DINGLI JCPT2212DC, Operators Manual With Maintenance Information

Page 1: ...i Machinery Co Ltd First Edition March 2020 WARNING THE MANUFACTURER SHALL NOT BE HELD LIABLE IN CASE OF FAULTS OR ACCIDENTS DUE TO NEGLIGENCE INCAPACITY INSTALLATION BY UNQUALIFIED TECHNICIANS AND IMPROPER USE OF THE MACHINE DO NOT OPERATE THIS MACHINE UNTIL YOU READ AND UNDERSTAND ALL THE DANGERS WARNINGS AND CAUTIONS IN THIS MANUAL ...

Page 2: ...OPERATOR S MANUAL with Maintenance Information Version of the Record i Version of the Record Version Number Create Date SM0120113_Rev1 0 2020 03 SM0120113_Rev1 1 2020 05 ...

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Page 4: ... Owners Users and operators We appreciate your choice of our machine for your application Our number one priority is user safety which is best achieved by our joint efforts We feel that you make a major contribution to safety if you as the equipment users and operators 1 Comply with employer job site and governmental rules 2 Read understand and follow the instructions in this and other manuals sup...

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Page 6: ...u read understand and obey all applicable governmental regulations You are properly trained to safely operate the machine Decal Legend DINGLI product decals use symbols color coding and signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to...

Page 7: ...cleaners because they may damage the safety sign material Operator Only the trained and qualified are permitted to operate this machine Always use safety belt and helmet when aerially working If you are subject to dizziness or seizures or are bothered by heights you must not operate this type of machinery An operator must not use drugs or alcohol that can change his her alertness or coordination A...

Page 8: ...o a firm level surface If the tilt alarm sounds when the platform is raised use extreme caution to lower the platform For outdoor use machine Do not raise the platform when wind speeds may exceed 12 5 m s If wind speeds exceed 12 5 m s when the platform is raised lower the platform and do not continue to operate the machine Do not operate the machine in strong or gusty winds Do not increase the su...

Page 9: ...f this machine Do not transport tools and materials unless they are evenly distributed and can be safely handled by person s in the platform Do not use the machine on a moving or mobile surface or vehicle Be sure all tires are in good condition air filled tires are properly inflated and lug nuts are properly tightened Crushing Hazard Keep hands and limbs out of scissors Keep hands clear when foldi...

Page 10: ...r job site and governmental rules regarding use of personal protective equipment Observe and use color coded direction arrows on the platform controls and platform decal plate for drive and steer functions Do not operate a machine in the path of any crane or moving overhead machinery unless the controls of the crane have been locked out and or precautions have been taken to prevent any potential c...

Page 11: ...spection All compartments must remain closed and secured during operation Outrigger Safety When outdoors work may only be done in support mode Do not lower the outriggers unless the machine is on a firm surface Avoid drop offs holes unstable or slippery surfaces and other possible hazardous conditions When the auto level function is not being used and the outriggers are being lowered individually ...

Page 12: ...job site and governmental rules Lockout after Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Lower the platform 3 Turn the key switch to the off position and remove the key to secure from unauthorized use 4 Push in the red Emergency Stop buttons to off position 5 Disconnect the main power 6 Chock the wheels 7 Charge the batteries ...

Page 13: ...2 Lanyard anchorage point 10 Front wheel 3 Platform guard rails 11 Batteries Hydraulic manifold behind cover 4 Main Platform 12 Lift Cylinder 5 Platform extensions 13 Ground controls 6 Platform controls 14 Rear wheel 7 Manual storage containers 15 Outrigger 8 Scissor Arms 16 Entry ladder 4 7 8 16 13 11 12 10 9 1 2 3 5 6 14 15 ...

Page 14: ... 2 7 09440258 Decal Label Capacity 600kg 1 8 09430007 Decal Symbols Crushing hazard 10 9 09410005 Decal Danger Do not alter or disable limit switch 1 10 09420005 Decal Warning Collision hazard 4 11 09310338 Decal Instructions Maximum outrigger load 3830kg 4 12 09410069 Decal Warning Crushing hazard outrigger 4 13 09310199 Decal Instructions Maximum wheel load 3830kg 4 14 09310345 Decal Instruction...

