
4 Always perform function tests prior touse.
5 Only use the machine as it wasintended.
FundamentalsThe workplace inspection helps the operatordetermine if the workplace is suitable for safemachine operation. It should be performed bythe operator prior to moving the machine to theworkplace.
It is the operator's responsibility to read andremember the workplace hazards, then watchfor and avoid them while moving, setting upand operating the machine.
Workplace InspectionBe aware of and avoid the following hazardoussituations:
- Drop-offs or holes
- Bumps, floor obstructions or debris
- Sloped surfaces
- Unstable or slippery surfaces
- Overhead obstructions and high voltageconductors
- Hazardous locations
- Inadequate surface support to withstand allload forces imposed by the machine
- Wind and weather conditions
- The presence of unauthorized personnel
- Other possible unsafe conditions
OPERATOR’S MANUAL with Maintenance Information
Function Tests
21
Do Not Operate Unless:√ You learn and practice the principles of
safe machine operation contained in thisoperator's manual.
1 Avoid hazardous situations.
2 Always perform a pre-operationinspection.
3 Inspect the workplace.
4 Always perform function tests priorto use.
Know and understand the function testsbefore going on to the next section.
5 Only use the machine as it wasintended.
FundamentalsThe function tests are designed to discoverany malfunctions before the machine is putinto service.
The operator must follow the step-by-stepinstructions to test all machine functions.
A malfunctioning machine must never be used.If malfunctions are discovered, the machinemust be tagged and removed from service.Repairs to the machine may only be made bya qualified service technician, according to themanufacturer's specifications.
After repairs are completed, the operator mustperform a pre-operation inspection andfunction tests again before putting the machineinto service.
OPERATOR’S MANUAL with Maintenance Information
Function Tests
22
1 Select a test area that is firm, level andfree of obstruction.
At the Ground Controls2 Pull out the platform red Emergency Stop
button to the on position.
3 Turn the red Emergency Stop buttonclockwise to the on position.
4 Turn the key switch to ground control.
5 0bserve the diagnostic LED readout on theground controls.
⊙ Result: The LED readout will come on anddisplay SYSTEM READY.
6 Start the engine. See OperatingInstructions section.
Test Emergency Stop
7 Push in the ground red Emergency Stopbutton to the off position.
⊙ Result: The engine should turn off and nofunctions should operate.
8 Turn the red Emergency Stop buttonclockwise to the on position and restart theengine.
Test Up/Down Functions andFunction Enable
A buzzer with different sound frequency iscontrolled in central system. The descentalarm sounds at 60 beeps per minute. Thealarm that goes off when the machine is notlevel sounds at 150 beeps per minute. Anoptional automotive-style horn is alsoavailable.
9 Do not press the lift function enable button.Press and hold the platform up/downbutton.
⊙ Result: No function should operate.
10 Press and hold the lift function enablebutton. Press and hold the platform upbutton.
⊙ Result: The platform should rise.
11 Press and hold the lift function enablebutton. Press and hold the platform downbutton.
⊙ Result: The platform should lower thenstop at the height is 3.5m. The descentalarm should sound while the platform islowering.
12 Press and hold the lift function enablebutton. Press and hold the platform downbutton.
⊙ Result: The platform should lower to end.The descent alarm should sound while theplatform is lowering.
Test the Auxiliary Lowering
13 Activate the up function and raise theplatform approximately 60 cm.
14 Press the engine start/ flameout button toengine off.
15 Press and hold the lift function enablebutton. Press and hold the platform downbutton.
⊙ Result: The platform should lower.
16 Turn the key switch to platform control andrestart the engine.
At the Platform Controls
Test Emergency Stop
17 Push in the platform red Emergency Stopbutton to the off position.
⊙ Result: No functions should operate.
18 Pull the red Emergency Stop button out tothe on position.
⊙ Result: The LED readout will come on anddisplay SYSTEM READY
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Function Tests
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Test the Horn
19 Push the horn button.
⊙ Result: The horn should sound.
Test Up/Down Functions andFunction Enable
20 Start the engine.
21 Activate the up/down rocker switch in thedirection indicated by the blue arrow.
⊙ Result: The platform should not rise.
22 Press the lift function select button. Theindicator light should turn on.
23 Press and hold the function enable button.Activate the proportional control handle inthe direction indicated by the blue arrow.
⊙ Result: The platform should rise.
24 Activate the proportional control handle inthe direction indicated by the yellow arrow.
⊙ Result: The platform should lower. Thedescent alarm should sound while theplatform is lowering.
Test the Steering
Note: When performing the steer and drivefunction test, stand in the platform facing thesteer end of the machine.
25 Press the drive function select button. Theindicator light should turn on.
26 Push the steer mode select button forsteer FS mode (Front Steer mode).
27 Press and hold the function enable switchon the proportional control handle.Depress the thumb rocker switch on top ofthe proportional control handle in thedirection identified by the blue triangle onthe control panel.
⊙ Result: The front wheels should turn in thedirection that the blue triangle points on thecontrol panel.
28 Press and hold the function enable switchon the proportional control handle.Depress the thumb rocker switch in thedirection identified by the yellow triangleon the control panel.
⊙ Result: The front wheels should turn in thedirection that the yellow triangle points onthe control panel.
29 Push the steer mode select button forsteer AS mode (All wheel Steer mode).
30 Press and hold the function enable switchon the proportional control handle.Depress the thumb rocker switch on top ofthe proportional control handle in thedirection identified by the blue triangle onthe control panel.
⊙ Result: The front wheels should turn in thedirection that the blue triangle points on thecontrol panel and the rear wheels shouldturn in the direction that the yellow trianglepoints on the control panel
31 Press and hold the function enable switchon the proportional control handle.Depress the thumb rocker switch in thedirection identified by the yellow triangleon the control panel.
⊙ Result: The front wheels should turn in thedirection that the yellow triangle points onthe control panel and the rear wheelsshould turn in the direction that the bluetriangle points on the control panel
32 Push the steer mode select button forsteer CS mode (Crab Steer mode).
33 Press and hold the function enable switchon the proportional control handle.Depress the thumb rocker switch on top ofthe proportional control handle in thedirection identified by the blue triangle onthe control panel.
⊙ Result: The front wheels should turn in thedirection that the blue triangle points on the
OPERATOR’S MANUAL with Maintenance Information
Function Tests
24
control panel and the rear wheels shouldturn in the direction that the blue trianglepoints on the control panel
34 Press and hold the function enable switchon the proportional control handle.Depress the thumb rocker switch in thedirection identified by the yellow triangleon the control panel.
⊙ Result: The front wheels should turn in thedirection that the yellow triangle points onthe control panel and the rear wheelsshould turn in the direction that the yellowtriangle points on the control panel
Test Drive and Braking
35 Press and hold the function enable switchon the proportional control handle.
36 Slowly move the proportional controlhandle in the direction indicated by theblue arrow on the control panel until themachine begins to move, then return theproportional control handle to the centerposition.
⊙ Result: The machine should move in thedirection that the blue arrow points on thecontrol panel, then come to an abrupt stop.
37 Press and hold the function enable switchon the proportional control handle.
38 Slowly move the proportional controlhandle in the direction indicated by theyellow arrow on the control panel until themachine begins to move, then return theproportional handle to the center position.
⊙ Result: The machine should move in thedirection that the yellow arrow points on thecontrol panel, then come to an abrupt stop.
Note: The brakes must be able to hold themachine on any slope it is able to climb.
Test Limited Drive Speed
39 Press the lift function select button. Raise
the platform approximately 3.5 m from theground.
40 Press the drive function select button.
41 Press and hold the function enable switchon the proportional control handle slowlymove the proportional control handle to thefull drive position.
⊙ Result: The maximum achievable drivespeed with the platform raised should notexceed 12.5cm/s.
¤ Result: If the drive speed with the platformraised exceeds 12.5cm/s, immediately tagand remove the machine from service.
Test the Tilt Sensor Operation
Note: Perform this test from the ground withthe platform controller. Do not stand in theplatform.
42 Fully lower the platform.
43 Drive both wheels on one side onto an18cm block.
44 Raise the platform at least 3.5 m.
⊙ Result: The platform should stop and the tiltalarm will sound. The indicator light on thelift function select button will be red.
45 Press the drive function select button.
46 Move the proportional control handle in thedirection indicated by the blue arrow, thenmove the proportional control handle in thedirection indicated by the yellow arrow.
⊙ Result: The drive function should not workin either direction.
47 Press the lift function enable button.
48 Lower the platform and drive the machineoff the block.
Test the Oscillate System
Note: Perform this test from the ground withthe platform controller. Do not stand in the
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Function Tests
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platform.
49 Fully lower the platform.
50 Drive the Left front wheel onto an 18cmblock.
51 Raise the platform at least 3.5 m.
52 Press the drive function select button
53 Activate the proportional control handle inthe direction indicated by the yellow arrow
⊙ Result: The left front or right rear wheelremains elevated in position off ground
54 Press the lift function enable button.
55 Lower the platform to stowed position,activation drives forward and backwardmoving machine.
⊙ Result: Lockout cylinders should releaseand allow wheel to rest on ground
56 Drive the right front wheel onto an 18cmblock.
57 Raise the platform at least 3.5 m.
58 Press the drive function select button
59 Activate the proportional control handle inthe direction indicated by the yellow arrow
⊙ Result: The right front or left rear wheelremains elevated in position off ground
60 Press the lift function enable button.
61 Lower the platform to stowed position,activation drives forward and backwardmoving machine.
⊙ Result: Lockout cylinders should releaseand allow wheel to rest on ground
Test the Up Limit Switch and theOutriggers
62 Push and hold the lift function enablebutton. Raise the platform.
⊙ Result: The platform should rise to 12 mand then stop. The platform should not rise
above 12 m unless the outriggers arelowered.
63 Press the drive function select button.Drive the machine forward.
⊙ Result: The drive function should operate.
64 Press the lift function select button.
65 Lower the platform. If the platform is higherthan 3.5 m from the ground, the outriggerswill not lower.
66 Lower the platform to the end.
67 Push and hold the auto level button.
68 Press and hold the function enable switch.Activate the proportional control handle inthe direction indicated by the yellow arrow.The outriggers will extend and level themachine. A beep will sound when themachine is level.
