operator’smanual - premier platforms

SELF-PROPELLED SCISSOR LIFTS

OPERATOR’S MANUALwith Maintenance Information

For JCPT0808/JCPT1008/JCPT1012/JCPT1212/JCPT1412/JCPT1612B/JCPT1612S

( Hydraulic Motor / DC Motor Drive )

Part Number: SM0110111_Rev9.1

Zhejiang Dingli Machinery Co., Ltd. Ninth Edition, July 2018 Printing

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

SM0110111_Rev1.0 …………………………………………………………………………… 2010-07

SM0110111_Rev2.0 …………………………………………………………………………… 2011-03

SM0110111_Rev3.0 …………………………………………………………………………… 2012-12

SM0110111_Rev4.0 …………………………………………………………………………… 2013-08

SM0110111_Rev5.0 …………………………………………………………………………… 2014-03

SM0110111_Rev6.0 …………………………………………………………………………… 2014-12

SM0110111_Rev7.0 …………………………………………………………………………… 2016-01

SM0110111_Rev8.0 …………………………………………………………………………… 2018-01

SM0110111_Rev9.0 …………………………………………………………………………… 2018-07

SM0110111_Rev9.1 …………………………………………………………………………… 2018-10


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 9

Decals 10

Specifications 15

Control panel 29

Pre-operation Inspection 32

Workplace Inspection 34

Function Tests 35

Operating Instructions 40

Transport and Lifting Instructions 50

Maintenance 54

Schematic 82

Inspection and Repair Log 92

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 safety rules— operator's manual and machine 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 indicatethe presence of a potentially hazardoussituation which, if not avoided, could result indeath or serious 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

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.

Use mild soap and water to clean safety signs.

Do not use solvent-based cleaners becausethey may damage the safety sign material.

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.

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 – JCPT0808HD

Maximum occupants (Indoor use) 2

Maximum occupants (Outdoor use) 1

Platform allowable maximum load 380kg

Extension deck allowable maximum load 113kg


Maximum occupants (Indoor use ONLY) 2




Maximum occupants (Indoor / Outdoor use) 2








Safety Rules

3






Maximum capacity – JCPT1612HDB




Maximum capacity – JCPT1612HDS




Maximum capacity – JCPT0808DC










Maximum occupants (Indoor/Outdoor use) 2












Maximum capacity – JCPT1612DCB




Maximum capacity – JCPT1612DCS




Platform retracted Platform extended

Extension Platformonly only

Work Area SafetyDo not raise the platform unless the machineis on a firm, level surface.

Do not drive over 0.8 km/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 afirm, level surface. If the tilt alarm soundswhen the platform is raised, use extreme


Safety Rules

4

caution 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.

Maximum allowable manual force

Model Application manualforce

Maximumoccupants

JCPT0808HDOutdoor 200N 1

Indoor 400N 2

JCPT1008HD Indoor 400N 2


Indoor 400N 2


Indoor 400N 2

JCPT1412HD Indoor 400N 3

JCPT1612HDB Indoor 400N 2

JCPT1612HDS Indoor 400N 2

JCPT0808DCOutdoor 200N 1

Indoor 400N 2

JCPT1008DC Indoor 400N 2


Indoor 400N 2


Indoor 400N 2

JCPT1412DC Indoor 400N 3

JCPT1612DCB Indoor 400N 2

JCPT1612DCS Indoor 400N 2

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 operate the machine with the chassistrays open.

Do not contact adjacent structures with theplatform.

Do not alter or disable the limit switches.

Do not tie the platform to adjacent structures.


Safety Rules

5

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 use batteries that weigh less than theoriginal equipment. Batteries are used ascounterweight and are critical to machinestability. Each battery must weigh 28 kg. Thebatteries must weigh a minimum of 112 kg.(For JCPT0808HD/DC, JCPT1008HD/DC,JCPT1012HD/DC); Each battery must weigh30 kg. The batteries must weigh a minimum of120 kg (For JCPT1212HD/DC); Each batterymust weigh 37 kg. The batteries must weigh aminimum of 148 kg (For JCPT1412HD/DC,JCPT1612HDB/DCB, JCPT1612HDS/DCS).

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 safelyhandled 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-filled

tires are properly inflated and lug nuts areproperly tightened.

Crushing Hazard

Keep hands and limbs out of scissors.

Keep hands clear when folding rails.

Maintain a firm grasp on the platform rail whenremoving the rail pins. Do not allow theplatform guard rails to fall.

Use common sense and planning whenoperating the machine with the controller fromthe ground. Maintain safe distances betweenthe operator, the machine and fixed objects.

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.

Maximum slope rating stowed

Maximum side slope rating stowed

Model A B

JCPT0808HD 25% (14°) 25% (14°)

JCPT1008HD 25% (14°) 25% (14°)

JCPT1012HD 25% (14°) 25% (14°)

JCPT1212HD 25% (14°) 25% (14°)

JCPT1412HD 25% (14°) 25% (14°)


Safety Rules

6

Model A B

JCPT1612HDB 25% (14°) 25% (14°)

JCPT1612HDS 25% (14°) 25% (14°)

JCPT0808DC 25% (14°) 25% (14°)

JCPT1008DC 25% (14°) 25% (14°)

JCPT1012DC 25% (14°) 25% (14°)

JCPT1212DC 25% (14°) 25% (14°)

JCPT1412DC 25% (14°) 25% (14°)

JCPT1612DCB 25% (14°) 25% (14°)

JCPT1612DCS 25% (14°) 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.

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 is

secured 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 for drive and steerfunctions.

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.


Safety Rules

7

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 charger greater than24V to charge the batteries.

Do not use the machine as a ground forwelding.

Explosion and Fire HazardDo not operate the machine or charge thebatteries in hazardous locations wherepotentially flammable or explosive gases orparticles may be present.

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 decals are in place and legible.

Be sure the operator’s manual is complete,legible and in the storage container located inthe platform.

Bodily Injury HazardDo 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 onlyadvised when performing a pre-operationinspection. All compartments must remainclosed and secured during operation.

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.

Explosion Hazard

Keep sparks, flames and lighted tobacco awayfrom batteries. Batteries emit explosive gas.

The battery tray should remain open during theentire charging cycle.

Do not contact the battery terminals or thecable clamps with tools that may cause


Safety Rules

8

sparks.

Component Damage Hazard

Do not use any battery charger greater than24V to charge the batteries.

Electrocution/ Burn Hazard

Connect the battery charger toa grounded, AC 3-wireelectrical outlet only.

Inspect daily for damagedcords, cables and wires.

Replace damaged items before operating.

Avoid electrical shock from contact withbattery terminals. Remove all rings, watchesand other jewelry.

Tip-over Hazard

Do not use batteries that weigh less than theoriginal equipment. Batteries are used ascounterweight and are critical to machinestability. Each battery must weigh 28 kg. Thebatteries must weigh a minimum of 112 kg.(For JCPT0808HD/DC, JCPT1008HD/DC,JCPT1012HD/DC); Each battery must weigh30 kg. The batteries must weigh a minimum of120 kg (For JCPT1212HD/DC); Each batterymust weigh 37 kg. The batteries must weigh aminimum of 148 kg (For JCPT1412HD/DC,JCPT1612HDB/DCB, JCPT1612HDS/DCS).

Lifting Hazard

Use the appropriate number of people andproper lifting techniques when lifting batteries.

Lockout after Each Use1 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 andremove the key to secure fromunauthorized use.

4 Push in the red Emergency Stop buttons to“off” position.

5 Push in the main power switch to “off”position

6 Chock the wheels.

7 Charge the batteries.


Legend

9

Legend

1 Platform extension

2 Manual storage container

3 Platform control

4 Lanyard anchorage point

5 Platform guard rails

6 Platform extension release pedal

7 Main platform

8 Platform entry gate

9 Scissor arms

10 Lift cylinder

11 Ground controls (on opposite side ofmachine)

12 Entry ladder

13 Brake release pump

14 Non-steer tire

15 Battery charger

16 Pothole guard

17 Steer tire

18 Safety arm

12 3

45

7

8

9

10

6

18

17

11

12

1314

15

16


Decals

10

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 09440011 Decal, Label-Lanyard anchorage point 4