Page 15: ...int 4 26 09540001 Decal Label CE 1 27 09310349 Decal Notice Main power switch operation 1 28 09410003 Decal Warning Inspected and operation properly 1 29 09310343 Decal Instructions Grease filling port 1 30 09330018 Decal Instructions Grease filling port 1 31 09310052 Decal Instructions Highest oil level 1 32 09310053 Decal Instructions Lowest oil level 1 33 09310351 Decal Symbols Emergency operat...

Page 16: ...nance Information Decals 11 4 5 7 8 8 8 8 8 8 8 8 8 8 11 12 13 10 10 19 18 16 20 13 13 13 19 18 11 12 10 10 11 12 11 12 4 28 9 23 22 23 22 24 25 24 25 1 2 3 5 5 5 5 5 5 5 5 24 25 24 25 6 6 15 21 30 14 29 26 32 31 15 15 15 17 27 33 ...

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

Page 18: ...OPERATOR S MANUAL with Maintenance Information Decals 13 ...

Page 19: ...m hydraulic pressure functions 250bar Tire size 28 10 20 Airborne noise emissions 80 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s2 Maximum slope rating Stowed position 25 Maximum side slope rating Stowed position 5 Note Slope rating is subject to ground conditions and adequate traction Maximum working slope outdoor 0 Maximum working slop...

Page 20: ...ency Stop button 2 Indoor outdoor button 9 Platform down button 3 Overload indicator light 10 Lift function enable button 4 Standby 11 Emergency lowering down button 5 Standby 12 Platform up button 6 Battery gauge hour meter 13 Emergency lowering down enable button 7 Key switch 6 7 8 1 2 3 4 5 13 12 11 10 9 ...

Page 21: ...sed to Display the Working Hours and Battery level 7 Key switch Turn the key switch to the platform position and the platform controls will operate Turn the key switch to the off position and the machine will be off Turn the key switch to the base position and the ground controls will operate 8 Red Emergency Stop button Push in the red Emergency Stop button to the off position to stop all function...

Page 22: ...Drive function select button 9 LED readout screen 3 Standby 10 Torque speed select button 4 High speed select button 11 Lift function select button 5 Horn button 12 Proportional control handle 6 Outrigger function enable button 13 Thumb rocker switch 7 Outrigger auto level button 14 Function enable switch 14 13 12 11 10 6 6 8 9 1 2 3 4 5 6 7 6 ...

Page 23: ...on enable switch to enable the lift function on the platform control handle Move the control handle in the direction indicated by the blue arrow and the platform will raise Move the control handle in the direction indicated by the yellow arrow and the platform will lower The descent alarm should sound while the platform is lowering Drive function Press and hold the function enable switch to enable...

Page 24: ...discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any unauthorized variation fro...

Page 25: ...manifolds Battery pack and connections Drive motors Wear pads Tires and wheels Ground strap Limit switches alarms and horn Nuts bolts and other fasteners Platform overload components Platform entry gate Beacon if equipped Safety arm Platform extension s Scissor pins and retaining fasteners Platform control joystick Brake release components Pothole guard Check entire machine for Cracks in welds or ...

Page 26: ... if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Workplace Inspection Be aware of and avoid the following hazardous situations Drop offs or holes Bum...

Page 27: ... machine as it was intended Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service The operator must follow the step by step instructions to test all machine functions A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qu...

Page 28: ...down button Result No function should operate 10 Press and hold the lift function enable button Press and hold the platform up button Result The platform should rise 11 Press and hold the lift function enable button Press and hold the platform down button Result The platform should lower the descent alarm should sound while the platform is lowering The platform stop at the height is approximately ...

Page 29: ...Push the steer mode select button for steer FS mode Front Steer mode 30 Press and hold the function enable switch on the proportional control handle Depress the thumb rocker switch on top of the proportional control handle in the direction identified by the blue triangle on the control panel Result The front wheels should turn in the direction that the blue triangle points on the control panel Unt...