69 Raise the platform.
⊙ Result: The platform should rise to fullheight.
70 Lower the platform.
Test Auxiliary Lowering
71 Push and hold the function enable buttonand raise the platform approximately 60cm.
72 Press the engine start/ flameout button toengine off.
73 Push and hold the function enable button.Activate the control handle in the directionindicated by the yellow arrow.
⊙ Result: The platform should lower.
Test Platform Telescopic Functions
74 Push and hold the Platform retractableenable button. Press and hold the functionenable switch. Activate the proportionalcontrol handle in the direction indicated bythe blue arrow
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Function Tests
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⊙ Result: The platform should spread.
75 Push and hold the Platform retractableenable button. Press and hold the functionenable switch. Activate the proportionalcontrol handle in the direction indicated bythe yellow arrow.
⊙ Result: The platform should retract
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Operating Instructions
27
Do Not Operate Unless:√ You learn and practice the principles of
safe machine operation contained in thisoperator's manual.
1 Avoid hazardous situations.
2 Always perform a pre-operationinspection.
3 Inspect the workplace.
4 Always perform function tests prior touse.
5 Only use the machine as it wasintended.
FundamentalsThis machine is a self-propelled hydraulic liftequipped with a work platform on the scissormechanism. Vibrations emitted by thesemachines are not hazardous to an operator inthe work platform. The machine can be usedto position personnel with their tools andsupplies at position above ground level andcan be used to reach work areas locatedabove and over machinery or equipment.
A full and detailed implementation of EN ISO13849-1/2 is correctly applied on our MEWPdesign. SISTEMA, a software tool for PLCalculation Tool, is also used to perform somerelatively straightforward calculations onsubsystem to determine the overall PL of thesystem. Reliability data, diagnostic coverage[DC], the system architecture [Category],common cause failure and, where relevant,requirements for software are used to assessthe PL to comply with PLr of SRP/CS inClause 5.11 of EN 280.
The Operating Instructions section providesinstructions for each aspect of machineoperation.
It is the operator's responsibility to follow allthe safety rules and instructions in theoperator's manual.
Using the machine for anything other thanlifting personnel, along with their tools andmaterials, to an aerial work site is unsafe anddangerous.
Only trained and authorized personnel shouldbe permitted to operate a machine. If morethan one operator is expected to use amachine at different times in the same workshift, they must all be qualified operators andare all expected to follow all safety rules andinstructions in the operator's manual. Thatmeans every new operator should perform apre-operation inspection, function tests, and aworkplace inspection before using themachine.
OPERATOR’S MANUAL with Maintenance Information
Operating Instructions
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Emergency StopPush in the red Emergency Stop button to theoff position at the ground controls or theplatform controls to stop all machine functionsand turn the engine off.
Repair any function that operates when eitherred Emergency Stop button is pushed in.
Starting the Engine1 At the ground controls, turn the key switch
to the desired position.
2 Be sure both ground and platform controlred Emergency Stop buttons are pulled outto the on position.
3 Press the engine start button.
When the temperature is too low, the enginewill be preheated automatically.
If the engine fails to start after 15 seconds ofcranking, determine the cause and repair anymalfunction. Wait 60 seconds before trying tostart again.
In cold conditions, -6°C and below, warm theengine for 5 minutes before operating toprevent hydraulic system damage.
In extreme cold conditions, -18°C and below,machines should be equipped with optionalcold start kits. Attempting to start the enginewhen temperatures are below -18°C mayrequire the use of a booster battery.
Operation from Ground1 Turn the key switch to ground control.
2 Pull out the platform red Emergency Stopbutton to the on position.
3 Turn the red Emergency Stop buttonclockwise to the on position.
4 Start the engine.
To Position Platform
1 Press the lift function enable button.
2 Press the platform up/down button toactivate the up function or the downfunction.
Drive and steer functions are not availablefrom the ground controls.
Engine Idle Select
Select the engine idle (rpm) by press.
Operation from Platform1 Turn the key switch to platform control.
2 Pull out the ground and platform redEmergency Stop buttons to the onposition.
3 Start the engine.
To Position Platform
1 Press the lift function select button.
2 Press and hold the function enable switchon the control handle.
3 Activate the proportional control handle inthe desired direction.
To Steer
1 Press the drive function select button.
2 Press and hold the function enable switchon the control handle.
3 Push the steer mode select button forsteer mode (FS. AS CS)
4 Turn the steer wheels with the thumbrocker switch located on the top of thecontrol handle.
To Drive
1 Press the drive function select button.
2 Press and hold the function enable switchon the control handle.
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Operating Instructions
29
3 Increase speed: Slowly move the controlhandle off center.
Decrease speed: Slowly move the controlhandle toward center.
Stop: Return the control handle to center orrelease the function enable switch.
Use the direction arrows on the platformcontrols to identify the direction the machinewill travel.
Machine travel speed is restricted when theplatform is raised.
Drive Select Switch
The drive controls can operate in two differentdrive speed modes. When the engine lowerspeed idle select button light is on, slow drivespeed mode is active. When the engine highspeed idle select button light is on, fast drivespeed mode is active.
Driving on a slope
Determine the slope and side slope ratings forthe machine and determine the slope grade.
Maximum slope rating, stowed position 30%,Maximum side slope rating, stowed position25%
Note: Slope rating is subject to groundconditions and adequate traction.
Press the drive speed select switch to the fastdrive speed mode.
To determine the slope grade
Measure the slope with a digital inclinometeror use the following procedure.
You will need:
Carpenter’s level
Straight piece of wood, at least 1 m longtape measure
Lay the piece of wood on the slope
At the downhill end, lay the level on the top
edge of the piece of wood and lift the end untilthe piece of wood is level.
While holding the piece of wood level,measure the distance from the bottom of thepiece of wood to the ground.
Divide the tape measure distance (rise) by thelength of the piece of wood (run) and multiplyby 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 orside slope rating, the machine must bewinched or transported up or down the slope.See Transport and Lifting section.
To Extend and Retract Platform1 Push and hold the platform spread button.
2 Push and hold the platform retractingbutton.
Auxiliary LoweringAt the Ground Controls
Press and hold the lift function enable button.Press and hold the platform down button.
At the Platform Controls
Press the lift function select button.
Push and hold the function enable button.Activate the control handle in the directionindicated by the yellow arrow.
Operation from Ground with
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Operating Instructions
30
ControllerMaintain safe distances between operator,machine and fixed objects.
Be aware of the direction the machine willtravel when using the controller.
Outrigger Operation1 Position the machine below the desired
work area.
Note: The engine must be running for theoutriggers to operate.
2 Push and hold the auto level button.
3 Press and hold the function enable switch.Activate the proportional control handle inthe direction indicated by the yellow arrow.The outriggers will extend and level themachine. A beep will sound when themachine is level.
The indicator light on the lift function enablebutton will turn on when one but not alloutriggers are down. All drive and lift functionsare disabled.
The indicator lights on the lift function enablebutton and on the individual outrigger buttonswill turn off when all the outriggers are in firmcontact with the ground.
The drive function is disabled while theoutriggers are down.
To control individual outrigger
1 Push and hold one or more outriggerbuttons.
2 Press and hold the function enable switch.Activate the proportional control handle inthe direction indicated by the yellow arrow.The outriggers will extend and level themachine.
How to use the Safety ArmThe safety arm on the left and on the right sideof the scissor system needs to be used formaintenance work. This safety arm relief thelifting cylinder and they hold the workingplatform safe.
To put the safety arm into the retainer theworking platform has to be lifted. Afterwardsthe screws can be released so that the safetyarm can be allinged downward.
When lowering the lifting system the safetyarm will be engage into the retainers among.The lowering procedure will be interruptedautomatically if the safety arms are on block.
Safety screw
Arm Retainer
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Operating Instructions
31
Don’t engage the safety armunless unload the platform.
Using this safety arm isnecessary during operations near the scissorsystem if the platform is lifted!
How to Fold Down theGuardrailsThe platform railing system consists of threefold down rail section for the extension deckand three sections for the main deck. Allsections are held in place by four latches.
Closed latch
Open latch
1 Fully lower the platform and retract theplatform extension.
2 Remove the platform controls.
3 Opening the latches in the corners the railshave to be folded in correct order of thenumbering.
2 4 6 1
3 5
1
2
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Operating Instructions
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How to Raise the GuardrailsFollow the fold down instructions but in reverseorder.
Emergency operating with handpumpEmergency Lifting
1 Unplug the lever and put it into the handpump (1).
2 Press and hold the button(3).
3 Operate the hand pump with the lever, theplatform should rise.
Emergency Lowering
1 Unplug the lever and put it into the handpump (1).
2 Press and hold the button(2).
3 Operate the hand pump with the lever, theplatform should rise.
Retracting outriggers
1 Unplug the lever andput it into the handpump (1).
2 Turn the knob (4) inthe direction of thearrow.
3 Choose the outrigger which needs toretract, turn the corresponding knob in thedirection of the arrow.
4 Operate the hand pump with the lever, theoutrigger emergency retract
Retracting Platform
1 Unplug the lever and put it into the handpump (1).
2 Turn the knob (6) in the direction of thearrow.
5
6
3
4
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Operating Instructions
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3 Operate the hand pump with the lever, theplatform should rise.
Do not emergency lift/lowerthe platform and retract outriggers simultaneity;Reset the knob after all operations completed.
Emergency actuation ofoutriggers only in normal position danger oftipping!
1
2 3 4 5 6 7 8 9 10
After Each Use1 Select a safe parking location - firm level
surface, clear of obstructions and traffic.
2 Lower the platform.
3 Turn the key switch to the off position andremove the key to secure fromunauthorized use.
4 Chock the wheels.
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Transport and Lifting Instructions
34
Observe and Obey:√ Common sense and planning must be
applied to control the movement of themachine when lifting it with a crane orforklift.
√ The transport vehicle must be parked on alevel surface.
√ The transport vehicle must be secured toprevent rolling while the machine is beingloaded.
√ Be sure the vehicle capacity, loadingsurfaces and chains or straps are sufficientto withstand the machine weight. See theserial label for the machine weight.
√ The machine must be on a level surface orsecured before releasing the brakes.