2 09340001 Decal, Notice-Keep the manual with the machine 1

3 09440001 Decal, Danger-General safety rules 1

4 09440003 Decal, Danger-Tip-over hazard, tilt-alarm 1

5 09340003 Decal, Instructions-Refer the operator to theinstructions for use 2

6

09440013 Decal, Label-Capacity 380kg 1 JCPT0808HD/DC





09440038 Decal, Label-Capacity 250kg 1 JCPT1612HDB/DCBJCPT1612HDS/DCS

7 09440005 Decal, Warning-Use indoors only 1

JCPT1008HD/DCJCPT1412HD/DCJCPT1612HDB/DCBJCPT1612HDS/DCS

8 09310001 Decal, Instructions-Forklift pockets 2

9 09310003 Decal, Instructions-Tie down point 4

10 09310002 Decal, Instructions-Lift point 4

11

09310008 Decal, Instructions-Maximum wheel load: 1000kg 4 JCPT0808HD/DC





09310018 Decal, Instructions-Maximum wheel load: 1350kg 4 JCPT1612HDB/DCBJCPT1612HDS/DCS

No. Part No. Description Qty. Remark


Decals

11

12 09310006 Decal, Notice-Main power switch operation 1

13 09540001 Decal, Label-CE 3

14 09410001 Decal, Danger-Explosion/burn hazard 1

15

09430003 Decal, Danger-Keep away from moving parts 3

JCPT0808HD/DCJCPT1008HD/DCJCPT1012HD/DCJCPT1212HD/DC

09430003 Decal, Danger-Keep away from moving parts 5JCPT1412HD/DCJCPT1612HDB/DCBJCPT1612HDS/DCS

16

09430001 Decal, Danger-Safety arm 2

JCPT0808HD/DCJCPT1008HD/DCJCPT1012HD/DCJCPT1212HD/DC

09430001 Decal, Danger-Safety arm 4JCPT1412HD/DCJCPT1612HDB/DCBJCPT1612HDS/DCS

17

09440009 Decal, Caution-Max. manual force 400N(Indoor)200N (Outdoor) 2 JCPT0808HD/DC

JCPT1212HD/DC

09440007 Decal, Caution-Max. manual force 400N 2

JCPT1008HD/DCJCPT1012HD/DCJCPT1412HD/DCJCPT1612HDB/DCBJCPT1612HDS/DCS

18

09640001 Decal, Cosmetic-JCPT0808 2 JCPT0808HD/DC





09640072 Decal, Cosmetic-JCPT1612B 2 JCPT1612HDB/DCB

09640074 Decal, Cosmetic-JCPT1612S 2 JCPT1612HDS/DCS

19 09410005 Decal, Danger-Do not alter or disable limit switch 1

20 09310004 Decal, Instructions-Emergency lower 1

21 09410003 Decal, Warning-Inspected and operation properly 1


Decals

12

Safety tape

12

34 5

1

11

6

8

910

1213

14

16

17

18

11

15

89

10

11

17

18

16

15

19

2021

15

9

10

910

13

11

11

5

7

13


Decals

13


Decals

14


Specifications

15

Model: JCPT0808HD

Height, working maximum 8 m

Height, platform maximum 6 m

Height, stowed maximumRails up

2.23 m

Height, stowed maximumRails folded

1.87 m

Width 0.83 m

Length, platform retracted 2.48 m

Length, platform extended 3.38 m

Platform dimensionsPlatform length × width 2.27×0.81 m

Platform extension length 0.9 m

Maximum load capacity 380 kg

Maximum wind speed 12.5 m/s

Wheelbase 1.87 m

Turning radius (outside) 2.10 m

Turning radius (inside) 0 m

Ground clearance 10 cm

Ground clearancePothole guards deployed

1.9 cm

Weight （See Serial Label）

Machine weights vary with option configurations

Power source 4 Batteries , 6V 225AH

Controls Proportional

AC outlet in platform Standard

Maximum hydraulic pressure(functions)

240 bar

System voltage 24 V

Tire size Φ381×127 mm

Airborne noise emissions <70 dB

Maximum sound level at normal operatingworkstations (A-weighted)

Vibration value does not exceed 2.5m/s2

Maximum slope rating,Stowed position 25%

Maximum side slope rating,Stowed position 25%


Maximum working slope X-1.5°,Y-3°

Drive speeds

Stowed, maximum 3.5 km/h

Platform raised, maximum 0.8 km/h

Floor loading information

Tire load, maximum 1000 kg

Tire contact pressure 11.1 kg/cm2

1086.9 kPa

Occupied floor pressure 1339 kg/m2

13.1 kPa

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.


Specifications

16

Model: JCPT1008HD




2.36 m


2.00 m

Width 0.83 m






Maximum wind speed 0 m/s

Wheelbase 1.87 m





1.9 cm







240 bar

System voltage 24 V









Drive speeds






1045 kPa

Occupied floor pressure 1287.4 kg/m2

12.6 kPa




Specifications

17

Model: JCPT1012HD




2.36 m


1.83 m

Width 1.15 m







Wheelbase 1.87 m





1.9 cm







240 bar

System voltage 24 V








Maximum working slope X-1.5°, Y-3°

Drive speeds






1182.6 kPa


11.5 kPa




Specifications

18

Model: JCPT1212HD




2.49 m


1.96 m

Width 1.15 m







Wheelbase 1.87 m





1.9 cm







240 bar

System voltage 24 V









Drive speeds






1259.7 kPa


12.3 kPa




Specifications

19

Model: JCPT1412HD

Height, working maximum 13.8 m

Height, platform maximum 11.8 m


2.62 m


2.09 m

Width 1.19 m







Wheelbase 1.87 m





1.9 cm







240 bar

System voltage 24 V









Drive speeds






1083.7 kPa


11.5 kPa




Specifications

20

Model: JCPT1612HDB




2.62 m


2.09 m

Width 1.25 m







Wheelbase 2.22 m





1.9 cm







240 bar

System voltage 24 V









Drive speeds






1142 kPa


9.9 kPa




Specifications

21

Model: JCPT1612HDS




2.75 m


2.22 m

Width 1.19 m







Wheelbase 1.87 m





1.9 cm







240 bar

System voltage 24 V









Drive speeds






1142 kPa


9.9 kPa




Specifications

22

Model: JCPT0808DC




2.23 m


1.87 m

Width 0.83 m







Wheelbase 1.87 m





1.9 cm







240 bar

System voltage 24 V









Drive speeds






1104.6 kPa


13.3 kPa




Specifications

23

Model: JCPT1008DC




2.36 m


2.00 m

Width 0.83 m







Wheelbase 1.87 m





1.9 cm







240 bar

System voltage 24 V









Drive speeds






1062.7 kPa


12.8 kPa




Specifications

24

Model: JCPT1012DC




2.36 m


1.83 m

Width 1.15 m







Wheelbase 1.87 m





1.9 cm







240 bar

System voltage 24 V









Drive speeds






1198 kPa


11.7 kPa




Specifications

25

Model: JCPT1212DC




2.49 m


1.96 m

Width 1.15 m







Wheelbase 1.87 m





1.9 cm







240 bar

System voltage 24 V









Drive speeds






1267.4 kPa


12.3 kPa




Specifications

26

Model: JCPT1412DC




2.62 m


2.09 m

Width 1.19 m







Wheelbase 1.87 m





1.9 cm







240 bar

System voltage 24 V









Drive speeds






1097.5 kPa


11.6 kPa




Specifications

27

Model: JCPT1612DCB




2.62 m


2.09 m

Width 1.25 m







Wheelbase 2.22 m





1.9 cm







240 bar

System voltage 24 V









Drive speeds






1159.2 kPa


10.1 kPa




Specifications

28

Model: JCPT1612DCS




2.75 m


2.22 m

Width 1.19 m







Wheelbase 1.87 m





1.9 cm







240 bar

System voltage 24 V









Drive speeds






1142 kPa


9.9 kPa




Control Panel

29

Ground Control Panel

1 Key switch

Turn the key switch to the platform positionand the platform controls will operate. Turnthe key switch to the off position and themachine will be off. Turn the key switch tothe base position and the ground controls willoperate.

2 Platform up / down switch

Move the switch up and the platform willraise. Move the switch down and the platformwill lower.

3 Circuit breaker

When the current was overloaded, thecircuit breaker will cut off the circuit.

4 Overload indicator light

Light on indicates when overloaded.

5 Red Emergency Stop button

Push in the red Emergency Stop buttonto the off position to stop all functions.Turn the red Emergency Stop buttonclockwise to the on position to operatethe machine.

1 2 3 4 5


Control Panel

30

Platform Control Panel

1 Thumb rocker switch

2 Drive function select button

3 Drive speed button


5 LED readout screen

6 Horn button

7 Lift function select button

8 Proportional control handle

9 Function enable switch

9

8

7

6

5

1

2

3

4


Control Panel

31

Platform Control Panel1 Thumb rocker switch

Press the thumb rocker switch in eitherdirection to activate steer function.

2 Drive function select button

Press this button to activate the drivefunction.

3 Drive speed button

Press this button to activate the slow orfast drive function.


Push in the red Emergency Stop button tothe off position to stop all functions. Pullout the red Emergency Stop button to theon position to operate the machine.

5 LED readout screen

Diagnostic readout and battery chargeindicator.

6 Horn Button

Push the horn button and the horn willsound. Release the horn button and thehorn will stop.

7 Lift function select button

Press this button to activate the liftfunction.

8 Proportional control handle

Lift function: Press and hold the functionenable switch to enable the lift function onthe platform control handle. Move thecontrol handle in the direction indicated bythe blue arrow and the platform will raise.Move the control handle in the directionindicated by the yellow arrow and theplatform will lower. The descent alarmshould sound while the platform islowering.

Drive function: Press and hold the functionenable switch to enable the drive functionon the platform control handle. Move thecontrol handle in the direction indicated bythe blue arrow on the control panel and themachine will move in the direction that theblue arrow points. Move the control handlein the direction indicated by the yellowarrow on the control panel and themachine will move in the direction that theyellow arrow points.

9 Function enable switch

Press and hold the function enable switchto enable the drive/lift function.


Pre-operation Inspection

32





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

33

Pre-operation Inspection Be sure that the operator’s manual are

complete, legible and in the storagecontainer located in the platform.

Be sure that all decals are legible and inplace. See Decals section.

Check for hydraulic oil leaks and properoil level. Add oil if needed. SeeMaintenance 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

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 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

Be sure side rails are installed and railpins and bolts are fastened.