Page 30: ...andle in the direction indicated by the arrow Result The drive function should not work in either direction 43 Press and hold the function enable switch on the proportional control handle Depress the thumb rocker switch in the direction identified by the blue triangle on the control panel Result The front wheels should turn in the direction that the blue triangle points on the control panel Until ...

Page 31: ...the yellow triangle on the control panel Result The rear wheels should turn in the direction that the blue triangle points on the control panel Until the steering angle is less than 30 degrees 58 Lower the platform to the stowed position 59 Press and hold the function enable switch on the proportional control handle Depress the thumb rocker switch on top of the proportional control handle in the d...

Page 32: ...until the machine begins to move then return the proportional handle to the center position Result The machine should move in the direction that the yellow arrow points on the control panel then come to an abrupt stop Note The brakes must be able to hold the machine on any slope it is able to climb Test Limited Drive Speed 72 Press the lift function select button Raise the platform approximately 3...

Page 33: ...able switch on the proportional control handle slowly move the proportional control handle to the full drive position Result The pothole guards should return to the stowed position Test the Outrigger System 90 Press the lift function enable button Raise the platform 91 Push and hold the auto level button 92 Press and hold the function enable switch Activate the proportional control handle in the d...

Page 34: ...direction indicated by the blue arrow Result The platform should rise 110 Press and hold the function enable switch Slowly move the control handle in the direction indicated by the yellow arrow Result The platform should lower to the stowed position 111 Turn on Indoor outdoor button light and select the outdoor mode 112 Press and hold the function enable switch on the control handle 113 Slowly mov...

Page 35: ...o used to perform some relatively straightforward calculations on subsystem to determine the overall PL of the system Reliability data diagnostic coverage DC the system architecture Category common cause failure and where relevant requirements for software are used to assess the PL to comply with PLr of SRP CS in Clause 5 11 of EN 280 The Operating Instructions section provides instructions for ea...

Page 36: ...lect button 2 Press and hold the function enable switch on the control handle 3 Activate the proportional control handle in the desired direction To Steer 1 Press the drive function select button 2 Press and hold the function enable switch on the control handle 3 Push the steer mode select button for steer mode FS bS 4 Turn the steer wheels with the thumb rocker switch located on the top of the co...

Page 37: ...e and fixed objects Be aware of the direction the machine will travel when using the controller Outrigger Operation 1 Position the machine below the desired work area 2 Push and hold the outrigger auto level button 3 Press and hold the function enable switch Activate the proportional control handle in the direction indicated by the yellow arrow The outriggers will extend and level the machine A be...

Page 38: ...ts securely on the shaft Keep clear of the safety arm when lowering the platform Don t engage the safety arm unless unload the platform Using this safety arm is necessary during operations near the scissor system if the platform is lifted How to Fold Down the Guardrails The platform railing system consists of three fold down rail section for the extension deck and three sections for the main deck ...

Page 39: ...m 1 Pull out the extension platform fixed screw 2 Unlock the extension part of the platform with the hand levers on the railing 3 Push the extension part forward to the desired length 4 Lock the extension part again with the hand levers 5 The retraction of the carrier part is carried out in the reverse order Do not stand on the platform extension while trying to extend it 1 2 5 6 3 4 ...

Page 40: ... Emergency Lowering 1 Unplug the lever and put it into the hand pump 1 2 Press and hold the button 2 3 Operate the hand pump with the lever the platform should lower Retracting outriggers 1 Unplug the lever and put it into the hand pump 1 2 Press and hold the button 4 3 Choose the outrigger which needs to retract Press the corresponding knob in the direction of the arrow ...

Page 41: ...etract Do not emergency lift lower the platform and retract outriggers simultaneity Emergency actuation of outriggers only in normal position danger of tipping After Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Lower the platform 3 Turn the key switch to the off position and remove the key to secure from unauthorized use 4 Push in the red Emergenc...

Page 42: ... machine must be on a level surface or secured before releasing the brakes Do not drive the machine on a slope that exceeds the slope or side slope rating See Driving on a Slope in the Operating Instructions section If the slope of the transport vehicle bed exceeds the maximum slope rating the machine must be loaded and unloaded using a winch as described Free wheel Configuration for Winching Choc...

