JCPT2223RTA 操作手册英文（SM0117123 Rev1.0）

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


Version of the Record

i

Version of the RecordVersion Number Create Date

SM01117123_Rev1.0 ………………………………………………………………………… 2017-09


i

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:[email protected]


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.


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.


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.


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.


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.


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.


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.


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


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


10 9514011 Cosmetic – Mark 2

11 9414107 Caution – Max. Manual Force: 400N 2

12 9614091 Cosmetic – JCPT2223RTA 2





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


22 9331013 Instructions – Tie Down Point 4


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


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


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


Decals

12


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%


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.


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


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


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


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.


Pre-operation Inspection

18





Know and understand the pre-operationinspection before going on to the nextsection.




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.


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.


Workplace Inspection

20






Know and understand the workplaceinspection before going on to the nextsection.



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


Function Tests

21






4 Always perform function tests priorto use.

Know and understand the function testsbefore going on to the next section.


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.


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.


⊙ 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.


⊙ 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


Function Tests

23

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).


⊙ 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


⊙ 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).


⊙ Result: The front wheels should turn in thedirection that the blue triangle points on the


Function Tests

24

control panel and the rear wheels shouldturn in the direction that the blue trianglepoints on 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.


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


Function Tests

25

platform.

49 Fully lower the platform.

50 Drive the Left front wheel onto an 18cmblock.


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


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.


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


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.


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


Function Tests

26

⊙ 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


Operating Instructions

27








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.



28

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.


4 Start the engine.

To Position Platform


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



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





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%


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



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



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



32

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


2 Press and hold the button（2）.


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


2 Turn the knob (6) in the direction of thearrow.

5

6

3

4



33


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.


3 Turn the key switch to the off position andremove the key to secure fromunauthorized use.

4 Chock the wheels.


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.



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.



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


Maintenance

37

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.


Maintenance

38

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


Maintenance

39

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


Maintenance

40

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.


Maintenance

41

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.


Maintenance

42

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


Maintenance

43

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.


Maintenance

44

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


Engine specifications require that this one-timeprocedure be performed after 50 hours ofoperation.


A-12


Axle specifications require that this procedurebe performed every 100 hours.



Maintenance

45

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.


Maintenance

46

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.


Maintenance

47

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.


Maintenance

48

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


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.


Maintenance

49

B-6

Test the Key Switch


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


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.


Maintenance

50

B-8

Test the Automotive-style Horn


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



4 Push down the horn button at the platformcontrols.

⊙ Result: The horn should sound.

B-9

Test the Drive Brakes


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


Maintenance

51

B-10

Test the Drive Speed - StowedPosition


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.





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


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.





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.


Maintenance

52

B-12

Perform Hydraulic Oil Analysis


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


Engine specifications require that thisprocedure be performed every 250 hours orquarterly, whichever comes first.


B-14


Axle specifications require that this procedurebe performed every 250 hours or quarterly,whichever comes first.



Maintenance

53

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.


Maintenance

54

C-2


Engine specifications require that thisprocedure be performed every 500 hours orsemi-annually, whichever comes first.


C-3


Axle specifications require that this procedurebe performed every 500 hours



Maintenance

55

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.


Maintenance

56

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.


Maintenance

57

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


Engine specifications require that thisprocedure be performed every 1000 hours orannually, whichever comes first.


D-5


Axle specifications require that this procedurebe performed every 1000 hours or annually,whichever comes first.


Oil drainplug

Oil fillplug

Check levelplug


Maintenance

58

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.


Maintenance

59

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


Engine specifications require that thisprocedure be performed every 2000 hours ortwo years, whichever comes first.


E-3


Engine specifications require that thisprocedure be performed every 3000 hours,


E-4


Engine specifications require that thisprocedure be performed every 4000 hours,



Maintenance

60

E-5


Engine specifications require that thisprocedure be performed every 6000 hours.


E-6


Engine specifications require that thisprocedure be performed every 12,000 hours.



Maintenance

61

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


23 23 Chassis Lift Sw Fault Chassis Lift Switch ON atpower-up


24 24 Chassis Down Sw Fault Chassis Down Switch ON atpower-up


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


27 27 Drive Enable Sw Flt Platform Drive Enable SwitchON at power-up


28 28 Off Neutral Drive Joystick Platform Joystick not in neutralON at power-up


31 31 Platform Choke Sw Fault Platform Choke Switch ON atpower-up


32 32 Platform Start Sw Fault Platform Start Switch ON atpower-up


33 33 Left Front outrig Sw FltPlatform Left Front OutriggerEnable Switch ON at power-up


34 34 Right Front outrig Sw Flt Platform Right Front OutriggerEnable Switch ON at power-up


35 35 Left Rear outrig Sw Flt Platform Left Rear OutriggerEnable Switch ON at power- up


36 36 Right Rear outrig Sw Flt Platform Right Rear OutriggerEnable Switch ON at power-up


37 37 Auto Level Switch Fault Platform Outrigger Auto LevelEnable Switch ON at power-up



Maintenance

62

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


40 40 LR OR Limit Switch Fault Left Rear Outrigger LimitSwitches are both ON


41 41 RR OR Limit Switch Fault Right Rear Outrigger LimitSwitches are both ON


49 49 Drive Coil 1 Fault Power FET, channel DRIVE 1fails

check the wiring,replace the valve





52 52 Func Prop Coil Fault power FET, channelPROPORTIONAL 1 fails


54 54 Up Coil Fault Power FET, channel DOWNfails


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


61 61 Reverse 1 Coil Fault Power FET, channel REVERSELEFT fails


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



Maintenance

63

Displayfor

PlatformDisplay for Ground Description Repair

82 82 Left Rear Otrg Coil Flt Power FET, channel LEFTREAR OUTRIGGER fails


83 83 Right Front Otrg Coil Flt Power FET, channel RIGHTFRONT OUTRIGGER fails


84 84 Right Rear Otrg Coil Flt Power FET, channel RIGHTREAR OUTRIGGER fails


85 85 Outrigger Ext Coil Fit Power FET, channel EXTENDOUTRIGGER fails


86 86 Outrigger Ret Coil Fit Power FET, channel RETRACTOUTRIGGER fails


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.


Schematic

64

Hydraulic Schematic - Function model


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


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

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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

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(16)

K26

BN

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(16)

K68

BN

/YE

(16)

K19

BN

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(16)

K70

BN

/YE

(16)

K65

BN

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(16)

120Ω

120Ω

Pow

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Pow

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Pow

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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


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

eft V

a.R

ise

Va.

Brak

e Va

.

Pla

tform

Ext

end

Va.

Plat

form

Ret

ract

Va.

Om

nidi

rect

iona

l Va.

Forw

ard

Va.

Bac

kwar

d Va

.

RF

Sta

biliz

er V

a.

Sta

biliz

er E

xten

d Va

.S

tabi

lizer

Ret

ract

Va.

LF S

tabi

lizer

Va.

LR S

tabi

lizer

Va.

RR

Sta

biliz

er V

a.

RF

Sta

biliz

er L

imit

Sw

.

RR

Sta

biliz

er L

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.

Lift

Dow

n Li

mit

Sw.

Key

Sw

itch

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


Inspection and Repair Log

68

Inspection and Repair Log

Date Comments

Documents

JCPT2223RTA 操作手册 英文（SM0117123 Rev1.0）

JCPT2223RTA 操作手册英文（SM0117123 Rev1.0）