Be sure that the chassis trays areclosed and latched and the batteriesare properly connected.

Note: If the platform must be raised to inspectthe machine, make sure the safety arm is inplace. See Operating Instructions section.


Workplace Inspection

34






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

35






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

36

1 Select a test area that is firm, level andfree of obstruction.

2 Be sure the battery pack is connected.

3 Pull out the main power switch to “on”position.

At the Ground Controls4 Turn the ground red Emergency Stop

button clockwise to the on position. Pullout the platform red Emergency Stopbutton to the on position.

5 Turn the key switch to ground control.

6 Observe the LED readout screen on theplatform controls.

⊙ Result: The LED shouldlook like the picture atright.

7 Observe the LED readout screen on theECU window.

⊙ Result: The LED shouldlook like the picture atright.

Test Emergency Stop

8 Push in the ground red Emergency Stopbutton to the off position.

⊙ Result: No functions should operate.

9 Turn the red Emergency Stop buttonclockwise to the on position.

Test Up/Down Functions

A buzzer with different sound frequency iscontrolled in central system. The descentalarm sounds at 60 beeps per minute. Thedescent delay alarm sounds at 120 beeps perminute. The alarm that goes off when thepothole guards have not deployed sounds at180 beeps per minute. The alarm that goes offwhen the machine is not level sounds at 180beeps per minute. An optionalautomotive-style horn is also available.

10 Turn the key switch to off or platformposition.

11 Move up and hold the platform up / downswitch.

⊙ Result: No function should operate.

12 Turn the key switch to ground controlposition.

13 Move up and hold the platform up / downswitch.

⊙ Result: The platform should raise.

14 Move down and hold the platform up /down switch.

⊙ Result: The platform should lower. Thedescent alarm should sound while theplatform is lowering. The platform stop atthe height is approximately 2m from theground. The descent delay alarm willsound.

Note: Be sure the area below the platform isclear of personnel and obstructions beforecontinuing.

15 Move down and hold the platform up /down switch.

⊙ Result: The platform should lower to end.The descent delay alarm should soundwhile the platform is lowering.

Test the Emergency Lowering

16 Activate the up function and raise theplatform approximately 60 cm.

17 Pull the emergency lowering knob locatedon the ground controls side of themachine.

⊙ Result: The platform should lower. Thedescent alarm will not sound.

18 Turn the key switch to platform control.


Function Tests

37

At the Platform ControlsTest Emergency Stop

19 Push in the platform red Emergency Stopbutton to the off position.


20 Pull out the red Emergency Stop button tothe on position.

⊙ Result: The LED indicator light shouldcome on.

Test the Horn

21 Push the horn button.

⊙ Result: The horn should sound.

Test Function Enable and Up/DownFunctions

22 Do not hold the function enable switch onthe control handle.

23 Slowly move the control handle in thedirection indicated by the blue up arrow,then in the direction indicated by the yellowdown arrow.


24 Press the lift function select button.

25 Press and hold the function enable switchon the control handle.

26 Slowly move the control handle in thedirection indicated by the blue up arrow.

⊙ Result: The platform should raise. Thepothole guards should deploy.

27 Release the control handle.

⊙ Result: The platform should stop raising.

28 Press and hold the function enable switch.Slowly move the control handle in thedirection indicated by the yellow downarrow.

⊙ Result: The platform should lower. The

descent alarm should sound while theplatform is lowering.

Test the Steering

Note: When performing the steer and drivefunction tests, stand in the platform facing thesteer end of the machine.

29 Press the drive function select button. Theindicator light should turn on.


31 Depress the thumb rocker switch on top ofthe control handle in the direction identifiedby the blue left arrow on the control panel.

⊙ Result: The steer wheels should turn in thedirection that the blue left arrow points onthe control panel.

32 Depress the thumb rocker switch in thedirection identified by the white right arrowon the control panel.

⊙ Result: The steer wheels should turn in thedirection that the white right arrow pointson the control panel.

Test Drive and Braking

33 Press the drive function select button. Theindicator light should turn on.


35 Slowly move the control handle in thedirection indicated by the blue up arrow onthe control panel until the machine beginsto move, then return the handle to thecenter position.

⊙ Result: The machine should move in thedirection that the blue up arrow points onthe control panel, then come to an abruptstop.



Function Tests

38

37 Slowly move the control handle in thedirection indicated by the yellow downarrow on the control panel until themachine begins to move, then return thehandle to the center position.

⊙ Result: The machine should move in thedirection that the yellow down arrow pointson the control panel, then come to anabrupt stop.

Note: The brakes must be able to hold themachine on any slope it is able to climb.

Test Limited Drive Speed

38 Press and hold the function enable switch.Raise the platform approximately 2m fromthe ground.

⊙ Result: The pothole guards should deploy.


40 Slowly move the control handle to the fulldrive position.

⊙ Result: The maximum achievable drivespeed with the platform raised should notexceed 22 cm/s.

¤ Result: If the drive speed with the platformraised exceeds 22 cm/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.

41 Fully lower the platform.

42 Place a 3.5×20cm or similar piece of woodunder both wheels on one side and drivethe machine up onto them.

43 Raise the platform approximately 2m fromthe ground.

⊙ Result: The platform should stop and the tiltalarm will sound at 180 beeps per minute.

The platform controls LED readout shoulddisplay LL.

44 Press the drive function select button.


46 Move the control handle in the directionindicated by the blue up arrow, then movethe control handle in the direction indicatedby the yellow down arrow.

⊙ Result: The drive function should not workin either direction.

47 Lower the platform and drive the machineoff the block.

Test the Pothole Guards

Note: The pothole guards should automaticallydeploy when the platform is raised. Thepothole guards activate another limit switchwhich allows the machine to continue tofunction. If the pothole guards do not deploy,an alarm sounds and the machine will notdrive and lift.

48 Raise the platform.

⊙ Result: When the platform is raisedapproximately 2m from the ground, thepothole guards should deploy.

49 Press on the pothole guards on one side,and then the other.

⊙ Result: The pothole guards should notmove.

50 Lower the platform.

⊙ Result: The pothole guards should return tothe stowed position.

51 Place a 3.5×20cm or similar piece of woodunder a pothole guard. Raise the platform.

⊙ Result: When the platform is raisedapproximately 2m from the ground, thepothole alarm will sound at 180 beeps perminute, and the platform controls LED


Function Tests

39

screen readout should display 18.



54 Move the control handle in the directionindicated by the blue up arrow, and thenmove the control handle in the directionindicated by the yellow down arrow.

⊙ Result: The drive function should not workin either direction.


56 Depress the thumb rocker switch on top ofthe control handle in the direction identifiedby the blue and white arrow on the controlpanel.

⊙ Result: The steer function should not workin either direction.

57 Lower the platform and remove the3.5×20cm wood block.


Operating Instructions

40








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.



41

Emergency StopPush in the red Emergency Stop button to theoff position at the ground controls or theplatform controls to stop all machine functions.

Repair any function that operates when eitherred Emergency Stop button is pushed in.

Emergency Lowering1 Pull the emergency lowering knob.

Operation from Ground1 Be sure the battery pack is connected

before operating the machine.


3 Turn the ground red Emergency Stopbutton clockwise to the on position. Pullout the platform red Emergency Stopbutton to the on position.

To Position Platform

1 Move the platform up/down switchaccording to the markings on the controlpanel.

Drive and steer functions are not availablefrom the ground controls.

Operation from Platform1 Be sure the battery pack is connected

before operating the machine.



To Position Platform



3 Move the control handle according to themarkings on the control panel.

To Steer



3 Turn the steer wheels with the thumbrocker switch located on the top of thecontrol handle.

To Drive



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 color-coded direction arrows on theplatform controls to identify the direction themachine will travel.

Machine travel speed is restricted when theplatform is raised.

Battery condition will affect machineperformance. Machine drive speed andfunction speed will drop when the battery levelindicator is flashing.

To reduce drive speed

The drive controls can operate in two differentdrive speed modes. When the drive speedbutton light is on, slow drive speed mode isactive. When the button light is off, fast drivespeed mode is active.

Press the drive speed button to select thedesired drive speed.



42

Driving on a slope

Determine the slope and side slope ratings forthe machine and determine the slope grade.

JCPT0808, JCPT1012, JCPT1008, JCPT1212,JCPT1412, JCPT1612B, JCPT1612Smaximum slope rating, stowed position 25%,maximum side slope rating, stowed position25%.


Press the drive speed button to the fast drivespeed 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 long

Tape measure

Lay the piece of wood on the slope.

At the downhill end, lay the level on the topedge 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.

Operation from Ground withControllerMaintain safe distances between operator,machine and fixed objects.

Be aware of the direction the machine willtravel when using the controller.

Battery Level Indicator

Full Low

Use the LED readout screen to determine thebattery level.

How to use the Safety Arm1 Raise the platform until the distance of the

two sets of scissor at least 0.5m.

2 Lift the safety arm, move it to the center ofthe scissor arm and rotate up to a verticalposition.

3 Lift the upper safety arm, move it to thecenter of the scissor arm and rotate downto a vertical position. (for JCPT1412,JCPT1612B, JCPT1612S).

4 Lower the platform until the safety armrests securely on the link. Keep clear ofthe safety arm when lowering the platform.