Page 43: ...e the extension deck s Use the tie down points on the chassis for anchoring 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 and remove the key before transporting Inspect the entire machine for loose or unsecured items If the railings have been folded down secure them with straps before transpo...

Page 44: ...Lifting Instructions Fully lower the platform Be sure the extension decks controls and covers are secure Remove all loose items on the machine Determine the center of gravity of your machine using the table and the picture on this page Attach the rigging only to the designated lifting points on the machine There are two lifting points on each end of the machine Adjust the rigging to prevent damage...

Page 45: ...ch type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annually and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have ...

Page 46: ...hall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in this manual Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after...

Page 47: ...ection to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist A Y N R A 1 Inspect the manuals and decals A 2 Pre operation inspection A 3 Check the Batteries A 4 Check the Hydraulic Oil Level A 5 Function t...

Page 48: ... that the operator s manual is present and complete in the storage container on the platform 2 Examine the pages of manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and the manual are legible and in good condition Result The operator s manual is not appropriate for the machine or the manual is not in good condition or is ille...

Page 49: ... A 3 Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions Electrocution hazard Contact with hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries contain...

Page 50: ...oose the appropriate hydraulic oil according to the ambient temperature used Example L HV32 or L HV68 A 5 Perform Function Tests Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and ...

Page 51: ...ntenance free or sealed batteries 5 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 6 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows Add 0 004 to the reading of each cell for every 5 5 C above 26 7 C Subtract 0 004 from the reading of each cell for every 5 5 C below 26 7 C Result...

Page 52: ...lease contact the DINGLI Service Department B 2 Inspect the Electrical Wiring DINGLI requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and...

Page 53: ...latform and return the safety arm to the stowed position 11 Lower the platform to the stowed position and turn the machine off B 3 Inspect the Tires and Wheels Dingli requires that this procedure be performed every 250 hours or quarterly whichever comes Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result in a...

Page 54: ...read sealant to the plug s and then install the plug s in the drive hub 5 Repeat this procedure for each drive hub B 5 Test the Key Switch Dingli requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper key switch action and response is essential to safe machine operation Failure of the key switch to activate the appropriate control panel could cause a ha...

Page 55: ... position pull out the platform red Emergency Stop button to the on position 4 Push down the red Emergency Stop button at the platform controls to the off position Result No machine functions should operate Note The red Emergency Stop button at the ground controls will stop all machine operation even if the key switch is switched to platform control B 7 Test the Automotive style Horn Dingli requir...

Page 56: ...ncy Stop button to the on position 3 Lower the platform to the stowed position 4 Press the drive function select button 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line 6 Bring the machine to top drive speed before reaching the test line Release the function enable switch or the joystick when your reference point on the machine c...

Page 57: ...e the time when the machine reference point passes over the finish line The time is less than 14 6 sec B 10 Test the Drive Speed Raised Position Dingli requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive function movement is essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive perf...

Page 58: ...ng points on the chassis The lubricating points on the platform The following points must be lubricated on the scissor joint in particular Scissor shaft Sliding blocks lifting cylinder The following points must be lubricated on the chassis in particular Steering Sliding tracks of the sliding blocks The following points must be lubricated on the platform in particular Sliding blocks sliding tracks ...

Page 59: ...essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that chan...

Page 60: ...Result The overload alarm at the platform controls should not sound indicating a normal condition Result The overload alarm at the platform controls sounds Calibrate the platform overload system 5 Add an additional weight to the platform not to exceed20 of the maximum rated load Result The overload alarm at the platform controls sound indicating a normal condition Result The overload alarm at the ...

Page 61: ...hat there are no leaks 8 Clean up any oil that may have spilled 9 Raise the platform and return the safety arm to the stowed position 10 Lower the platform to the stowed position and turn the machine off D 2 Check the Free wheel Configuration Dingli specifications require that this procedure be performed every 1000 hours or annually whichever comes first Proper use of the free wheel configuration ...

Page 62: ... Lift the wheels off the ground and place blocks under the drive chassis for support Crushing hazard The chassis could fall if not properly supported 10 Release the brake 11 Manually rotate each front wheel Result Each wheel should rotate with minimum effort 12 Reset the brake Rotate each wheel to check for engagement Raise the machine and remove the blocks Lower the machine ...