√ Do not drive the machine on a slope thatexceeds the slope or side slope rating. SeeDriving on a Slope in the OperatingInstructions section.
√ If the slope of the transport vehicle bedexceeds the maximum slope rating, themachine must be loaded and unloadedusing a winch as described.
Free-wheel Configuration forWinchingChock the wheels to prevent the machine fromrolling.
Loosen nuts of screws provided for themechanical and manual release of the brakingunits, and then move the nuts backwards byapproximately 8 mm.
Tighten screws so as to fasten them onto thepressure plate.
Using a wrench, tighten the screws in analternate sequence by 1/4 turn at a time so asto compress the Belleville washers anddisengage the braking disks
Before maintaining brakes,when the axle is installed on the vehicle, followall safety instructions in the OriginalEquipment Manufacturer (OEM) manual thatcame with the vehicle.
Tighten maximum by oneturn.
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Transport and Lifting Instructions
35
Securing to Truck or Trailer for
TransitAlways chock the machine wheels inpreparation for transport.
Retract and secure the extension deck(s).
Use the tie-down points on the chassis foranchoring down to the transport surface.
Use a minimum of four chains or straps.
Use chains or straps of ample load capacity.
Turn the key switch to the off position andremove the key before transporting.
Inspect the entire machine for loose orunsecured items.
If the railings have been folded down, securethem with straps before transporting.
OPERATOR’S MANUAL with Maintenance Information
Transport and Lifting Instructions
36
Observe and Obey:√ Only qualified riggers should rig and lift the
machine.
√ Be sure the crane capacity, loadingsurfaces and straps or lines are sufficient towithstand the machine weight. See theserial plate for the machine weight.
Lifting InstructionsFully lower the platform. Be sure the extensiondecks, controls and covers are secure.Remove all loose items on the machine.
Determine the center of gravity of yourmachine using the table and the picture on thispage.
Attach the rigging only to the designated liftingpoints on the machine. There are two liftingpoints on each end of the machine.
Adjust the rigging to prevent damage to themachine and to keep the machine level.
Center of gravity X Axis Y Axis
JCPT2223RTA 1.7m 1.3m
X Axis
Y A
xis
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Maintenance
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Observe and Obey:√ Only routine maintenance items specified in
this manual shall be performed by theoperator.
√ Scheduled maintenance inspections shallbe completed by qualified servicetechnicians, according to the manufacturer'sspecifications and the requirementsspecified in this manual.
Maintenance Symbols Legend
The following symbols havebeen used in this manual to help communicatethe intent of the instructions. When one ormore of the symbols appear at the beginningof a maintenance procedure, it conveys themeaning below.
Indicates that tools will be required toperform this procedure.
Indicates that new parts will berequired to perform this procedure.
Indicates that a cold engine is requiredbefore performing this procedure.
Indicates that a warm engine will berequired to perform this procedure.
Indicates that dealer service will berequired to perform this procedure
Pre-delivery Preparation ReportThe pre-delivery preparation report containschecklists for each type of scheduledinspection.
Make copies of the Pre-delivery Preparationreport to use for each inspection. Storecompleted forms as required.
Maintenance ScheduleThere are five types of maintenanceinspections that must be performed accordingto a schedule— daily, quarterly, semi-annually,annually, and two year. The ScheduledMaintenance Procedures Section and theMaintenance Inspection Report have beendivided into five subsections—A, B, C, D, andE. Use the following chart to determine whichgroup(s) of procedures are required to performa scheduled inspection.
Inspection Checklist
Daily or every 8 hours A
Quarterly or every 250 hours A+B
Semi-annually or every 500 hours A+B +C
Annually or every 1000 hours A+B +C +D
Two year or every 2000 hours A+B+C+D+E
Maintenance Inspection ReportThe maintenance inspection report containschecklists for each type of scheduledinspection.
Make copies of the Maintenance InspectionReport to use for each inspection. Maintaincompleted forms for a minimum of 4 years orin compliance with your employer, jobsite andgovernmental regulations and requirements.
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Maintenance
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Pre-delivery Preparation Report
Fundamentals
It is the responsibility of the dealer to performthe Pre-delivery Preparation.
The Pre-delivery Preparation is performedprior to each delivery. The inspection isdesigned to discover if anything is apparentlywrong with a machine before it is put intoservice.
A damaged or modified machine must neverbe used. If damage or any variation fromfactory delivered condition is discovered, themachine must be tagged and removed fromservice.
Repairs to the machine may only be made bya qualified service technician, according to themanufacturer’s specifications.
Scheduled maintenance inspections shall beperformed by qualified service technicians,according to the manufacturer’s specificationsand the requirements listed in this manual.
Instructions
Use the operator’s manual on your machine.
The Pre-delivery Preparation consists ofcompleting the Pre-operation Inspection, theMaintenance items and the Function Tests.
Use this form to record the results. Place acheck in the appropriate box after each part iscompleted. Follow the instructions in theoperator’s manual.
If any inspection receives an N, remove themachine from service, repair and re-inspect it.After repair, place a check in the R box.
LegendY = yes, completed
N = no, unable to complete
R = repaired
Comments
Pre-Delivery Preparation Y N R
Pre-operation inspectioncompletedMaintenance itemscompleted
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
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Maintenance
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Maintenance Inspection ReportModelSerial numberDateHour meterMachine ownerInspected by (print)Inspector signatureInspector titleInspector company
Instructions• Make copies of this report to use for eachinspection.• Select the appropriate checklist(s) for the typeof inspection to be performed.
Daily or 8 hoursInspection: A
Quarterly or 250 hoursInspection: A+ B
Semi-annually or 500hours Inspection: A+B+C
Annually or 1000 hoursInspection: A+B+C+D
Two year or 2000 hoursInspection: A+B+C+D+E
• Place a check in the appropriate box aftereach inspection procedure is completed.• Use the step-by-step procedures in thissection to learn how to perform theseinspections.• If any inspection receives an “N”, tag andremove the machine from service, repair andre-inspect it. After repair, place a check in the “R’box.Legend
Y = yes, acceptableN = no, remove from serviceR = repaired
Checklist A Y N RA-1 Manuals and decalsA-2 Pre-operation inspectA-3 Check the BatteriesA-4 Check the Engine Oil LevelA-5 Check the Hydraulic Oil LevelA-6 Check the Engine Coolant LevelA-7 Function testsA-8 Engine maintenance
A-9 Drive Axle MaintenancePerform after 40 hours:A-10 30 day servicePerform after 50 hours:A-11 Engine maintenancePerform every 100 hours:A-12 Drive Axle MaintenanceChecklist B Y N RB-1 BatteryB-2 Electrical wiringB-3 Exhaust systemB-4 Tires and wheelsB-5 Drive hub oil levelB-6 Key switchB-7 Emergency StopB-8 HornB-9 Drive brakesB-10 Drive speed - stowedB-11 Drive speed - raisedB-12 Hydraulic oil analysisB-13 Engine maintenanceB-14 Drive Axle MaintenanceChecklist C Y N RC-1 Platform overloadC-2 Engine maintenanceC-3 Drive Axle MaintenanceChecklist DD-1 Scissor arm wear padsD-2 Free-wheel configurationD-3 Replace the Drive Axle OilD-4 Engine maintenanceD-5 Drive Axle MaintenanceChecklist E Y N RE-1 Test or replace hydraulic oilPerform every 2000 hours:E-2 Engine maintenancePerform every 3000 hours:E-3 Engine maintenancePerform every 4000 hours:E-4 Engine maintenancePerform every 6000 hours:E-4 Engine maintenancePerform every 12,000 hours:E-6 Engine maintenance
OPERATOR’S MANUAL with Maintenance Information
Maintenance
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Checklist A ProceduresA-1
Inspect the Manuals and Decals
Maintaining the operator’s manual in goodcondition is essential to safe machineoperation. Manuals are included with eachmachine and should be stored in the containerprovided in the platform. An illegible or missingmanual will not provide safety and operationalinformation necessary for a safe operatingcondition.
In addition, maintaining all of the safety andinstructional decals in good condition ismandatory for safe machine operation. Decalsalert operators and personnel to the manypossible hazards associated with using thismachine. They also provide users withoperation and maintenance information. Anillegible decal will fail to alert personnel of aprocedure or hazard and could result in unsafeoperating conditions.
1 Check to make sure that the operator’smanual is present and complete in thestorage container on the platform.
2 Examine the pages of manual to be surethat they are legible and in good condition.
⊙ Result: The operator’s manual isappropriate for the machine and themanual are legible and in good condition.
¤ Result: The operator’s manual is notappropriate for the machine or the manualis not in good condition or is illegible.Remove the machine from service until themanual is replaced.
3 Open the operator’s manual to the decalsinspection section. Carefully andthoroughly inspect all decals on themachine for legibility and damage.
⊙ Result: The machine is equipped with allrequired decals, and all decals are legible andin good condition.
¤ Result: The machine is not equipped withall required decals, or one or more decalsare illegible or in poor condition. Removethe machine from service until the decalsare replaced.
4 Always return the manual to the storagecontainer after use.
Note: Contact your authorized DINGLIdistributor or DINGLI Industries if replacementmanuals or decals are needed.
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A-2
Perform Pre-operation Inspection
Completing a Pre-operation Inspection isessential to safe machine operation. ThePre-operation Inspection is a visual inspectionperformed by the operator prior to each workshift. The inspection is designed to discover ifanything is apparently wrong with a machinebefore the operator performs the function tests.The Pre-operation Inspection also serves todetermine if routine maintenance proceduresare required.
Complete information to perform thisprocedure is available in the appropriateoperator’s manual. Refer to the Operator’sManual on your machine.
A-3
Check the Batteries
Proper battery condition is essential to goodengine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in engine componentdamage and hazardous conditions.
Electrocution hazard. Contactwith hot or live circuits may result in death orserious injury. Remove all rings, watches andother jewelry.
Bodily injury hazard. Batteriescontain acid. Avoid spilling or contactingbattery acid. Neutralize battery acid spills withbaking soda and water.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cableconnections are tight and free ofcorrosion.
3 Be sure that the battery hold-down barsare secure.
4 Remove the battery vent caps.
5 Check the battery acid level. If needed,replenish with distilled water to thebottom of the battery fill tube. Do notoverfill.