Don’t engage the safety armunless unload the platform.

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 wire lockpins.



43

1 Fully lower the platform and retract theplatform extension.

2 Remove the platform controls.

3 From inside the platform, remove the twofront extension deck wire lock pins.

4 Fold down the front rail assembly. Keephands clear of pinch points.

5 Replace the two removed pins back intoeach side rail bracket.

6 Fold down the extension platform left railassembly. Keep hands clear of pinchpoints.

7 Fold down the extension platform right railassembly. Keep hands clear of pinchpoints.

8 Carefully open the gate and move to therear step or the ground.

9 From the rear step or from the ground,remove the left rear main deck wire lockpins.

10 Fold down the left rail assembly. Keephands clear of pinch points.

11 Replace the removed pin back into rear railbracket.

12 Remove the right rear main deck wire lockpins.

13 Fold down the right rail assembly. Keephands clear of pinch points.

14 Replace the removed pin back into rear railbracket.

15 Fold down the rear rail assembly. Keephands free of pinch points.

How to Raise the GuardrailsFollow the fold down instructions but in reverseorder.

To Extend and Retract Platform1 Press the platform lock pin pedal on the

extension deck by foot.

2 Push the platform extension guardrail toextend the platform to the desired position.

Do not stand on the platform extensionwhile trying to extend it.



44

Error indicator readoutThe LED readout screen displays fault codes that provide information about themachine operating status and about malfunctions. The fault codes listed in thefollowing charts describe malfunctions and can aid in troubleshooting the machineby pinpointing the area or component affected.

List of Fault Codes

Display Description Lift Reaction

01 System initialization Fault Disables All Motion

02 System communication Fault Disables All Motion

03 Invalid option setting Fault Disables All Motion

12 Chassis Up/Down Switch ON at Power-up Fault Disable Chassis Control

18 Pothole Guard Fault Disable Lifting and Driving

31 Pressure Sensor Fault Disables All Motion

32 Angle Sensor Fault Disables All Motion

36 Low Battery Alert Warning Only

42 Platform Left Turn Switch ON at power-up Message Warning Only

43 Platform Right Turn Switch ON at power-up Message Warning Only

46 Platform Joystick Enable Switch ON at power-up Fault Disable Platform Control

47 Platform Joystick not in neutral at power-up Message Warning Only

52 Drive Forward Coil Fault Disable Lifting and Driving

53 Drive Reverse Coil Fault Disable Lifting and Driving

54 Lift Up Coil Fault Disable Lifting and Driving

55 Lift Down Coil Fault Disable Lifting and Driving

56 Right Turn Coil Fault Disable Lifting and Driving

57 Left Turn Coil Fault Disable Lifting and Driving

58 General Brake Coil Fault Disable Lifting and Driving

59 Parallel Coil Fault Disable Lifting and Driving

61 Motor Controller Current Sensor Fault Controller Dependent

62 Motor Controller Hardware Failsafe Fault Controller Dependent

63 Motor Controller Motor Output Fault Controller Dependent

64 Motor Controller SRO Fault Controller Dependent



45

Display Description Lift Reaction

65 Motor Controller Throttle Fault Controller Dependent

66 Motor Controller Emergency Reverse Fault Controller Dependent

67 Motor Controller HPD Fault Controller Dependent

68 Low Voltage Fault Disable All Motion

69 High Neutral Current Fault (ZAPI Only) Disable All Motion

70 Steering Input Out of Range (ZAPI Only) Disable All Motion

71 Motor Controller Main Contactor Fault Disable Lifting and Driving

72 Motor Controller Over Voltage Fault Controller Dependent

73 Motor Controller Thermal Cutback Fault Controller Dependent

74 Motor Controller Motor Fault Controller Dependent

75 Motor Controller Pump Motor Fault Controller Dependent

76 Motor Controller Left Drive Motor Fault Controller Dependent

77 Motor Controller Right Drive Motor Fault Controller Dependent

78 Pump Motor Short Fault Disable Lifting and Driving

79 Left Drive Motor Short Fault Disable Lifting and Driving

80 Over 80% Load Warning Warning Only

81 Right Drive Motor Short Fault Disable Lifting and Driving

82 Left Brake Coil Fault Disable Lifting and Driving

83 Right Brake Coil Fault Disable Lifting and Driving

84 Motor Post Shorted Disable Lifting and Driving

85 Brake Release Switch On Warning Only

86 Brake Release Not Showed Warning Only

87 Brake Release Warning Only

89 Motor Field Open Disable Lifting and Driving


91 Left Motor Field Short Disable Lifting and Driving

92 Right Motor Field Short Disable Lifting and Driving


OL Overloaded Platform Fault Disable All Motion

LL Machine Tilted Beyond Safe Limits Fault Disable Lifting and Driving



46

Troubleshooting Guide

Display Description

01 System Initialization Fault: ECU may be malfunctioning, replace it.

02 System Communication Fault: Check communications cable connections and otherwiring. If that does not resolve the problem, try replacing the PCU or ECU.

03 Invalid Option setting Fault: Set appropriate option for this lift.

12 Chassis Toggle Switch ON at power-up Fault: Check the wires to the Toggle Switch orlook for a stuck Toggle Switch.

18Pothole Guard Fault: Check that the pothole guards are extended, check the potholelimit switches. Check wires to the switches, check the down limit switch andconnections.

31 Pressure Sensor Fault: Check the wiring to the sensor and then the sensor itself. Alsocheck to make sure that the correct option is properly selected (or not) for load sensing.

32 Angle Sensor Fault: Check the wiring to the sensor and then the sensor itself. Alsocheck to make sure that the correct option is properly selected (or not) for load sensing

36 Low Voltage Alert: Check battery voltage and charge batteries if necessary.

42 Platform Left Turn Switch ON at power-up Message: Ensure that nothing is holding theJoystick Toggle Switches down. If OK, consider replacing the Joystick or PCU.

43 Platform Right Turn Switch ON at power-up Message: Ensure that nothing is holdingthe Joystick Toggle Switches down. If OK, consider replacing the Joystick or PCU.

46Platform Joystick Enable Switch ON at power-up Fault: Ensure that nothing is holdingthe Enable switch closed. Also check the neutral zone parameters. If OK, considerreplacing the Joystick or PCU.

47Platform Joystick not in neutral at power-up Message: Make sure that the Joystick is inthe neutral (upright) position. Check the neutral zone parameter setting in DingliScissor Programmer. If it’s OK, consider replacing the Joystick or the PCU.

52 Drive Forward Coil Fault: Check the connections to the Coil’s terminals and make surethey are tight. If so, check the coil itself to see if it is open or shorted.

53 Drive Reverse Coil Fault: Check the connections to the Coil’s terminals and make surethey are tight. If so, check the coil itself to see if it is open or shorted.

54 Lift Up Coil Fault: Check the connections to the Coil’s terminals and make sure they aretight. If so, check the coil itself to see if it is open or shorted.

55 Lift Down Coil Fault: Check the connections to the Coil’s terminals and make sure theyare tight. If so, check the coil itself to see if it is open or shorted.

56 Right Turn Coil Fault: Check the connections to the Coil’s terminals and make sure theyare tight. If so, check the coil itself to see if it is open or shorted.

57 Left Turn Coil Fault: Check the connections to the Coil’s terminals and make sure theyare tight. If so, check the coil itself to see if it is open or shorted.

58 General Brake Coil Fault: Check the connections to the Coil’s terminals and make surethey are tight. If so, check the coil itself to see if it is open or shorted.



47

Display Description

59 Parallel Coil Fault: Check the connections to the Coil’s terminals and make sure theyare tight. If so, check the coil itself to see if it is open or shorted.

61Motor Controller Current Sensor Fault: Drive or Lift Motor may be overheating. Let thelift cool down. If that does not help, cycle power to reset the Motor controller. If theproblem persists, check the wiring and if OK, try replacing the Motor Controller.

62 Motor Controller Hardware Failsafe Fault: Cycle power. If that does not resolve theissue check for noise sources. If still needed, try replacing the Motor Controller.

63 Motor Controller Motor Output fault: Check wiring first then cycle power. If neededreplace controller.

64Motor Controller SRO Fault: Look at motor enable delay with the Dingli ScissorProgrammer, it may be too short. Make sure other Motor Controller parameters areproperly selected.

65 Motor Controller Throttle Fault: Check wiring. Make sure the correct throttle type isselected in the Motor Controller.

66 Motor Controller Emergency Reverse Fault: Ensure that the Emergency ReverseCheck Parameter is off in the Motor Controller.

67Motor Controller HPD Fault: Look at motor enable delay with the Dingli ScissorProgrammer, it may be too short. Make sure other Motor Controller parameters areproperly selected.

68 Low Voltage Fault: Check battery voltage and charge batteries if necessary. Check thebattery connections and tighten or clean. Check the voltage to the ECU and PCU.

69

High Neutral Current: The MC is sensing current in the motors when there should notbe. This could occur anytime the MC thinks the brakes are on and the motors are stillturning. This message sometimes comes just before other faults but should be ignoredin those cases.

70

Steering Input Out of Range: There is an inappropriate voltage at the steering input ofthe ZAPI motor controller. The ZAPI may need to be “trained” for the three steeringvoltages (on Differential Steered machines). Or the steering voltage from the ECU wasat some point outside of the range that was recorded during the “training” session.Retrain the controller and/or check for fluctuating voltages due to lose wires, etc.