Page 63: ...an penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Crushing hazard Keep hands clear of the safety arm when lowering the platform 1 Raise the platform use the Safety Arm 2 Disconnect the battery pack from the machine 3 Remove the oil drain plug at bottom 4 Drain all of the oil into a suitable conta...

Page 64: ...nce Information Maintenance 59 Component damage hazard The pump can be damaged if operated without oil Be careful not to empty the hydraulic tank while in the process of filling the hydraulic system Do not allow the pump to cavitate ...

Page 65: ...ring 25 25 Left Turn switch Fault Platform Left Turn Switch ON at power up Check the switch replace the platform 26 26 Right Turn switch Fault Platform Right Turn Switch ON at power up Check the switch replace the platform 27 27 Drive Enable Sw Flt Platform Drive Enable Switch ON at power up Check the switch replace the platform 28 28 Off Neutral Drive Joystick Platform Joystick not in neutral ON ...

Page 66: ...ring replace the valve 47 47 Steer Switch Coil Fault Steer Switch Coil Fault check the wiring replace the valve 48 48 Pothole Ret Coil Fault Pothole Retract Coil Fault check the wiring replace the valve 49 49 Pothole Ext Coil Fault Pothole Extend Coil Fault check the wiring replace the valve 50 50 Outrigger Fault Outdoor Mode Outrigger not Extend Or all four Outriggers are not Extend check the out...

Page 67: ...Power FET channel RIGHT REAR OUTRIGGER fails check the wiring replace the valve 85 85 Outrigger Ext Coil Fit Power FET channel EXTEND OUTRIGGER fails check the wiring replace the valve 86 86 Outrigger Ret Coil Fit Power FET channel RETRACT OUTRIGGER fails check the wiring replace the valve 90 90 RR MC Comm Fault Rear right Motor controller communication fault check the wiring replace the controlle...

Page 68: ...S1 S2 S3 S4 A B CB A A B CB B A B CB A A B CB A B A C D A CB E A1 B1 MA1 Tank Function valve Pump1 Pump2 Manual pump Front steer cylinder Rear steer cylinder Counterbalance valve Counterbalance valve Counterbalance valve Counterbalance valve Counterbalance valve Counterbalance valve LF Outrigger cylinder RF Outrigger cylinder LR Outrigger cylinder RR Outrigger cylinder Lift cylinder CB F CB G CB H...

Page 69: ...2 BN 16 PE GB3 GS2 11 3 1 0130 WH 20 FU11 350A FU10 350A FU6 10A 0310 BN 20 0203 RD 16 0222 WH 20 0202 WH 18 0204 BU 18 0205 BK 18 0213 BU 20 0214 WH 20 0225 RD 18 M2 3 BK 0 RD 0 M6 CAN2H YE 20 CAN2L GN 20 BK 0 1 0205 3 0205 0210 BN 20 0220 BN 20 FU5 10A FU9 350A 0230 WH 20 GND1 1 BK 14 001 1 RD 14 2 001 2 RD 14 4 GND1 2 BK 14 1 0112 WH 18 F G H D C B E A D C B A H G F E 2 1 3 4 6 7 8 5 1 2 3 6 7 ...

Page 70: ...1 12 108A WH 18 107A WH 18 14 13 209B YE 20 205C GN 20 105A WH 18 106A WH 18 11 12 103B WH 18 1 7 104C WH 20 004 2 RD 20 SQ9 SQ8 104C WH 20 8 201B WH 20 201B WH 20 13 SR1 12V IN 1 RD 14 48VIN 1 BN 16 209B YE 20 205C GN 20 GND2 9 BK 14 4 1 3 5 CD1 48V CURTIS Display U2 6 7 2 8 105C WH 20 4 105C WH 20 SQ3 KA3 GND1 2 BK 14 4 2 12V IN 2 RD 14 HL2 GND2 1 BK 20 GND2 3 BK 20 020A WH 18 3 003 RD 20 103B2 ...

Page 71: ...OPERATOR S MANUAL with Maintenance Information Inspection and Repair Log 66 Inspection and Repair Log Date Comments ...