DINGLI JCPT2223RTA, Operators Manual With Maintenance Information

Page 1: ...gli Machinery Co Ltd First Edition September 2017 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 1 ...

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Page 4: ...OPERATOR S MANUAL with Maintenance Information Version of the Record i Version of the Record Version Number Create Date SM01117123_Rev1 0 2017 09 ...

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Page 6: ... 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 8: ...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 9: ...y 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 An operator on prescription or over the counter drugs needs medical advice on whether or not he she can safely operate machines Electrocution Hazard This...

Page 10: ...lt 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 surface area of the platform or th...

Page 11: ...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 folding...

Page 12: ...with employer 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...

Page 13: ...eak or hydraulic leak can penetrate and or burn skin Improper contact with components under any cover will cause serious injury Only trained maintenance personnel should access compartments Access by the operator is only advised when performing a pre operation inspection All compartments must remain closed and secured during operation Outrigger Safety Do not lower the outriggers unless the machine...

Page 14: ...ion Hazard Avoid contact with electrical terminals pollute Hazard Dispose of old battery must comply with job site and governmental rules Lockout after Each Use 1 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 and remove the key to secure from unauthorized use 4 Chock the wheels ...

Page 15: ...te 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 ...

Page 16: ...or use 2 5 9114013 Label Platform Console Panel 1 6 9414123 Label Lanyard Anchorage 6 7 9914025 Cosmetic Warning 1 8 9414063 Label Capacity 750kg 1 9 9914023 Cosmetic Warning 1 10 9514011 Cosmetic Mark 2 11 9414107 Caution Max Manual Force 400N 2 12 9614091 Cosmetic JCPT2223RTA 2 13 9514105 Cosmetic Mark 1 14 9914021 Cosmetic Warning 1 15 9514051 Cosmetic Mark 1 16 9914019 Cosmetic Warning 1 17 94...

Page 17: ...osion Burn Hazard 1 31 9911023 Instructions JCPT2223RTA 4 4 SELF PROPELLED ROUGH TERRAIN 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 Hydraulic Oil Tank 36 9332017 Instructions Lowest Hydraulic Oil Level 2 On the Hydraulic Oil Tank and Diesel Tank 37 933...

Page 18: ...rmation Decals 11 27 21 23 22 24 26 28 29 30 31 23 22 19 13 14 15 16 17 17 17 17 12 11 10 18 34 33 32 21 23 22 26 23 22 21 21 35 36 37 38 39 37 36 4 26 26 25 20 20 25 25 25 20 20 28 29 31 1 2 3 4 5 6 6 6 6 6 6 6 6 7 8 9 12 11 10 17 18 17 17 ...

Page 19: ...OPERATOR S MANUAL with Maintenance Information Decals 12 ...

Page 20: ...essure functions 240bar Tire size 355 55D625 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 30 Maximum side slope rating Stowed position 25 Note Slope rating is subject to ground conditions and adequate traction Maximum working slope X 2 Y 3 Drive speeds Stowed maximum 6 6 k...

Page 21: ...ency 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 control selection 6 7 8 1 2 3 4 5 13 12 11 10 9 ...

Page 22: ...splays the number of hours the machine has operated 7 Key switch for platform off ground 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 posi...

Page 23: ...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 ...

Page 24: ...ine start flameout button Press this button to start flameout the engine 12 Engine lower speed Idle select button Press this button to select the engine idle setting Light on indicates high idle is selected 13 Lift function select button Press this button to activate the lift function 14 Proportional control handle Move the control handle control the drive function Lift function and platform retra...

Page 25: ...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 26: ...operly installed or missing parts and unauthorized modifications Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds 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...

Page 27: ... 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 28: ... 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 29: ...ess the lift function enable button Press and hold the platform up 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 then stop at the height is 3 5m The descent ...

Page 30: ...d hold the function enable switch on the proportional control handle Depress the thumb rocker switch in the direction identified by the yellow triangle on the control panel Result The front wheels should turn in the direction that the yellow triangle points on the control panel 29 Push the steer mode select button for steer AS mode All wheel Steer mode 30 Press and hold the function enable switch ...

Page 31: ...at 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 39 Press the lift function select button Raise the platform approximately 3 5 m from the ground 40 Press the drive function select button 41 Press and hold the function enable switch on the proportional control handle...

Page 32: ...Push and hold the lift function enable button Raise the platform Result The platform should rise to 12 m and then stop The platform should not rise above 12 m unless the outriggers are lowered 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 higher than 3 5 ...

Page 33: ...ts 26 Result The platform should spread 75 Push and hold the Platform retractable enable button Press and hold the function enable switch Activate the proportional control handle in the direction indicated by the yellow arrow Result The platform should retract ...