71 Motor Controller Main Contactor Fault: Check the connections to the main contactor.Replace the contactor if necessary. Replace the Motor Controller if necessary.

72Motor Controller Over Voltage Fault: Check battery voltage and make sure the batterycharger is not on. The cycle power to the lift. If that does not resolve the issue, tryreplacing the Motor Controller.

73Motor Controller Thermal Cutback Fault: Drive or Lift Motor may be overheating. Let thelift cool down. If that does not help cycle power to reset the Motor controller. If thatdoesn’t resolve the issue, replace the Motor Controller.

74 Motor Controller Motor Fault: Check connections to the motors. Cycle power to the liftand if that does not resolve the issue, replace the Motor Controller.

75 Motor Controller Pump Motor Fault: Check connections to the Pump Motor. Cyclepower to the lift and if that does not resolve the issue, replace the Motor Controller.



48

Display Description

76 Motor Controller Left Drive Motor Fault: Check connections to the motors. Cycle powerto the lift and if that does not resolve the issue, replace the Motor Controller.

77 Motor Controller Right Drive Motor Fault: Check connections to the motors. Cyclepower to the lift and if that does not resolve the issue, replace the Motor Controller.

78 Pump Motor Short Fault: Check connections to the pump motor. Cycle power to the liftand if that does not resolve the issue, replace the Motor Controller.

79 Left Drive Motor Short Fault: Check the Motor connections and make sure they aretight. Check the Motor for a short.

80 Over 80% Load Warning: Platform is getting close to its limit of weight. Consider notadding more load.

81 Right Drive Motor Short Fault: Check the Motor connections and make sure they aretight. Check the Motor for a short.

82 Left Brake Coil Fault: Check the connections to the Coil’s terminals and make sure theyare tight. If so, check the coil itself to see if it is open or shorted.

83 Right Brake Coil Fault: Check the connections to the Coil’s terminals and make surethey are tight. If so, check the coil itself to see if it is open or shorted.

84 Motor Post shorted: Check the connections of the controller and motor. Make sure thewiring is not shorted.

85 Brake Release Switch On: Check the wires to brake release switch or look for a stuckswitch.

86 Brake Release Not Stowed: Check if the platform is below down limit height. Check thedown limit switch and connections.

87 Brake Release Need Switch On: Check the wires to brake release switch or look for aStuck switch. Check the wires to the Toggle Switch or look for a stuck Toggle Switch.

89 Motor Field Open: The field voltage is different from 1/2 battery voltage. Checkconnections of the field wires or leakage to the vehicle frame.

90 Over 90% Load Warning: Platform is getting close to its limit of weight. Consider notadding more load.

91 Left Motor Field Short: Check connections of the field wires or leakage to the vehicleframe.

92 Right Motor Field Short: Check connections of the field wires or leakage to the vehicleframe.

99 Over 99% Load Warning: Platform has reached its limit of weight. Do not add moreload.

OL Overloaded Platform Fault: Remove the excess load immediately.

LLMachine Tilted Beyond Safe Limits Fault: If the machine is tilted, find a way to make itlevel. If the machine is level, check the wiring to the tilt sensor and then the sensoritself.

For more information, please consult the appropriate Dingli Service Dept.



49

Battery and Charger Instructions

Observe and Obey:√ Do not use an external charger or booster

battery.

√ Charge the battery in a well-ventilated area.

√ Use proper AC input voltage for chargingas indicated on the charger.

√ Use only a Dingli authorized battery andcharger.

To Charge Battery1 Be sure the batteries are connected before

charging.

2 Open the battery compartment. Thecompartment should remain open for theentire charging cycle.

Maintenance - free battery

3 Connect the battery charger to a groundedAC circuit.

4 The charger will indicate when the batteryis fully charged.

Standard Battery

5 Remove the battery vent caps and checkthe battery acid level. If necessary, addonly enough distilled water to cover theplates. Do not overfill prior to the chargecycle.

6 Replace the battery vent caps.

7 Connect the battery charger to a groundedAC circuit.

8 The charger will indicate when the batteryis fully charged.

9 Check the battery acid level when thecharging cycle is complete. Replenish withdistilled water to the bottom of the fill tube.Do not overfill.

Dry Battery Filling andCharging Instructions1 Remove the battery vent caps and

permanently remove the plastic seal fromthe battery vent openings.

2 Fill each cell with battery acid (electrolyte)until the level is sufficient to cover theplates.

Do not fill to maximum level until the batterycharge cycle is complete. Overfilling cancause the battery acid to overflow duringcharging. Neutralize battery acid spills withbaking soda and water.

3 Install the battery vent caps.

4 Charge the battery.

5 Check the battery acid level when thecharging cycle is complete. Replenish withdistilled water to the bottom of the fill tube.Do not overfill.


Transport and Lifting Instructions

50

Observe and Obey:√ Common sense and planning must be

applied to control the movement of themachine when lifting it with a crane orforklift.

√ Only qualified aerial lift operators shouldmove the machine on or off the truck.

√ 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 allow the rails to fall when the snappins are removed. Maintain a firm grasp onthe rails when the rails are lowered.

√ 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.

Brake Release OperationFor the Hydraulic Motor Drive Model

1 Chock the wheels to prevent the machinefrom rolling.

2 Be sure the winch line is properly securedto the drive chassis tie points and the pathis clear of all obstructions.

3 Push in the black brake release knob toopen the brake valve.

4 Pump the red brake release pump knob.

5 If you want to close the brake release, justpull out the black brake release knob.

For the DC Motor Drive Model

1 Chock the wheels to prevent the machinefrom rolling.


3 Move down and hold the platform up /down switch in ground control, meanwhileturn on the key switch to the "Ground"position. The brake will be released afterAlarm alerts.

4 If you want to close the brake release, justturn off the key switch in “ground” position.

Towing the Hydraulic Drive Model is notrecommended. If the machine must be towed,do not exceed 3.5 km/h.

Towing the DC Motor Drive Model is notrecommended. If the machine must be towed,do not exceed 4.0 km/h.



51

Securing to Truck or Trailer forTransitAlways chock the machine wheels inpreparation for transport.

Retract and secure the extension deck(s).

Turn the key switch to the off position andremove the key before transporting.

Inspect the entire machine for loose orunsecured items.

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.

If the railings have been folded down, securethem with straps before transporting.



52

Observe and Obey:√ Only qualified riggers should rig and lift the

machine.

√ Only qualified forklift operators should liftthe machine with a forklift.

√ Be sure the crane capacity, loadingsurfaces and straps or lines are sufficient towithstand the machine weight. See theserial plate for the machine weight.

Lifting the Machine with aForkliftBe sure the extension deck, controls andcomponent trays are secure. Remove all looseitems on the machine.

Fully lower the platform. The platform mustremain lowered during all loading andtransport procedures.

Use the forklift pockets located on both sidesof the ladder.

Position the forklift forks in position with theforklift pockets.

Drive forward to the full extent of the forks.

Raise the machine 15 cm and then tilt the forksback slightly to keep the machine secure.

Be sure the machine is level when loweringthe forks.

Lifting the machine from theside can result in component damage.



53

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

Model X Axis Y Axis

JCPT0808HDJCPT0808DC

90.5 cm 56.5cm


80.6cm 57.6cm


89cm 64.4cm


83cm 68.2cm


83cm 72.1cm

JCPT1612HDBJCPT1612DCB

98cm 70.5cm

JCPT1612HDSJCPT1612DCS

93.7cm 80.2cm


Maintenance

54

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 be requiredto 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

55

Pre-delivery Preparation ReportFundamentals

It is the responsibility of the dealer to performthe Pre-delivery Preparation.

The Pre-delivery Preparation is performedprior to each delivery. The inspection isdesigned to discover if anything is apparentlywrong with a machine before it is put intoservice.

A damaged or modified machine must neverbe used. If damage or any variation fromfactory delivered condition is discovered, themachine must be tagged and removed fromservice.

Repairs to the machine may only be made bya qualified service technician, according to themanufacturer’s specifications.

Scheduled maintenance inspections shall beperformed by qualified service technicians,according to the manufacturer’s specificationsand the requirements listed in this manual.

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists ofcompleting the Pre-operation Inspection, theMaintenance items and the Function Tests.

Use this form to record the results. Place acheck in the appropriate box after each part iscompleted. Follow the instructions in theoperator’s manual.

If any inspection receives an N, remove themachine from service, repair and re-inspect it.After repair, place a check in the R box.

LegendY = yes, completed

N = no, unable to complete

R = repaired

Comments

Pre-Delivery Preparation Y N R

Pre-operation inspectioncompletedMaintenance itemscompleted

Function tests completed

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company


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56

Maintenance Inspection Report

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions• Make copies of this report to use for eachinspection.

• Select the appropriate checklist(s) for thetype of 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.