6 Install the vent caps.
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Maintenance
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A-4
Check the Engine Oil Level
Maintaining the proper engine oil level isessential to good engine performance andservice life.
Operating the machine with an improper oillevel can damage engine components.
Check the oil level with theengine off.
1 Open the engine cover
2 Release the latches on the engine tray andfully rotate out
3 Check the oil level dipstick. Add oil asneeded.
Oil type 5W-30
Oil type – cold conditions 0W-20
A-5
Check the Hydraulic Oil Level
Maintaining the hydraulic oil at the proper levelis essential to machine operation. Improperhydraulic oil levels can damage hydrauliccomponents. Daily checks allow the inspectorto identify changes in oil level that mightindicate the presence of hydraulic systemproblems.
Perform this procedure withthe platform in the stowed position and theengine off.
1 Visually inspect the sight of hydraulic oillevel from the side of the hydraulic oil tank.
⊙ Result: The hydraulic oil level should bewithin the top 5 cm of the tank.
2 Add oil if necessary. Do not overfill.
Hydraulic oil specifications
Hydraulic oil type L-HV46
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A-6
Check the Engine Coolant Level
Maintaining the engine coolant at the properlevel is essential to engine service life.Improper coolant level will affect the engine'scooling capability and damage enginecomponents. Daily checks will allow theinspector to identify changes in coolant levelthat might indicate cooling system problems.
Check the fluid level in the radiator. Add fluidas needed.
Bodily injury hazard. Fluids inthe radiator are under pressure and extremelyhot. Use caution when removing cap andadding fluids.
A-7
Perform Function Tests
Completing the function tests is essential tosafe machine operation. Function tests aredesigned to discover any malfunctions beforethe machine is put into service. Amalfunctioning machine must never be used. Ifmalfunctions are discovered, the machinemust be tagged and removed from service.
Complete information to perform thisprocedure is available in the appropriateoperator’s manual. Refer to the Operator’sManual on your machine.
A-8
Perform Engine Maintenance
Engine specifications require that thisprocedure be performed every 8 hours or daily,whichever comes first.
Required maintenance procedures andadditional engine information is available in theengine operator’s manual.
A-9
Perform Drive Axle Maintenance
Axle specifications require that this procedurebe performed every 8 hours or daily,whichever comes first.
Required maintenance procedures andadditional Axle information is available in theAxle operator’s manual.
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A-10
Perform 30 Day Service
The 30 day maintenance procedure is a onetime procedure to be performed after the first30 days or 40 hours of usage. After thisinterval, refer to the maintenance tables forcontinued scheduled maintenance.
1 Perform the following maintenanceprocedures:
•·B-6 Inspect the Tires and Wheels(including lug nut torque)
•·B-15 Perform Engine Maintenance
A-11
Perform Engine Maintenance
Engine specifications require that this one-timeprocedure be performed after 50 hours ofoperation.
Required maintenance procedures andadditional engine information is available in theengine operator’s manual.
A-12
Perform Drive Axle Maintenance
Axle specifications require that this procedurebe performed every 100 hours.
Required maintenance procedures andadditional Axle information is available in theAxle operator’s manual.
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Checklist B ProceduresB-1Inspect the Batteries
DINGLI requires that this procedure beperformed every 250 hours or quarterly,whichever comes first.
Proper battery condition is essential to goodmachine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in component damageand hazardous conditions.
Electrocution / burn hazard.Contact with electrically charged circuits couldresult in death or serious injury. Remove allrings, watches and other jewelry.
Bodily injury hazard.Batteries contain acid. Avoid spilling orcontacting battery acid. Neutralize battery acidspills with baking soda and water.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connectionsare free of corrosion.
Note: Adding terminal protectors and acorrosion preventative sealant will helpeliminate corrosion on the battery terminalsand cables.
3 Be sure that the battery retainers andcable connections are tight.
4 Fully charge the battery. Allow the batteryto rest 24 hours before performing thisprocedure to allow the battery cells toequalize.
Models without maintenance-free or sealedbatteries:
5 Remove the battery vent caps and checkthe specific gravity of each battery cell witha hydrometer. Note the results.
6 Check the ambient air temperature andadjust the specific gravity reading for eachcell as follows:
• Add 0.004 to the reading of each cell forevery 5.5° C above 26.7° C.
• Subtract 0.004 from the reading of eachcell for every 5.5° C below 26.7° C.
⊙ Result: All battery cells display an adjustedspecific gravity of 1.277 or higher. Thebattery is fully charged. Proceed to step 10.
¤ Result: One or more battery cells display aspecific gravity of 1.217 or below. Proceedto step 7.
7 Perform an equalizing charge OR fullycharge the batteries and allow the batteryto rest at least 6 hours.
8 Remove the battery vent caps and checkthe specific gravity of each battery cell witha hydrometer. Note the results.
9 Check the ambient air temperature andadjust the specific gravity reading for eachcell as follows:
• Add 0.004 to the reading of each cell forevery 5.5° C above 26.7° C.
• Subtract 0.004 from the reading of eachcell for every 5.5° C below 26.7° C.
⊙ Result: All battery cells display a specificgravity of 1 .277 or greater. The battery isfully charged. Proceed to step 10.
¤ Result: The difference in specific gravityreadings between cells is greater than 0.1OR the specific gravity of one or more cellsis less than 1.217. Replace the battery.
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10 Check the battery acid level. If needed,replenish with distilled water to 1/8 inch I 3mm below the bottom of the battery filltube. Do not overfill.
11 Install the vent caps and neutralize anyelectrolyte that may have spilled.
All models:
12 Check each battery pack and verify thatthe batteries are wired correctly.
13 Inspect the battery charger plug and pigtailfor damage or excessive insulation wear.Replace as required.
14 Connect the battery charger to a properlygrounded 110 - 230V / 50 – 60 Hz singlephase AC power supply.
⊙ Result: The charger should operate andbegin charging the batteries.
¤ Result: If, simultaneously, the charger alarmsounds and the LEDs blink, correct thecharger connections at the fuse and battery.The charger will then operate correctly andbegin charging the batteries.
Note: For best results, use an extension ofadequate size with a length no longer than15m.
Note: If you have any further questionsregarding the battery charger operation,please contact the DINGLI ServiceDepartment.
B-2
Inspect the Electrical Wiring
DINGLI requires that this procedure beperformed every 250 hours or quarterly,whichever comes first.
Maintaining electrical wiring in good conditionis essential to safe operation and goodmachine performance. Failure to find andreplace burnt, chafed, corroded or pinchedwires could result in unsafe operatingconditions and may cause componentdamage.
Electrocution / burn hazard.Contact with electrically charged circuits couldresult in death or serious injury. Remove allrings, watches and other jewelry.
1 Inspect the underside of the chassis fordamaged or missing ground strap(s).
2 Inspect the following areas for burnt,chafed, corroded and loose wires:
· Ground control panel
· Hydraulic power unit module tray
· Battery pack module tray
· Platform controls
· Engine
3 Inspect for a liberal coating of dielectricgrease in the following locations:
· Between the ECM and platform controls
· Engine ECM
· All wire harness connectors
· Level sensor
4 Turn the key switch to ground control andpull out the red Emergency Stop button tothe on position at both the ground andplatform controls.
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5 Start the engine from the ground controlsand raise the platform approximately 5.5mfrom the ground.
6 Release the safety arm latch, lift the safetyarm and rotate up to a vertical position.
7 Lower the platform onto the safety arm.Stop the engine.
Crushing hazard. Keephands clear of the safety arm when loweringthe platform.
8 Inspect the center chassis area andscissor arms for burnt, chafed and pinchedcables.
9 Inspect the following areas for burnt,chafed, corroded, pinched and loosewires:
· Scissor arms
· ECM to platform controls
· Power to platform wiring
10 Inspect for a liberal coating of dielectricgrease in all connections between theECM and the platform controls.
11 Raise the platform and return the safetyarm to the stowed position.
12 Lower the platform to the stowed positionand turn the machine off.
B-3
Check the Exhaust System
Dingli requires that this procedure beperformed every 250 hours or quarterly,whichever comes first.
Maintaining the exhaust system is essential togood engine performance and service life.Running the engine with a damaged or leakingexhaust system can cause componentdamage and unsafe operating conditions.
Bodily injury hazard. Do notinspect while the engine is running. Removethe key to secure from operation.
Bodily injury hazard. Bewareof hot engine components. Contact with hotengine components may cause severe burns.
1 Open the cover.
2 Be sure that all fasteners are tight.
3 Inspect all welds for cracks.
4 Inspect for exhaust leaks; i.e., carbonbuildup around seams and joints.
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B-4
Inspect the Tires and Wheels
Dingli requires that this procedure beperformed every 250 hours or quarterly,whichever comes
Maintaining the tires and wheels in goodcondition is essential to safe operation andgood performance. Tire and/or wheel failurecould result in a machine tip-over. Componentdamage may also result if problems are notdiscovered and repaired in a timely fashion.
1 Check all tire treads and sidewalls for cuts,cracks, punctures and unusual wear.
2 Check each wheel for damage, bends andcracks.
3 Check each lug nut for proper torque.
lug nut torque, dry 600Nm
lug nut torque, lubricated 450Nm
B-5
Check the Oil Level in the Drive Hubs
Dingli requires that this procedure beperformed every 250 hours or quarterly,whichever comes
Failure to maintain proper drive hub oil levelsmay cause the machine to perform poorly andcontinued use may cause componentdamage.
1 Before draining oil it is mandatory to rotatethe planetary gear reduction in order tomove the oil plug in filling position, thenloosen the oil plug and wait until theinternal pressure is completely released.
2 Remove the plug located and check the oillevel.
⊙ Result: The oil level should be even with thebottom of the plug hole.
3 If necessary, remove the plug and add oiluntil the oil level.
4 Apply pipe thread sealant to the plug(s),and then install the plug(s) in the drivehub.
5 Repeat this procedure for each drive hub.
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B-6
Test the Key Switch
Dingli requires that this procedure beperformed every 250 hours or quarterly,whichever comes first.
Proper key switch action and response isessential to safe machine operation. Failure ofthe key switch to activate the appropriatecontrol panel could cause a hazardousoperating situation.