Page 34: ...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 35: ...equire the use of a booster battery Operation from Ground 1 Turn the key switch to ground control 2 Pull out the platform red Emergency Stop button to the on position 3 Turn the red Emergency Stop button clockwise to the on position 4 Start the engine To Position Platform 1 Press the lift function enable button 2 Press the platform up down button to activate the up function or the down function Dr...

Page 36: ...ode To determine the slope grade Measure the slope with a digital inclinometer or use the following procedure You will need Carpenter s level Straight piece of wood at least 1 m long tape 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 until the piece of wood is level While holding the piece of wood level measure th...

Page 37: ...utton and on the individual outrigger buttons will turn off when all the outriggers are in firm contact with the ground The drive function is disabled while the outriggers are down To control individual outrigger 1 Push and hold one or more outrigger buttons 2 Press and hold the function enable switch Activate the proportional control handle in the direction indicated by the yellow arrow The outri...

Page 38: ... 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 All sections are held in place by four latches Closed latch Open latch 1 Fully lower the platform and retract the platform extension 2 Remove the platform controls 3 Opening the latches in the corners the rails have to be folded in correct or...

Page 39: ...ing 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 rise Retracting outriggers 1 Unplug the lever and put it into the hand pump 1 2 Turn the knob 4 in the direction of the arrow 3 Choose the outrigger which needs to retract turn the corresponding knob in the direction of the arrow 4 Operate the hand pump wi...

Page 40: ...iggers simultaneity Reset the knob after all operations completed Emergency actuation of outriggers only in normal position danger of tipping 1 2 3 4 5 6 7 8 9 10 After Each Use 1 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 and remove the key to secure from unauthorized use 4 Chock the wheels ...

Page 41: ...de 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 Chock the wheels to prevent the machine from rolling Loosen nuts of screws provided for the mechanical and manual release of the braking units ...

Page 42: ...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 43: ...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 44: ...ion Report The pre delivery preparation report contains checklists for each 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 M...

Page 45: ...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 46: ...tion inspect A 3 Check the Batteries A 4 Check the Engine Oil Level A 5 Check the Hydraulic Oil Level A 6 Check the Engine Coolant Level A 7 Function tests A 8 Engine maintenance A 9 Drive Axle Maintenance Perform after 40 hours A 10 30 day service Perform after 50 hours A 11 Engine maintenance Perform every 100 hours A 12 Drive Axle Maintenance Checklist B Y N R B 1 Battery B 2 Electrical wiring ...

Page 47: ... 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 48: ...3 Check the Batteries Proper battery condition is essential to good engine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine 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 cont...

Page 49: ...old conditions 0W 20 A 5 Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems Perform this procedure with the platform in the stowed position and the...

Page 50: ...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 removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A 8 Perform Engine Main...

Page 51: ...Inspect the Tires and Wheels including lug nut torque B 15 Perform Engine Maintenance A 11 Perform Engine Maintenance Engine specifications require that this one time procedure be performed after 50 hours of operation Required maintenance procedures and additional engine information is available in the engine operator s manual A 12 Perform Drive Axle Maintenance Axle specifications require that th...

Page 52: ...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 53: ...garding the battery charger operation please 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 re...

Page 54: ...between the ECM and the platform controls 11 Raise the platform and return the safety arm to the stowed position 12 Lower the platform to the stowed position and turn the machine off B 3 Check the Exhaust System Dingli requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the exhaust system is essential to good engine performance and service life ...

Page 55: ...dry 600Nm lug nut torque lubricated 450Nm B 5 Check the Oil Level in the Drive Hubs Dingli requires that this procedure be performed every 250 hours or quarterly whichever comes Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage 1 Before draining oil it is mandatory to rotate the planetary gear reduction in order to ...

Page 56: ...ult The engine should stop and no functions should operate B 7 Test the Emergency Stop Dingli requires that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning Emergency Stop is essential for safe machine operation An improperly operating red Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous s...

Page 57: ... machine operation The drive brake function should operate smoothly free of hesitation jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when they are actually not fully operational 1 Mark a test line on the ground for reference 2 Start the engine from the platform controls 3 Choose a point on the machine i e contact patch of a tire as a visual...

Page 58: ...te the time when the machine reference point passes over the finish line The time is less than 6 6 sec B 11 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 59: ...il distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hydraulic Oil B 13 Perform Engine Maintenance Engine specifications require that this procedure be performed every 250 hours or quarterly whichever c...

Page 60: ... 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 4 Add an additional weight to the platform not to exceed 10 of the maximum rated load Result The overload alarm at the platform controls sound indicating a normal condition Result The overload alarm at the platform controls ...