LegendY = yes, acceptableN = no, remove from serviceR = 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 tests

Perform after 40 hours:

A-6 30 day service

Perform every 100 hours:

A-7 Grease steer yokes

Checklist B Y N RB-1 Batteries

B-2 Electrical wiring

B-3 Tires and wheels

B-4 Emergency stop

B-5 Key switch

B-6 Horn (if equipped)

B-7 Drive brakes

B-8 Drive speed - stowed

B-9 Drive speed - raised

B-10 Drive speed - slow

B-11 Hydraulic oil analysis

B-12 Tank venting system

B-13 Latch componentsB-14 Test the down limit switch, thepothole limit switches and the levelSensorB-15 Test the up limit switches

Checklist C Y N RC-1 Platform overload (if equipped)C-2 Breather cap - models withoptional oil

Checklist D Y N RD-1 Scissor arm wear pads

D-2 Hydraulic filter

Checklist E Y N RE-1 Hydraulic oil


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57

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 legibleand in 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 machinery if replacementmanuals or decals are needed.


Maintenance

58

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 goodmachine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in component damageand hazardous conditions.

Electrocution hazard.Contact with hot or live circuits may result indeath or serious injury. Remove all rings,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 tight and free of corrosion.

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 the bottomof the battery fill tube. Do not overfill.

6 Install the vent caps.


Maintenance

59

A-4

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 procedurewith the platform in the stowed position.

1 Visually inspect the sight of hydraulic oillevel from the side of the hydraulic oil tank.

⊙ Result: The hydraulic oil level should be atthe mark of the fuel tank. (Refer to thefollowing table).

Model Scale line（L）

JCPT0808HD/DCJCPT1008HD/DCJCPT1012HD/DC

15

JCPT1212HD/DCJCPT1412HD/DC

17.5

JCPT1612HDB/DCBJCPT1612HDS/DCS

19

2 Add oil if necessary. Do not overfill.

Original Hydraulic oilspecifications：L-HV46

Customers shall choose the appropriatehydraulic oil according to the ambienttemperature used.

Example: L-HV32 or L-HV68

A-5

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.


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60

A-6

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.

Perform the following maintenanceprocedures:

• B-3 Inspect the Tires, Wheels and CastleNut Torque

• D-2 Replace the Hydraulic Tank ReturnFilter Element

A-7

Grease the Steer Yokes

DINGLI requires that this procedure beperformed every 100 hours of operation.

Regular application of lubrication to the steeryokes is essential to good machineperformance and service life. Continued use ofan insufficiently greased steer yoke will resultin component damage.

1 Open the steer yoke cover.

2 Locate the grease add hole on the top ofthe steer yoke.

3 Pump multipurpose grease into the steeryoke until the steer yoke is full and greaseis being forced past the bearings.

4 Install the cover.

5 Repeat this step for the other steer yoke.

Grease Specification

Chevron Ultra-duty grease, EP NLGI 1 (lithiumbased) or equivalent


Maintenance

61

Checklist B ProceduresB-1

Inspect 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 Release the battery pack latch and rotatethe battery pack out and away from thechassis.

3 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.

4 Be sure that the battery retainers andcable connections are tight.

5 Fully charge the batteries. Allow thebatteries to rest 24 hours beforeperforming this procedure to allow thebattery cells to equalize.

Models without maintenance-free or sealedbatteries:

6 Remove the battery vent caps and checkthe specific gravity of each battery cell witha hydrometer. Note the results.

7 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 11.

¤ Result: One or more battery cells display aspecific gravity of 1.217 or below. Proceedto step 8.

8 Perform an equalizing charge OR fullycharge the batteries and allow thebatteries to rest at least 6 hours.

9 Remove the battery vent caps and checkthe specific gravity of each battery cell witha hydrometer. Note the results.

10 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 is


Maintenance

62

fully charged. Proceed to step 11.

¤ Result: The difference in specific gravityreadings between cells is greater than 0.1OR the specific gravity of one or more cellsis less than 1.177. Replace the battery.

11 Check the battery acid level. If needed,replenish with distilled water to 3 mmbelow the bottom of the battery fill tube. Donot overfill.

12 Install the vent caps and neutralize anyelectrolyte that may have spilled.

a batteriesb 250A fusec quick disconnectd battery charger

All models:

13 Check each battery pack and verify thatthe batteries are wired correctly.

14 Inspect the battery charger plug and pigtailfor damage or excessive insulation wear.Replace as required.

15 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.


Maintenance

63

B-2

Inspect the Electrical Wiring


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

3 Turn the key switch to ground control. Turnthe ground red Emergency Stop buttonclockwise to the on position. Pull out theplatform red Emergency Stop button to theon position.

4 Raise the platform until the distance of thetwo sets of scissor at least 0.5m.




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

• ECU to platform controls

• Power to platform wiring

10 Inspect for a liberal coating of dielectricgrease in the following locations:

• Between the ECU and platform controls

• All wire harness connectors Level sensor

11 Raise the platform and return the safetyarm to the stowed position.

12 Lower the platform to the stowed positionand turn the machine off.


Maintenance

64

B-3

Inspect the Tires and Wheels(including castle nut torque)


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 the tire surface and sidewalls forcuts, cracks, punctures and unusual wear.

2 Check each wheel for damage, bends andcracks.

For HD model machine

3 Remove the cotter pin and check eachcastle nut for proper torque.

Note: Always replace the cotter pin with a newone when removing the castle nut or whenchecking the torque of the castle nut.

4 Install a new cotter pin. Bend the cotter pinto lock it in place.

Castle nut torque, dry 406.7Nm

Castle nut torque, lubricated 305Nm

For DC model machine

3 Check each bolt for proper torque.

Bolt torque, dry 88Nm

Bolt torque, lubricated 66Nm

B-4

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.


2 Push in the red Emergency Stop button atthe ground controls to the off position.

⊙ Result: No machine functions shouldoperate.

3 Turn the key switch to platform control.Turn the ground red Emergency Stopbutton clockwise to the on position. Pullout the platform red Emergency Stopbutton to the on position.

4 Push in the red Emergency Stop button atthe platform controls to the off position.

⊙ Result: No machine functions shouldoperate.

Note: The red Emergency Stop button at theground controls will stop all machine operation,even if the key switch is switched to platformcontrol.


Maintenance

65

B-5

Test the Key Switch


Proper key switch action and response isessential to safe machine operation. Themachine can be operated from the ground orplatform controls and the activation of one orthe other is accomplished with the key switch.Failure of the key switch to activate theappropriate control panel could cause ahazardous operating situation.

Perform this procedure from the ground usingthe platform controls. Do not stand in theplatform.



3 Check the platform up/down function fromthe ground controls.

⊙ Result: The machine functions should notoperate.


5 Check the machine functions from theplatform controls.

⊙ Result: The machine functions should notoperate.

6 Turn the key switch to the off position.

⊙ Result: No function should operate.

B-6

Test the Automotive-style Horn (ifequipped)


The horn is activated at the platform controlsand sounds at the ground as a warning toground personnel. An improperly functioninghorn will prevent the operator from alertingground personnel of hazards or unsafeconditions.


2 Push down the horn button at the platformcontrols.

⊙ Result: The horn should sound.


Maintenance

66

B-7

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 not fullyoperational.

Perform this procedure with the machine on afirm level surface that is free of obstructions,with the platform extension deck fully retractedand the platform in the stowed position.

1 Mark a test line on the ground forreference.


3 Lower the platform to the stowed position.


a

a drive function select button

5 Choose a point on the machine; i.e.,contact patch of a tire, as a visualreference for use when crossing the testline.

6 Bring the machine to top drive speedbefore reaching the test line. Release thefunction enable switch or the joystick whenyour reference point on the machinecrosses the test line.

7 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.

8 Replace the brakes and repeat thisprocedure beginning with step 1.

Braking distance, maximum

High range on paved surface 61cm±30cm


Maintenance

67

B-8

Test the Drive Speed - StowedPosition


Proper drive functions are essential to safemachine operation. The drive function shouldrespond quickly and smoothly to operatorcontrol. Drive performance should also be freeof hesitation, jerking and unusual noise overthe entire proportionally controlled speedrange.

Perform this procedure with the machine on afirm, level surface that is free of obstructions.

1 Create start and finish lines by markingtwo lines on the ground 12.2 m apart.




a

a drive function select button

5 Choose a point on the machine; i.e.,contact patch of a tire, as a visualreference for use when crossing the startand finish lines.

6 Bring the machine to top drive speedbefore reaching the start line. Begin timingwhen your reference point on the machinecrosses the start line.

7 Continue at full speed and note the timewhen your reference point on the machinepasses over the finish line. Refer tospecifications.


Maintenance

68

B-9

Test the Drive Speed - RaisedPosition







a b

a lift function select buttonb drive function select button

4 Press and hold the function enable switchon the joystick.

5 Raise the platform approximately 2 m fromthe ground.




9 Continue at full speed and note the timewhen your reference point on the machinepasses over the finish line. Refer tospecifications.


Maintenance

69

B-10

Test the Slow Drive Speed







4 Press the slow speed select button.

a

a slow speed select button



7 Continue at full speed and note the timewhen your reference point on the machinepasses over the finish line. The time is lessthan 25 sec.


Maintenance

70

B-11

Perform Hydraulic Oil Analysis


Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil may cause the machine toperform poorly and continued use may causecomponent damage. Extremely dirtyconditions may require oil changes to beperformed more often.

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 replaced at the twoyear inspection, test the oil quarterly. Replacethe oil when it fails the test. See E-1, Test orReplace the Hydraulic Oil.

B-12

Inspect the Hydraulic Tank CapVenting System

DINGLI requires that this procedure beperformed quarterly or every 250 hours,whichever comes first. Perform this proceduremore often if dusty conditions exist.