1 Pull out the red Emergency Stop button tothe on position at both the ground andplatform controls.
2 Turn the key switch to ground controls andstart the engine.
3 Check any machine function from theplatform controls.
⊙ Result: The machine functions should notoperate.
4 Turn the key switch to platform controlsand start the engine.
5 Check any machine function from theground controls.
⊙ Result: The machine functions should notoperate.
6 Turn the key switch to the off position.
⊙ Result: The engine should stop and nofunctions should operate.
B-7
Test the Emergency Stop
Dingli requires that this procedure beperformed every 250 hours or quarterly,whichever comes first.
A properly functioning Emergency Stop isessential for safe machine operation. Animproperly operating red Emergency Stopbutton will fail to shut off power and stop allmachine functions, resulting in a hazardoussituation.
As a safety feature, selecting and operatingthe ground controls will override the platformcontrols, except the platform red EmergencyStop button.
1 Start the engine from ground controls.
2 Push in the red Emergency Stop button tothe off position.
⊙ Result: The engine should shut off and nomachine functions should operate.
3 Start the engine from platform controls.
4 Push in the red Emergency Stop button tothe off position.
⊙ Result: The engine should shut off and nomachine functions should operate.
Note: The red Emergency Stop button at theground or platform controls will stop allmachine operation without regard to theposition of the key switch.
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B-8
Test the Automotive-style Horn
Dingli requires that this procedure beperformed every 250 hours or quarterly,whichever comes first.
A functional horn is essential to safe machineoperation. The horn is activated at the platformcontrols and sounds at the ground as awarning to ground personnel. An improperlyfunctioning horn will prevent the operator fromalerting ground personnel of hazards or unsafeconditions.
1 Turn the key switch to platform controls
2 Pull out the platform red Emergency Stopbutton to the on position.
3 Turn the red Emergency Stop buttonclockwise to the on position.
4 Push down the horn button at the platformcontrols.
⊙ Result: The horn should sound.
B-9
Test the Drive Brakes
Dingli requires that this procedure beperformed every 250 hours or quarterly,whichever comes first.
Proper brake action is essential to safemachine operation. The drive brake functionshould operate smoothly, free of hesitation,jerking and unusual noise.Hydraulically-released individual wheel brakescan appear to operate normally when they areactually not fully operational.
1 Mark a test line on the ground forreference.
2 Start the engine from the platform controls.
3 Choose a point on the machine; i.e.,contact patch of a tire, as a visualreference for use when crossing the testline.
4 Bring the machine to top drive speedbefore reaching the test line. Release thefunction enable switch on the controlhandle or release the control handle whenyour reference point on the machinecrosses the test line.
5 Measure the distance between the test lineand your machine reference point.
⊙ Result: The machine stops within thespecified braking distance. No actionrequired.
¤ Result: The machine does not stop withinthe specified braking distance.
Note: The brakes must be able to hold themachine on any slope it is able to climb.
6 Replace the brakes and repeat thisprocedure beginning with step 1.
Braking distance, maximum
High range on paved surface 270cm
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B-10
Test the Drive Speed - StowedPosition
Dingli requires that this procedure beperformed every 250 hours or quarterly,whichever comes
Proper drive function movement is essential tosafe machine operation. The drive functionshould respond quickly and smoothly tooperator control. Drive performance shouldalso be free of hesitation, jerking and unusualnoise over the entire proportionally control ledspeed range.
1 Create start and finish lines by markingtwo lines on the ground 12.2m apart.
2 Turn the key switch to platform controls
3 Pull out the platform red Emergency Stopbutton to the on position.
4 Turn the red Emergency Stop buttonclockwise to the on position.
5 Start the engine from the platform controls.
6 Lower the platform to the stowed position.
7 Choose a point on the machine; i.e.,contact patch of a tire, as a visualreference for use when crossing the startand finish lines.
8 Bring the machine to maximum drivespeed before reaching the start line. Begintiming when your reference point on themachine crosses the start line.
9 Continue at full speed and note the timewhen the machine reference point passesover the finish line. The time is less than6.6 sec.
B-11
Test the Drive Speed -Raised Position
Dingli requires that this procedure beperformed every 250 hours or quarterly,whichever comes first.
Proper drive function movement is essential tosafe machine operation. The drive functionshould respond quickly and smoothly tooperator control. Drive performance shouldalso be free of hesitation, jerking and unusualnoise over the entire proportionally control ledspeed range.
1 Create start and finish lines by markingtwo lines on the ground 12.2m apart.
2 Turn the key switch to platform controls
3 Pull out the platform red Emergency Stopbutton to the on position.
4 Turn the red Emergency Stop buttonclockwise to the on position.
5 Start the engine from the platform controls.
6 Press and hold the function enable button.Raise the platform approximately 4.0mfrom the ground.
7 Choose a point on the machine; i.e.,contact patch of a tire, as a visualreference for use when crossing the startand finish lines.
8 Bring the machine to maximum drivespeed before reaching the start line. Begintiming when your reference point on themachine crosses the start line.
9 Continue at full speed and note the timewhen the machine reference point passesover the finish line. The time is less than88 sec.
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B-12
Perform Hydraulic Oil Analysis
Dingli requires that this procedure beperformed every 250 hours or quarterly,whichever comes first.
Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and a clogged suctionstrainer may cause the machine to performpoorly and continued use may causecomponent damage. Extremely dirtyconditions may require oil changes to beperformed more often.
Note: Before replacing the hydraulic oil, the oilmay be tested by an oil distributor for specificlevels of contamination to verify that changingthe oil is necessary. If the hydraulic oil is notreplaced at the two year inspection, test the oilquarterly. Replace the oil when it fails the test.See E-1, Test or Replace the Hydraulic Oil.
B-13
Perform Engine Maintenance
Engine specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.
Required maintenance procedures andadditional engine information is available in theengine operator’s manual.
B-14
Perform Drive Axle Maintenance
Axle specifications require that this procedurebe performed every 250 hours or quarterly,whichever comes first.
Required maintenance procedures andadditional Axle information is available in theAxle operator’s manual.
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Checklist C ProceduresC-1
Test the Platform Overload System
Dingli specifications require that this procedurebe performed every 500 hours orsemi-annually, whichever comes first OR whenthe machine fails to lift the maximum ratedload.
Testing the platform overload system regularlyis essential to safe machine operation.Continued use of an improperly operatingplatform overload system could result in thesystem not sensing an overloaded platformcondition. Machine stability could becompromised resulting in the machine tippingover.
Note: Perform this procedure with the machineon a firm, level surface that is free ofobstructions.
1 Turn the key switch to platform control andpull out the red Emergency Stop button tothe on position at both the ground andplatform controls.
2 Determine the maximum platform capacity.
3 Using a suitable lifting device, place anappropriate test weight equal to themaximum platform capacity in the centerof the platform floor.
⊙ Result: The overload alarm at the platformcontrols should not sound, indicating anormal condition.
¤ Result: The overload alarm at the platformcontrols sounds. Calibrate the platformoverload system.
4 Add an additional weight to the platformnot to exceed 10% of the maximum ratedload.
⊙ Result: The overload alarm at the platformcontrols sound, indicating a normalcondition.
¤ Result: The overload alarm at the platformcontrols does not sound. Calibrate theplatform overload system.
5 Test all machine functions from theplatform controls.
⊙ Result: All platform control functions shouldnot operate.
6 Turn the key switch to ground control.
7 Test all machine functions from the groundcontrols
⊙ Result: All ground control functions shouldnot operate.
8 Lift the test weight off the platform floorusing a suitable lifting device.
⊙ Result: The overload alarm at the platformcontrols should not sound, indicating anormal condition.
¤ Result: The overload alarm at the platformcontrols sounds. Calibrate the platformoverload system.
9 Test all machine functions from the groundcontrols.
⊙ Result: All ground control functions shouldoperate.
10 Turn the key switch to platform control.
11 Test all machine functions from theplatform controls.
⊙ Result: All platform control functions shouldoperate.
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C-2
Perform Engine Maintenance
Engine specifications require that thisprocedure be performed every 500 hours orsemi-annually, whichever comes first.
Required maintenance procedures andadditional engine information is available in theengine operator’s manual.
C-3
Perform Drive Axle Maintenance
Axle specifications require that this procedurebe performed every 500 hours
Required maintenance procedures andadditional Axle information is available in theAxle operator’s manual.
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Checklist D ProceduresD-1
Replace the Hydraulic Tank ReturnFilter Element
DINGLI requires that this procedure beperformed every 1000 hours or annually,whichever comes first.
Replacement of the hydraulic tank return filteris essential for good machine performanceand service life. A dirty or clogged filter maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require that thefilter be replaced more often.
Beware of hot oil. Contactwith hot oil may cause severe burns.
1 Raise the platform, use the Safety Arm.
2 Open the cover.
3 Tag and disconnect the hydraulic tankreturn line .Cap the fitting on the filterhead.
4 Clean the area around the oil filter.Remove the filter with an oil filter wrench.
5 Apply a thin layer of oil to the new oil filtergasket.
6 Install the new filter and tighten it securelyby hand.
7 Use a permanent ink marker to write thedate and number of hours from the hourmeter onto the filter.
8 Turn the key switch to ground control andpull out the red Emergency Stop button tothe on position at both the ground andplatform controls.
9 Activate and hold the platform up toggleswitch.
10 Inspect the filter and related componentsto be sure that there are no leaks.
11 Clean up any oil that may have spilled.
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D-2
Check the Free-wheel Configuration
Dingli specifications require that this procedurebe performed every 1000 hours or annually,whichever comes first.
Proper use of the free-wheel configuration isessential to safe machine operation. Thefree-wheel configuration is used primarily fortowing. A machine configured to free-wheelwithout operator knowledge may cause deathor serious injury and property damage.
Collision hazard. Select awork site that is firm and level.
Component damage hazard.If the machine must be towed, do not exceed6.6km/h.
1 Chock the wheels at the steer end of themachine.
2 Center a lifting jack of ample capacity(30,000 lbs / 15,000 kg) under the drivechassis between the wheels at thenon-steer end of the machine.
3 Lift the wheels off the ground and placeblocks under the drive chassis for support.
Crushing hazard. Thechassis could fall if not properly supported.