Page 61: ...rs or semi annually whichever comes first Required maintenance procedures and additional engine information is available in the engine operator s manual C 3 Perform Drive Axle Maintenance Axle specifications require that this procedure be performed every 500 hours Required maintenance procedures and additional Axle information is available in the Axle operator s manual ...

Page 62: ... cause severe burns 1 Raise the platform use the Safety Arm 2 Open the cover 3 Tag and disconnect the hydraulic tank return line Cap the fitting on the filter head 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 filter gasket 6 Install the new filter and tighten it securely by hand 7 Use a permanent ink marker to write t...

Page 63: ...r end of the machine 3 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 4 Release the brake 5 Manually rotate each wheel at the non steer end Result Each wheel should rotate with minimum effort 6 Reset the brake Rotate each wheel to check for engagement Raise the machine and remove the blocks Lower ...

Page 64: ...lug 3 Fill the oil fill plug hole until the oil level is even with the bottom of the side check level plug hole Apply pipe thread sealant to the plugs Install the plugs 4 Repeat steps 1 through 3 for all the other Drive Axles Oil specifications Oil type API GL4 or GL5 D 4 Perform Engine Maintenance Engine specifications require that this procedure be performed every 1000 hours or annually whicheve...

Page 65: ...y charged circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Spraying hydraulic oil can 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 1 Disconnect the battery pack from the machine 2 Open the power unit module cover 3 Remove the oil d...

Page 66: ...dure be performed every 2000 hours or two years whichever comes first Required maintenance procedures and additional engine information is available in the engine operator s manual E 3 Perform Engine Maintenance Engine specifications require that this procedure be performed every 3000 hours Required maintenance procedures and additional engine information is available in the engine operator s manu...

Page 67: ...ed every 6000 hours Required maintenance procedures and additional engine information is available in the engine operator s manual E 6 Perform Engine Maintenance Engine specifications require that this procedure be performed every 12 000 hours Required maintenance procedures and additional engine information is available in the engine operator s manual ...

Page 68: ...ch 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 at power up Check the switch replace the platform 31 31 Platform Choke Sw Fault Platform ...

Page 69: ...iring replace the valve 54 54 Up Coil Fault Power FET channel DOWN fails check the wiring replace the valve 55 55 Down Coil Fault Power FET channel RT fails check the wiring replace the valve 56 56 Right Turn Coil Fault Power FET channel LT fails check the wiring replace the valve 57 57 Left Turn Coil Fault Power FET channel LT fails check the wiring replace the valve 58 58 Brake Coil Fault Power ...

Page 70: ...annel 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 95 95 Machine Type Fauit Wrong Machine Type Selected Reinstall Machine Type OL 98 Platform Overload Platform Overload Fau...

Page 71: ...OPERATOR S MANUAL with Maintenance Information Schematic 64 Hydraulic Schematic Function model ...

Page 72: ...ulic Schematic Drive model Oi l cool er 5899 1312 YO344 X2 X1 T2 T1 G S MA B MB Fe Ps R a b Tank Dr i ve pump Fi l ter 5899 0711 PLFA C110X10 MH Fa1 Fa A Fs G T2 U T1 B A Vgmi n Vgmax BRK CHG P T Fr ont axl e P1 P1 P1 P1 P3 M C1 0 8mm SV2 SV1 Dr i ve motor Rear axl e ...

Page 73: ...e Power Negative Power Negative Power Postive Power Postive Power Postive CAN1L CAN1H CAN0L CAN0H Magnetizing Fuel Pump Relay Fuel Pump Relay Start Signal Switch Common Air Filter Switch Signal Stop Signal Cooling Water Level Cooling Water Level Signal Start Relay Start Relay Switch Public Negative Fault Diagnostic Switch Signal Neutral Switch Signal Fuel Pump Power Switch GB Battery 24 24 24 24 2...

Page 74: ...11C WH 20 GND13 BK 14 004E RD BU 16 004F RD BU 14 001A 1 RD 12 001A 2 RD 12 207B WH 20 17 K31 BN YE 16 005 RD BU 16 KN1 SQ8 108C BK 20 8 16 15 17 18 19 3 4 1 2 5 2 1 3 4 004G RD 16 004G RD BU 14 GND14 BK 20 GND14 BK 14 6 004A RD BU 16 004A RD 16 004A RD BU 16 8 7 9 10 12 004C RD 16 004C RD BU 16 15 GND5 BK 16 18 20 21 6 7 8 9 10 15 16 17 18 19 20 GND6 BK 16 GND7 BK 16 GND8 BK 16 GND9 BK 12 GND11 B...

Page 75: ...OPERATOR S MANUAL with Maintenance Information Inspection and Repair Log 68 Inspection and Repair Log Date Comments ...