A free-breathing hydraulic tank cap is essentialfor good machine performance and service life.A dirty or clogged cap may cause the machineto perform poorly. Extremely dirty conditionsmay require that the cap be inspected moreoften.

1 Remove the breather cap from thehydraulic tank.

2 Check for proper venting.

⊙ Result: Air passes through the breather cap.

¤ Result: If air does not pass through the cap,clean or replace the cap. Proceed to step3.

Note: When checking for positive tank capventing, air should pass freely through the cap.

3 Using a mild solvent, carefully wash thecap venting system. Dry using lowpressure compressed air. Repeat step 2.

4 Install the breather cap onto the hydraulictank.


Maintenance

71

B-13

Check the Module Tray LatchComponents


Maintaining the module tray latch componentsin good condition is essential to goodperformance and service life. Failure to detectworn out latch components may result inmodule trays opening unexpectedly, creatingan unsafe operating condition.

1 Inspect each module tray rotary latch andrelated components for wear. Tighten anyloose fasteners.

2 Lubricate each module tray rotary latch.Using light oil, apply a few drops to each ofthe springs and to the sides of the rotarylatch mechanism.

B-14

Test the Down Limit Switch, thePothole Limit Switches and the LevelSensor


Maintaining the limit switches is essential tosafe operation and good machineperformance. Operating the machine with afaulty limit switch could result in reducedmachine performance and a potentially unsafeoperating condition.

Perform these procedures with the machine ona firm, level surface that is free of obstructions.

Down Limit Switch

1 Remove the platform controls from theplatform.







7 Tag and disconnect the platform controlbox at the platform.


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72

8 Follow the platform control cable down thescissor stack to the underside of thechassis deck. Tag and disconnect theplatform cable from the ECU cable at the6-pin Deutsch connector under the chassisdeck.

9 Securely install the platform control boxharness plug into the 6-pin Deutschconnector of the ECU cable.

10 Open the down limit switch cover, tag anddisconnect the wires of the down limitswitch wire harness.



13 Working at the platform controls, press thelift function select button. Lower theplatform to the stowed position.

⊙ Result: The LED readout screen will showcode 18, an alarm sounds and the liftfunction should operate. The machine isfunctioning properly.

¤ Result: The LED readout screen does notshow code 18, the alarm does not soundand the lift function should not operate.Replace the down limit switch.

14 Press the drive function select button.Attempt to drive the machine.

⊙ Result: The LED readout screen will showcode 18, an alarm sounds, and the steerand drive functions should not operate. Themachine is functioning properly.

¤ Result: The LED readout screen does notshow code 18, the alarm does not sound,and the steer and drive functions operate.Replace the down limit switch.

15 Press the lift function select button. Raisethe platform approximately 0.3 m.

⊙ Result: The LED readout screen will show

code 18 and an alarm sounds. Themachine is functioning properly.

¤ Result: The LED readout screen does notshow code 18 and the alarm does notsound. Replace the down limit switch.

16 Raise the platform until the pothole guardsare deployed.

⊙ Result: The LED readout screen does notshow code 18 and the alarm does notsound. The machine is functioningproperly.

¤ Result: The LED readout screen showscode 18 and an alarm sounds. Replace thedown limit switch.







22 Disconnect the platform controls from theECU cable.

23 Securely install the connector of the ECUcable into the platform control cable.

24 Working at the platform, securely installthe connector of the platform controls intothe platform control cable.

25 Securely connect the two wires of the


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73

down limit switch to wire harness.

26 Close and install the switch cover.




Level sensor

30 Move the machine onto a grade whichexceeds the rating of the level sensor.Refer to the serial label on the machine.

31 Press the lift function select button.Standing on the up-hill side of the machine,attempt to raise the platform toapproximately 2.4 m.

⊙ Result: The LED readout screen showscode LL, an alarm sounds, and themachine stops lifting after the potholeguards are deployed. The machine isfunctioning properly.

¤ Result: The LED readout screen does notshow code LL, the alarm does not soundand the machine will continue to lift theplatform after the pothole guards aredeployed. Adjust or replace the levelsensor.

32 Press the drive function select button.Standing on the up-hill side of the machine,attempt to steer and drive the machine.

⊙ Result: The LED readout screen showscode LL, an alarm sounds, and themachine will not steer or drive. Themachine is functioning properly.

¤ Result: The LED readout screen does notshow code LL, the alarm does not soundand the steer and drive functions operate.Adjust or replace the level sensor.

Pothole Limit Switches


Move the machine onto a firm, levelsurface.

34 Place a wooden block approximately 5 cmtall under the right pothole guard.

35 Press the lift function select button.Attempt to raise the platformapproximately 2.4m.

⊙ Result: The pothole guard contacts theblock and does not fully deploy, the LEDreadout screen shows code 18, an alarmsounds and the platform will lift to 2.4m orbeyond. The machine is functioningproperly.

¤ Result: The pothole guard contacts theblock and does not fully deploy, the LEDreadout screen does not show code 18, thealarm does not sound and the machine willcontinue to lift the platform after the potholeguards are deployed. Adjust or replace thepothole limit switch.

36 Press the drive function select button.Attempt to steer or drive the machine.

⊙ Result: The LED readout screen showscode 18, an alarm sounds, and themachine will not steer or drive. Themachine is functioning properly.

¤ Result: The LED readout screen does notshow code 18, the alarm does not soundand the steer and drive functions operate.Adjust or replace the down limit switch.

37 Lower the platform to the stowed positionand remove the block under the rightpothole guard.

38 Repeat this procedure beginning with step34 for the left pothole guard.

39 Lower the platform to the stowed position,remove the block under the left potholeguard.

40 Turn off the machine.


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74

B-15

Test the Up Limit Switch


Maintaining the limit switches is essential tosafe operation and good machineperformance.

Operating the machine with a faulty limit switchcould result in reduced machine performanceand a potentially unsafe operating condition.

Perform these procedures with the machine ona firm, level surface that is free of obstructions.






5 Open the limited switch house cover fromthe chassis.

6 While raising the platform from the groundcontrols, push in the roller of the up limitswitch to activate the limit switch.

⊙ Result: The platform stops raising. Themachine is functioning properly.

¤ Result: The platform continues to raise.Adjust or replace the up limit switch.

7 Install the limited switch house cover tochassis.

8 Put the safe arm to home position.



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75

Checklist C ProceduresC-1

Test the Platform Overload System (ifequipped)

DINGLI requires that this procedure beperformed every 500 hours or six months,whichever comes first or when the machinefails to lift the maximum rated load.

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.

The platform overload system is designed toprevent machine operation in the event theplatform is overloaded. Models equipped withthe platform overload option are provided withtwo additional machine control components:the overload pressure sensor and anglesensor.

The overload pressure sensor, which isadjustable and located at the barrel-end of thelift cylinder, is used to determine when thehydraulic lift cylinder requires too muchpressure to support the load inside theplatform. When this occurs, the overloadpressure sensor will send a signal to the ECU,which will not allow the machine to functionuntil the extra weight is removed from theplatform.

The angle sensor, located in the inner scissorarm 1, is used to determine the tilt of scissor,than to measure the height of platform.

a overload pressure sensor

b angle sensor

c limited switch cover







Maintenance

76

5 Open the limited switch house cover fromthe chassis.

6 Open the up limited switch cover.

a

bc

a up limited switchb down limited switchc slope sensor

7 Tag and disconnect the wires of the uplimit switch wire harness.

8 Securely connect together the terminals ofthe two wires of the up limit switch.


10 Raise the platform to release the safe arm.Put the safe arm to home position.

11 Fully raise the platform. Release the toggleswitch.

⊙ Result: The alarm should sound.

¤ Result: The alarm does not sound.Calibrate the platform overload system.

12 Using the emergency lowering knob, lowerthe platform to the stowed position.

13 Securely connect the wires of the up limitswitch.

14 Fully raise the platform. Release the toggleswitch.

⊙ Result: The alarm should not sound. Thesystem is functioning correctly.

¤ Result: The alarm sounds. The system isnot functioning correctly. Troubleshoot thelimit switch, limit switch wire harness or

limit switch mount bracket or the platformoverload system needs to be calibrated.

15 Lower the platform until the distance of thetwo sets of scissor at least 0.5m.



18 Lower the platform until the safety armrests securely on the link. Keep clear ofthe safety arm when lowering the platform

Crushing hazard. Keep handsclear of the safety arm when lowering theplatform.

19 Install the up limited switch cover.

20 Install the limited switch house cover.

21 Raise the platform to release the safe arm.

22 Put the safe arm to home position.



Maintenance

77

C-2

Replace the Hydraulic Tank BreatherCap

DINGLI requires that this procedure beperformed every 500 hours or semi-annually,whichever comes first.

The hydraulic tank is a vented-type tank. Thebreather cap has an internal air filter that canbecome clogged or, over time, can deteriorate.If the breather cap is faulty or improperlyinstalled, impurities can enter the hydraulicsystem which may cause component damage.Extremely dirty conditions may require that thecap be inspected more often.

1 Remove and discard the hydraulic tankbreather cap.

2 Install a new cap onto the tank.


Maintenance

78

Checklist D ProceduresD-1

Check the Scissor Arm Wear Pads

DINGLI requires that this procedure beperformed every 1000 hours or annually,whichever comes first.