4 Release the brake.
5 Manually rotate each wheel at thenon-steer end.
⊙ Result: Each wheel should rotate withminimum effort.
6 Reset the brake. Rotate each wheel tocheck for engagement. Raise the machineand remove the blocks. Lower themachine.
7 Chock the wheels at the non-steer end ofthe machine.
8 Center a lifting jack of ample capacity(30,000 lbs / 15,000 kg) under the drivechassis between the wheels at the steerend.
9 Lift the wheels off the ground and placeblocks under the drive chassis for support.
Crushing hazard. Thechassis could fall if not properly supported.
10 Release the brake.
11 Manually rotate each wheel at the steerend.
⊙ Result: Each wheel should rotate withminimum effort.
12 Reset the brake. Rotate each wheel tocheck for engagement. Raise the machineand remove the blocks. Lower themachine.
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D-3
Replace the Drive Axle Oil
Dingli specifications require that thisprocedure be performed every 1000 hours orannually, whichever comes first.
Replacing the drive Axle oil is essential forgood machine performance and service life.Failure to replace the drive Axle oil at yearlyintervals may cause the machine to performpoorly and continued use may causecomponent damage.
1 Remove the oil draining plug and drain oilonly when the pressure is completelyreleased. Install the plug when the oil isfully discharged.
2 Remove the oil fill plug and check levelplug.
3 Fill the oil fill plug hole until the oil level iseven with the bottom of the side checklevel plug hole. Apply pipe thread sealantto the plugs. Install the plugs.
4 Repeat steps 1 through 3 for all the otherDrive Axles
Oil specifications
Oil type API GL4 or GL5
D-4
Perform Engine Maintenance
Engine specifications require that thisprocedure be performed every 1000 hours orannually, whichever comes first.
Required maintenance procedures andadditional engine information is available in theengine operator’s manual.
D-5
Perform Drive Axle Maintenance
Axle specifications require that this procedurebe performed every 1000 hours or annually,whichever comes first.
Required maintenance procedures andadditional Axle information is available in theAxle operator’s manual.
Oil drainplug
Oil fillplug
Check levelplug
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Checklist E ProceduresE-1
Test or Replace the Hydraulic Oil
DINGLI requires that this procedure beperformed every 2000 hours or every twoyears, whichever comes first.
Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oilchanges to be performed more frequently.
Component damage hazard.The work area and surfaces where thisprocedure will be performed must be cleanand free of debris that could get into thehydraulic system.
Before replacing the hydraulic oil, the oil maybe tested by an oil distributor for specific levelsof contamination to verify that changing the oilis necessary. If the hydraulic oil is not replacedat the two year inspection, test the oil quarterly.Replace the oil when it fails the test.
In extreme cold conditions, -6°C and below,warm the engine for 5 minutes beforeoperating to prevent hydraulic systemdamage.
Electrocution / burn hazard:Contact with electrically charged circuits couldresult in death or serious injury. Remove allrings, watches and other jewelry.
Bodily injury hazard.Spraying hydraulic oil can penetrate and burnskin. Loosen hydraulic connections very slowlyto allow the oil pressure to dissipate gradually.Do not allow oil to squirt or spray.
1 Disconnect the battery pack from themachine.
2 Open the power unit module cover.
3 Remove the oil drain plug at bottom Drainall of the oil into a suitable container.
4 Tag and disconnect the hydraulic tankreturn line from the hydraulic filter headand remove the line from the tank. Cap thefitting on the filter head.
5 Tag and disconnect the hydraulic pumpinlet line and remove the line from the tank.Cap the fitting on the pump.
6 Remove the hydraulic tank retainingfasteners and remove the hydraulic tankfrom the machine.
7 Remove the breather cap from thehydraulic tank.
8 Clean the inside of the hydraulic tank usinga mild solvent. Allow the tank to drycompletely.
9 Tighten the drain plug.
10 Install the breather cap onto the hydraulictank.
11 Install the hydraulic tank and install andtighten the hydraulic tank retainingfasteners.
12 Install the hydraulic pump inlet line into thetank. Install the fitting onto the pump andtorque.
13 Install the hydraulic pump return line intothe tank. Install the fitting onto thehydraulic filter head and torque.
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14 Add the tank with hydraulic oil until thefluid is equal in the hydraulic tank. .
Component damage hazard.The pump can be damaged if operated withoutoil. Be careful not to empty the hydraulic tankwhile in the process of filling the hydraulicsystem. Do not allow the pump to cavitate.
E-2
Perform Engine Maintenance
Engine specifications require that thisprocedure be performed every 2000 hours ortwo years, whichever comes first.
Required maintenance procedures andadditional engine information is available in theengine operator’s manual.
E-3
Perform Engine Maintenance
Engine specifications require that thisprocedure be performed every 3000 hours,
Required maintenance procedures andadditional engine information is available in theengine operator’s manual.
E-4
Perform Engine Maintenance
Engine specifications require that thisprocedure be performed every 4000 hours,
Required maintenance procedures andadditional engine information is available in theengine operator’s manual.
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E-5
Perform Engine Maintenance
Engine specifications require that thisprocedure be performed every 6000 hours.
Required maintenance procedures andadditional engine information is available in theengine operator’s manual.
E-6
Perform Engine Maintenance
Engine specifications require that thisprocedure be performed every 12,000 hours.
Required maintenance procedures andadditional engine information is available in theengine operator’s manual.
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Fault StateIn the fault state, a fault code from the list will be displayed flashing at a 1 Hz rate (0.5 seconds on,0.5 off).
List of Fault Codes
Displayfor
PlatformDisplay for Ground Description Description
01 01 Internal ECU Fault Main ECU System Fault Replace Main ECU
02 02 Platform ECU Fault ECU/Platform CommunicationFault
Check the wiring,check theplatform/ground
t l20 20 Chassis Start Sw Fault Chassis Start Switch ON at
power-upCheck the switch,check the wiring
21 21 Chassis Choke Sw Fault Chassis Choke Switch ON atpower-up
Check the switch,check the wiring
22 22 Chassis Up Sw Fault Chassis Up Switch ON atpower-up
Check the switch,check the wiring
23 23 Chassis Lift Sw Fault Chassis Lift Switch ON atpower-up
Check the switch,check the wiring
24 24 Chassis Down Sw Fault Chassis Down Switch ON atpower-up
Check the switch,check the wiring
25 25 Left Turn switch Fault Platform Left Turn Switch ON atpower-up
Check the switch,replace the platform
26 26 Right Turn switch Fault Platform Right Turn Switch ONat power-up
Check the switch,replace the platform
27 27 Drive Enable Sw Flt Platform Drive Enable SwitchON at power-up
Check the switch,replace the platform
28 28 Off Neutral Drive Joystick Platform Joystick not in neutralON at power-up
Check the switch,replace the platform
31 31 Platform Choke Sw Fault Platform Choke Switch ON atpower-up
Check the switch,replace the platform
32 32 Platform Start Sw Fault Platform Start Switch ON atpower-up
Check the switch,replace the platform
33 33 Left Front outrig Sw FltPlatform Left Front OutriggerEnable Switch ON at power-up
Check the switch,replace the platform
34 34 Right Front outrig Sw Flt Platform Right Front OutriggerEnable Switch ON at power-up
Check the switch,replace the platform
35 35 Left Rear outrig Sw Flt Platform Left Rear OutriggerEnable Switch ON at power- up
Check the switch,replace the platform
36 36 Right Rear outrig Sw Flt Platform Right Rear OutriggerEnable Switch ON at power-up
Check the switch,replace the platform
37 37 Auto Level Switch Fault Platform Outrigger Auto LevelEnable Switch ON at power-up
Check the switch,replace the platform
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Displayfor
PlatformDisplay for Ground Description Repair
38 38 LF OR Limit Switch Fault Left Front Outrigger LimitSwitches are both ON
Check the limit switch,check the wiring
39 39 RF OR Limit Switch Fault Right Front Outrigger LimitSwitches are both ON
Check the limit switch,check the wiring
40 40 LR OR Limit Switch Fault Left Rear Outrigger LimitSwitches are both ON
Check the limit switch,check the wiring
41 41 RR OR Limit Switch Fault Right Rear Outrigger LimitSwitches are both ON
Check the limit switch,check the wiring
49 49 Drive Coil 1 Fault Power FET, channel DRIVE 1fails
check the wiring,replace the valve
50 50 Drive Coil 2 Fault Power FET, channel DRIVE 2fails
check the wiring,replace the valve
51 51 Drive Coil 3 Fault Power FET, channel DRIVE 3fails
check the wiring,replace the valve
52 52 Func Prop Coil Fault power FET, channelPROPORTIONAL 1 fails
check the wiring,replace the valve
54 54 Up Coil Fault Power FET, channel DOWNfails
check the wiring,replace the valve
55 55 Down Coil Fault Power FET, channel RT fails check the wiring,replace the valve
56 56 Right Turn Coil Fault Power FET, channel LT fails check the wiring,replace the valve
57 57 Left Turn Coil Fault Power FET, channel LT fails check the wiring,replace the valve
58 58 Brake Coil Fault Power FET, channel LT fails check the wiring,replace the valve
60 60 Forward 1 Coil Fault Power FET, channel FORWARDLEFT fails
check the wiring,replace the valve
61 61 Reverse 1 Coil Fault Power FET, channel REVERSELEFT fails
check the wiring,replace the valve
66 66 Low Oil Pressure Oil Pressure Fault check the wiring,replace the sensor
67 67 High Cool antTemperature Water Temperature Fault check the wiring,
replace the sensor
68 68 Low ECU Voltage Low Battery Voltage check the wiring,check the battery
69 69 Low Engine RPM Low RPM Fault check the wiring,check the engine
70 70 High Engine RPM High RPM Fault check the wiring,check the engine
81 81 Left Front Otrg Coil Flt Power FET, channel LEFTFRONT OUTRIGGER fails
check the wiring,replace the valve
OPERATOR’S MANUAL with Maintenance Information
Maintenance
63
Displayfor
PlatformDisplay for Ground Description Repair
82 82 Left Rear Otrg Coil Flt Power FET, channel LEFTREAR OUTRIGGER fails
check the wiring,replace the valve
83 83 Right Front Otrg Coil Flt Power FET, channel RIGHTFRONT OUTRIGGER fails
check the wiring,replace the valve
84 84 Right Rear Otrg Coil Flt Power FET, channel RIGHTREAR OUTRIGGER fails
check the wiring,replace the valve
85 85 Outrigger Ext Coil Fit Power FET, channel EXTENDOUTRIGGER fails
check the wiring,replace the valve
86 86 Outrigger Ret Coil Fit Power FET, channel RETRACTOUTRIGGER fails
check the wiring,replace the valve
95 95 Machine Type Fauit Wrong Machine Type Selected Reinstall MachineType
OL 98 Platform Overload Platform Overload Fault Remove the excessload immediately.
LL Machine Tilted Beyond SafeLimits Fault
check the wiring,replace the sensor
For more information, please consult the appropriate Dingli Service Dept.
OPERATOR’S MANUAL with Maintenance Information
Schematic
64
Hydraulic Schematic - Function model
OPERATOR’S MANUAL with Maintenance Information
Schematic
65
Hydraulic Schematic - Drive model
Oil cooler
5899-1312
YO344
X2X1
T2T1
GS
MA
BMB
FePs
R
ab
Tank
Drive pump
Filter 5899-0711
PLFA-C110X10
MH
Fa1
Fa
A
Fs
G
T2
UT1
B A
Vgmin
Vgmax
BRK
CHG
PT
Front axle
P1P1
P1P1
P3
M
C1
0.8mm SV2
SV1
Drive motor
Rear axle
OPERATOR’S MANUAL with Maintenance Information
Schematic
66
Electrical Schematic
004H
BN
/RD
(16)
ECU
K53
K75
K75
BK
(20)
K53
BK
(20)1 2
SB
3
GB+ RD (0)
GB- RD (0)
K01
K03
K05K02
K04
K06
K02
BK
(20)
K04
BK
(20)
K06
BK
(20)
K01
BK
(20)
K03
BK
(20)
K05
BK
(20)
FU4 30A
K76
K54
K54
BK
(20)
K76
BK
(20)
G1
B-
B+
D+
发电机充磁灯
HL4
K88
K88
BK
(20)
K64
K57
K64
BK
(20)
K57
BK
(20)
SL2
M1
Fuel
Pum
p R
elay
KA
4
K90
K26
K90
BK
(20)
K26
BK
(20)
FU3
20A
K87
K87
BK
(20)
K29
K29
BK
(20)
K13
K13
BK
(20)
K86
K86
BK
(20)
K31
K31
BK
(20)
K35
K35
BK
(20)
K28
K28
BK
(20)
K73
K73
BK
(20)
32
HL3
K68
K68
BK
(20)
K19
K19
BK
(20)
SB
4
K15
K15
BK
(20)
K70
K70
BK
(20)
K65
K65
BK
(20)
SL1
K44
K44
BK
(20)
50
K82
K82
BK
(20)
K85
K85
BK
(20)
51 46
K61
K61
BK
(20)
17
A19
A19
WH
(20)
47
A20
A20
WH
(20)
48
A24
A24
WH
(20)
22
A29
A29
WH
(20)
27
A28
A28
WH
(20)
24
A44
A44
WH
(20)
26
A40
A40
WH
(20)
28
A43
A43
WH
(20)
23
A27
A27
WH
(20)
29K
M1
R1
R2
R3
R4
A45
A45
WH
(20)
A35
A35
WH
(20)
A23
A23
WH
(20)
FU5 150A
A25
A25
WH
(20)
A26
A26
WH
(20)
A07
A07
WH
(20)
31 25 32
A04
A04
WH
(20)
A05
A05
WH
(20)
19 20
A39
A39
WH
(20)
A54
A54
WH
(20)
15 21
A38
A38
WH
(20)
01
A37
A37
WH
(20)
A52
A52
WH
(20)
14 13
A53
A53
WH
(20)
09
A33
A33
WH
(20)
A16
A16
WH
(20)
62 35
A48
A48
WH
(20)
A18
A18
WH
(20)
42 37
A32
A32
WH
(20)
A02
A02
WH
(20)
38 61
A46
A46
WH
(20)
A03
A03
WH
(20)
40 41
GB+1 RD (0)
6
006
RD
(12)
006A
RD
(12)
7 89
10D
+ B
N/R
D (1
6)
11 1213 14
16 15 17 18193 4 1 2
5
K88 RD/BU(16) K90
BN
/YE
(16)
K26
BN
/YE
(16)
K68
BN
/YE
(16)
K19
BN
/YE
(16)
K70
BN
/YE
(16)
K65
BN
/YE
(16)
120Ω
120Ω
Pow
er N
egat
ive
Pow
er N
egat
ive
Pow
er N
egat
ive
Pow
er P
ostiv
eP
ower
Pos
tive
Pow
er P
ostiv
e
CA
N1L
CA
N1H
CA
N0L
CA
N0H
Mag
netiz
ing
Fuel
Pum
p R
elay
Fuel
Pum
p R
elay
Sta
rt S
igna
lS
witc
h C
omm
onA
ir Fi
lter S
witc
h Si
gnal
Stop
Sig
nal
Coo
ling
Wat
er L
evel
Coo
ling
Wat
er L
evel
Sig
nal
Sta
rt R
elay
Sta
rt R
elay
Sw
itch
Pub
lic N
egat
ive
Faul
t Dia
gnos
tic S
witc
h Si
gnal
Neu
tral S
witc
h Si
gnal
Fuel
Pum
p
Pow
erS
witc
h
G
BB
atte
ry
24 242424
=24
Pos
ition
SIB
AS C
onne
ctor
CT4
62
=24
Pos
ition
SIB
AS
Con
nect
or C
T3
=24
Pos
ition
SIB
AS C
onne
ctor
CT2
=24
Pos
ition
SIB
AS
Con
nect
or C
T1
=62
Pos
ition
Egn
ine
Con
nect
or L
OC
Pre
heat
Rel
ayP
rehe
at R
elay
Faul
t Ala
rm In
dica
tor
Faul
t Ala
rm In
dica
tor
Wat
er In
fuel
Lev
elW
ater
In fu
el L
evel
Wat
er In
fuel
Lev
el
Exh
aust
Gas
Rec
iricu
latio
n +5
VE
xhau
st G
as R
eciri
cula
tion
GN
DEx
haus
t Gas
Rec
iricu
latio
n Si
gnal
Fuel
Low
Pre
ssur
e S
igna
l
Exh
aust
Gas
Rec
iricu
latio
n M
otor
Exh
aust
Gas
Rec
iricu
latio
n M
otor
Oil
Pres
sure
Sig
nal
Coo
ling
Tem
pera
ture
Sig
nal
Boos
t Pre
ssur
e/Te
mpe
ratu
reA
ir In
let T
empe
ratu
re
Rai
l Pre
ssur
e Fu
elR
ail P
ress
ure
Fuel
Rai
l Pre
ssur
e Fu
el S
igna
lA
ctua
tor M
prop
Act
uato
r Mpr
op
Inje
ctor
1In
ject
or1
Inje
ctor
2In
ject
or2
Inje
ctor
3In
ject
or3
Inje
ctor
4In
ject
or4
Cam
shaf
t Eng
ine
Spee
d
Cra
nksh
aft E
ngin
e Sp
eed
Cra
nksh
aft E
ngin
e Sp
eed
Cra
nksh
aft E
ngin
e Sp
eed
Cam
shaf
t Eng
ine
Spe
ed
Cam
shaf
t Eng
ine
Spee
d
Preh
eat R
elay
Fee
dbac
k Si
gnal
Sen
sor C
omm
onS
enso
r Com
mon
Sen
sor C
omm
on
Eng
ine
Eng
ine
Eng
ine
Eng
ine
Eng
ine
Eng
ine
Pre
heat
Con
tact
or
Glo
w P
lugs
Eng
ine
Sta
rt S
igna
lE
ngin
e S
top
Sign
alE
ngin
e S
top
Sign
al
Eng
ine
Mag
netiz
ing
Sig
nal
Pow
er P
ostiv
e
Pow
er n
egat
ive
Faul
t Ala
rm In
dica
tor
Faul
t Dia
gnos
tic S
witc
h
Coo
ling
Wat
erLe
vel
OPERATOR’S MANUAL with Maintenance Information
Schematic
67
006
RD
(16)
211A
WH
(20)
212A
WH
(20)
GN
(20)
YE
(20)
YE
(18)
GN
(18)
211A
YE
(20)
212A
GN
(20)
206B
BN
(20)
GN
D7
BK
(16)
206C
WH
(20)
005A
RD
(16)
RD
(18)
BN
/RD
(16)
005B
RD
(16)
WH
(18)
BN
/WH
(16)
BN
/BU
(16)
BU
(18)
GN
D10
BK
(16)
004D
RD
(16)
106A
GN
/YE
(16)
108A
BN
/YE
(16)
211C
WH
(20)
201A
WH
(20)
202A
WH
(20)
205A
WH
(20)
206A
WH
(20)
207A
WH
(20)
210A
WH
(20)
201B
WH
(20)
202B
WH
(20)
203B
WH
(20)
204B
WH
(20)
205B
WH
(20)
206B
WH
(20)
208B
WH
(20)
209B
WH
(20)
211B
WH
(20)
201C
WH
(20)
202C
WH
(20)
203C
WH
(20)
205C
WH
(20)
206C
WH
(20)
207C
WH
(20)
209C
WH
(20)
212C
WH
(20)
211C
RD
(14)
1A 2A
EC
UJ2
1A 2AJ1 3A 4A 5A 6A 7A 8A 9A 10A
11A
12A
1B 2B 3B 4B 5B 6B 7B 8B 9B 10B
11B
12B
1C 2C 3C 4C 5C 6C 7C 8C 9C 10C
11C
12C
3A 4A 5A 6A 7A 8A 9A 10A
11A
12A
1B 2B 3B 4B 5B 6B 7B 8B 9B 10B
11B
12B
1C 2C 3C 4C 5C 6C 7C 8C 9C 10C
11C
12C
H3
+ -
6 7
(Ga)
(Gb)
8 1(F
a)
9 10(V
a)
(Vb)
2(A
)
3 4 5
(b)
11
(AD
)
13(J
)
(Da)
12(D
b) (I)
(W)
(X)
SQ
1
SQ
2
SQ
3
SQ
4
SQ
5
SQ
6
SA
11 0 2
SQ
7
14
TILT
1AS
A1
LS1
12 13
M2 H
L2
SB2
SB
1
(SV
1)
(Ma)
(Mb)
(SV
2)
(C)
(a)
H1
RS1 FS
1
HM
B1 B
4 23 1
FU2
35A
001B
RD
(12)
101A
BK
(20)
102A
BK
(20)
103A
BK
(20)
104A
BK
(20)
105A
BK
(20)
106A
BK
(20)
107A
BK
(20)
108A
BK
(20)
110A
BK
(20)
111A
BK
(20)
112A
BK
(20)
102B
BK
(20)
103B
BK
(20)
104B
BK
(20)
101C
BK
(20)
105B
BK
(20)
106B
BK
(20)
107B
BK
(20)
109B
BK
(20)
110B
BK
(20)
111B
BK
(20)
102C
BK
(20)
103C
BK
(20)
104C
BK
(20)
105C
BK
(20)
106C
BK
(20)
24 242424
=24
Pos
ition
SIB
AS
Con
nect
or C
T4
GN
D15
BK
(20)
GN
D11
BK
(14)
209C
-1 R
D(1
2)
GN
D12
BK
(16)
209C
-1 R
D(1
2)
003 RD(12)
KA
1
KA
3
GN
D12
BK(
16)
003
RD
(12)
001A
-3 R
D/B
U(1
6)00
5 R
D/B
U(1
6)
211B
-1 W
H/V
T(16
)
005A
RD
/BU
(16)
GN
D12
BK
(16)
005B
BU
/VT(
16)
004B
RD
/BU
(16)
004B
RD
(14)
RD
(20)
RD
(20)
201B
BU
(20)
GN
D6
BK(1
6)20
3B Y
E(2
0)
WH
(20)
WH
(20)
GN
D10
BK
(16)
101A
GN
/RD
(16)
102A
GN
/WH
(16)
BK(
16)
103A
GN
/BU
(16)
104A
BN
/RD
(16)
107A
RD
+YE(
16)
106B
BU
/WH
(16)
107B
BU
/RD
(16)
103B
RD
/WH
(16)
110A
BN
/BU
(16)
105A
GN
/VT(
16)
23
106C
BK
(20)
109B
BU
/BN
(16)
110B
WH
/BU
16)
105B
BU
/GN
(16)
111B
VT/
YE
16)
BK
(20)
WH
(20)
2
102B
BN
/BK
(16)
104B
WH
/BK
(16)
KAP
1100
4D R
D/B
U(1
6)
24 414 15 16 171918 1 3 5
13 1411 16
KA2
205B
GN
(20)
2211
206A
BK
(20)
202A
BK
(20)
201A
BK
(20)
GN
D12
BK
(16)
GN
D3
BK(1
2)
GN
D4
BK(1
2)
004E
WH
(20)
004F
RD
(16)
GN
D13
BK
(20)
101C
BK
(20)
103C
BK
(20)
105C
BK
(20)
207A
BK
(20)
102C
BU
(20)
104C
BU
(20)
111A
BN
/GY
(16)
112A
BN
/GN
(16)
FU1
20A
001A
RD
(12)
GN
D1
BK
(12)
GN
D2
BK
(12)
GN
D9
BK(1
2)
GN
D8
BK(1
6)
211B
-1 R
D(1
6)
HL1
001A
RD
(12)
001B
RD
(12)
BK
(20)
WH
(20)
BK
(20)
WH
(20)
BK
(20)
WH
(20)
BK(
16)
BK(
16)
BK(
16)
BK(
16)
BK
(16)
BK(
16)
BK(
16)
BK(
16)
BK(
16)
BK(
16)
BK(
16)
BK(
16)
BK(
16)
BK(
16)
BK(
16)
BK(
16)
BK(
16)
BK(
16)
BK
(20)
BK(
20)
RD
(20)
BD
(20)
WH
(20)
21
K87
BN
/YE
(16)
211C WH(20)
GN
D13
BK
(14)
004E
RD
/BU
(16)
004F
RD
/BU
(14)
001A-1 RD(12) 001A
-2 R
D(1
2)
207B
WH
(20)
17
K31
BN
/YE
(16)
005
RD
/BU
(16)
KN
1
SQ
8
108C
BK
(20)
8
16 15 17 18 193 4 1 2
5 2 1 3 4
004G
RD
(16)
004G
RD
/BU
(14)
GN
D14
BK
(20)
GN
D14
BK
(14)
6
004A
RD
/BU
(16)
004A
RD
(16)
004A
RD
/BU
(16)
87 910 12
004C
RD
(16)
004C
RD
/BU
(16)
15
GN
D5
BK(1
6)18 20 21 6 78 9 10
15 1617 18 19 20
GN
D6
BK(1
6)
GN
D7
BK
(16)
GN
D8
BK
(16)
GN
D9
BK(1
2)
GN
D11
BK(
16)
62
(C1)
108B
BK
(20)
108B
GN
/WH
(16)
BK(
16)
22
H2
E1
Ste
er R
ight
Va.
Ste
er L
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a.R
ise
Va.
Brak
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.
Pla
tform
Ext
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Va.
Plat
form
Ret
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Va.
Om
nidi
rect
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l Va.
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Va.
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kwar
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.
RF
Sta
biliz
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a.
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biliz
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xten
d Va
.S
tabi
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Va.
LF S
tabi
lizer
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LR S
tabi
lizer
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RR
Sta
biliz
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a.
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biliz
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imit
Sw
.
RR
Sta
biliz
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imit
Sw
.
LF S
tabi
lizer
Lim
it Sw
.
Lift
Dow
n Li
mit
Che
ck S
w.
Tem
pera
ture
Sw
.
Lift
Up
Lim
it S
w.
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mit
Sw.
Key
Sw
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Si.
12M
Lim
it S
w.
LR S
tabi
lizer
Lim
it S
w.
Pow
er N
egat
ive
Pow
er N
egat
ive
Pow
er N
egat
ive
Pow
er N
egat
ive
Eng
ine
Spe
edLF
Sta
bliz
er
Driv
e S
peed
LED
LR S
tabl
izer
Sta
rt/S
top
RF
Sta
bliz
er
Pre
heat
Hor
n
RR
Sta
bliz
er
Stab
lizer
sLi
ft E
nabl
e
Driv
e E
nabl
e
Buzz
er
Em
erge
ncy
Sto
p Sw
itch
Key
Sw
itch
Em
erge
ncy
Sto
pS
witc
h
Pow
er P
ostiv
eP
ower
Pos
tive
Pow
er P
ostiv
e
Hor
n
Angl
e S
enso
r
Pre
ssur
e Se
nsor
Pre
ssur
e Se
nsor
Engi
ne S
tart
Si.
Engi
ne S
top
Rel
ay
Y A
xis
Si.
X A
xis
Si.
Pow
er P
ostiv
e
Pow
er R
elay
Eng
ine
Sto
p R
elay
Hou
r Met
ter
Func
tion
Ena
ble
Joys
tick
PC
U
Lift
Up
Lim
it Sw
itch
Lift
Dow
n Li
mit
Sw
itch
12M
Lim
it S
witc
hl
Ang
le S
enso
r
Pre
ssur
e Se
nsor
Tilt
Sens
or
Y A
xis
Sign
al
X A
xis
Sign
al
Hor
n
Fan
Bea
con
Bea
con
Buz
zer
Fan
Rel
ay
Hor
n R
elay
=24
Pos
ition
SIB
AS C
onne
ctor
CT3
=24
Pos
ition
SIB
AS
Con
nect
or C
T2
=24
Pos
ition
SIB
AS C
onne
ctor
CT1
=62
Pos
ition
Egn
ine
Con
nect
or L
OC
Beac
onFan
CA
NH
CA
NL
CA
NH
CA
NL
Pro
porti
onal
Va.
Brak
e Va
lve
Om
nidi
rect
iona
l Val
ve
Ste
er R
ight
Val
ve
Ste
er L
eft V
alve Ris
e V
alve
Pla
tform
Ext
end
Valv
e
Pla
tform
Ret
ract
Val
ve
Forw
ard
Val
ve
Bac
kwar
d V
alve
Pro
porti
onal
Val
ve
RF
Sta
biliz
er V
alve
Sta
biliz
er E
xten
d Va
lve
Stab
ilizer
Ret
ract
Val
ve
LF S
tabi
lizer
Val
ve
LR S
tabi
lizer
Val
ve
RR
Sta
biliz
er V
alve
Tem
pera
ture
Sw
itch
RF
Sta
biliz
er L
imit
Sw
itch
RR
Sta
biliz
er L
imit
Sw
itch
LF S
tabi
lizer
Lim
it Sw
itch
LR S
tabi
lizer
Lim
it S
witc
h
Em
erge
ncy
Dro
pSw
itch
Lift Down LimitCheck Switch
Engi
ne M
agne
tizin
g Si
gnal
LED
Lift
Up
Lift
Dow
n
Pre
heat
Star
t/Sto
p
Eng
ine
Spe
ed
Func
tion
Ena
ble
Osc
illat
ion
Axle
Lock
out V
a.
Osc
illatio
n Ax
le lo
ckou
t Val
ve
Varia
ble
Va.
Var
iabl
e V
alve
Sta
biliz
er
Cyl
inde
r des
cend
Va.
Cyl
inde
r Des
cend
Val
ve
Tran
sitio
n V
alve
Gro
up
Fnct
ion
Val
ve G
roup
Driv
e P
ump
Fron
t Axl
e M
edia
n Sw
.
Rea
r Axl
e M
edia
n Sw
.Fr
ont A
xle
Med
ian
Sw
itch
Rea
r Axl
e M
edia
n Sw
itch
Cra
b dr
ive
Va.
Cra
b W
alk
Valv
e
Diff
eren
tial
Va.
Diff
eren
tial V
alve
OPERATOR’S MANUAL with Maintenance Information
Inspection and Repair Log
68
Inspection and Repair Log
Date Comments
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