Maintaining the condition of the scissor armwear pads is essential to safe machineoperation. Continued use of worn out wearpads may result in component damage andunsafe operating conditions.

Perform this procedure with the platform in thestowed position.

1 Measure the distance between the numberone arm cross tube and the chassis deckat the ground controls side of the non-steerend of the machine.

⊙ Result: The measurement is 34mm or more.Proceed to step 2.

¤ Result: The measurement is less than34mm. Replace both wear pads.

a wear padb arm cross tubec chassis deck

2 Measure the distance between the numberone arm cross tube and the chassis deckat the battery pack side of the non-steerend of the machine.

⊙ Result: The measurement is 34mm or more.Proceed to step 3.

¤ Result: The measurement is less than 34mm. Replace both wear pads.

3 Apply a thin layer of dry film lubricant to thearea of the chassis where the scissor armwear pads make contact.


Maintenance

79

D-2

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.

The hydraulic tank returnfilter is mounted on the bracket between thefunction manifold and the hydraulic power unit.

1 Clean the area around the oil filter.Remove the filter with an oil filter wrench.

2 Apply a thin layer of oil to the new oil filtergasket.

3 Install the new filter and tighten it securelyby hand.

4 Use a permanent ink marker to write thedate and number of hours from the hourmeter onto the filter.


6 Activate and hold the platform up toggleswitch.

7 Inspect the filter and related componentsto be sure that there are no leaks.

8 Clean up any oil that may have spilled.


Maintenance

80

Checklist E ProcedureE-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 may cause the machine toperform poorly and continued use may causecomponent damage. Extremely dirtyconditions may require oil changes to beperformed more often.

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 replaced at the twoyear inspection, test the oil quarterly. Replacethe oil when it fails the test.

Note: Perform this procedure with the platformin the stowed position.

1 Disconnect the battery pack from themachine.

Electrocution / burn hazard:Contact with electrically charged circuits couldresult in death or serious injury. Remove allrings, watches and other jewelry.

2 Open the power unit module tray.

3 Remove the oil drain plug at bottom.

4 Drain all of the oil into a suitable container.

5 Tag and disconnect the hydraulic tankreturn line from the hydraulic filter headand remove the line from the tank. Cap thefitting on the filter head.

6 Tag and disconnect the hydraulic pumpinlet line and remove the line from the tank.Cap the fitting on the pump.

7 Remove the hydraulic tank retainingfasteners and remove the hydraulic tankfrom the machine.

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.

8 Clean up any oil that may have spilled.Properly discard the used oil.

9 Clean the inside of the hydraulic tank usinga mild solvent. Allow the tank to drycompletely.

10 Install a new filter onto the tank.

11 Tighten the drain plug. Torque tospecification.

Torque specifications

Hydraulic tank drain plug, dry 4.5Nm

Hydraulic tank drain plug, lubricated 3.4Nm

12 Install the hydraulic tank and install andtighten the hydraulic tank retainingfasteners. Torque to specification.

Torque specifications

Hydraulic tank retaining fasteners, dry 4Nm

Hydraulic tank drain plug, lubricated 2.9Nm


Maintenance

81

13 Install the hydraulic pump inlet line into thetank. Install the fitting onto the pump andtorque.

14 Install the hydraulic pump return line intothe tank. Install the fitting onto thehydraulic filter head and torque.

15 Fill the tank with hydraulic oil until the fluidis full in the hydraulic tank. Do not overfill.

16 Activate the pump to fill the hydraulicsystem with oil and bleed the system of air.

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.


Schematic

82

Hydraulic SchematicJCPT0808HD JCPT1008HD JCPT1012HD

SV2

1mm 1mm

S1 S2

P

M

T BRK

RV1

SV1

FR

RV4

CV2

RV3

CV1 1.1mm

SV4

SV3

D3

D2

D1

D4

L

P41

P42

CV2

1.5mm Lower valveNBCY-1001A-11

235bar

3.45bar

Tank

Pump5802-4-12

Valve 5805-0116R

Hand pump5805-0412(960020A10)

Platform loading（Option）

Steer cylinder

Lift cylinder

120bar

RV2=130bar(JCPT0808HD)RV2=160bar(JCPT1008HD)RV2=210bar(JCPT1012HD)


Schematic

83

JCPT1212HD JCPT1412HD

SV2

1mm 1mm

S1 S2

P

M

T BRK

RV1

SV1

FR

RV4

CV2

RV3

CV1 1.1mm

SV4

SV3

D3

D2

D1

D4

L

P41

P42

RV5

CV2

0.9mm

1.5mmLower valveNBCY-1001A-11

Lower valveNBCY-1001B-11

120bar

235bar

3.45bar

RV2=150bar（JCPT1212HD）RV2=190bar（JCPT1412HD）

180bar

Pump5802-4-12

Valve 5805-0116R

Tank

Platform loading(Option)

Steer cylinder

Lift cylinder Upper lift cylinder

Hand pump5805-0412(960020A10)


Schematic

84

JCPT1612HDB JCPT1612HDS

SV2

1mm 1mm

S1 S2

P

M

T BRK

RV1

SV1

FR

RV4

CV2

RV3

CV1 1.1mm

SV4

SV3

D3

D2

D1

D4

L

P41

P42

RV5

CV2

0.6mm



120bar

235bar

3.45bar

Pump5802-4-12

Valve 5805-0116R

Tank

Platform loading(Option)

Steer cylinder

Lift cylinder Upper lift cylinder

Hand pump5805-0412(960020A10)

180bar

RV2

220bar


Schematic

85

JCPT0808DC JCPT1008DC JCPT1012DC

Lift cylinder


Steer cylinder

P

M SV2

FRRV1

SV1

S1 S2 L

T

Tank

Pump5802-3.2-14

Function valve DPH-0918-10

1mm 1mm


120bar

RV1=130bar(JCPT0808DC)RV1=160bar(JCPT1008DC)RV1=210bar(JCPT1012DC)


Schematic

86

JCPT1212DC JCPT1412DC


1mm 1mm

1.5mm

0.9mm

120bar


Steer cylinder

Lift cylinder

Upper liftcylinder

Tank

Pump5802-4-12

P

M SV2

FRRV1

SV1

S1 S2 L

T

Lower valveNBCY-1001A-11


RV1=150bar(JCPT1212DC)RV1=190bar(JCPT1412DC)


Schematic

87

JCPT1612DCB JCPT1612DCS


Steer cylinder

Lift cylinder

Upper liftcylinder

Tank

Pump5802-4-12


1mm 1mm

1.0mm

0.6mm

120bar

Lower valveNBCY-1001A-11


RV1

220bar

P

M SV2

FRRV1

SV1

S1 S2 L

T


Schematic

88

Electrical SchematicJCPT0808HD JCPT1008HD JCPT1012HD JCPT1212HD

+ - B

COM K

110-

220V

AC

Inpu

t

Cha

rger

L N PE

+-

S C

010A

-7 B

U/R

D(1

6)

010-

5 R

D/B

U(1

6)

J K

010A

-1 G

N/W

H(1

6)

010B

BU

/RD

(16)

1C G

N/R

D(1

6)

1B G

N/Y

E(16

)

GN

D-1

BK(

16)

4 3 5 2 1

GN

(18)

RD

(18)

BU

(18)

YE(

18)

WH

(18)

4 3 5 2 1

010A-6 BU/RD(16)

2B G

N/R

D(1

8)1A

WH

(18)

5A-2

RD

(18)

010A

-2 R

D(1

8)01

0A-3

RD

(18)

010A

-4 R

D(1

8)01

0A-5

RD

(18)

B+

VT/

YE(1

6)

B S F A B C D

2B G

N/R

D(1

8)1A

WH

(18)

2C R

D(1

6)4A

RD

(16)

5A-1

RD

(16)

010A

-4 R

D(2

0)01

0A-5

RD

(20)

010A

BN

/RD

(16)

010A

-2 Y

E(1

6)

010A

-12

RD

(20)

010A

-13

RD

(20)

010A

-10

RD

(20)

SQ

5S

Q6

SQ

7S

Q8

SQ

1

SQ

2

SQ

3S

Q4

010A

-1 B

N/W

H(1

6)

010A

-11

RD

(18)

RD

(22)

RD

(22)

B-3

BK(

20)

B-2

BK(

20)

GN

D-1

BK(

16)

GN

D B

K(14

)

010A

-14

RD

(20)

9B W

H/B

K(16

)

12C

GN

/BU

(18)

11B

BU

/RD

(18)

10B

WH

/BU

(16)

12B

BN

/WH

(18)

12A

BN

/GY

(18)

11C

GN

/VT(

18)

4B W

H/V

T(18

)

3C G

N/Y

E(18

)

3C G

N/R

D(1

8)

6B W

H/B

U(1

8)

3A B

N/Y

E(18

)

F J E D E H G L K M L

12B

BN

/WH

(16)

12A

BN

/GY

(16)

11C

GN

/VT(

18)

HL1

B-1

WH

(20)

10B

-2 W

H/B

U(2

0)

11B

WH

(20)

12C

GN

(20)

WH

+GN

(22)

WH

+GN

(22)

BK(

22) BU

(20)

RD

(20)

3A B

N(1

8)

SA2

GN

D-2

BK(

16)

GN

D-3

BK(

16)

BU

(20)

B B

K(20

)B

K(22

)

M N N P RG

ND

-9 B

K(18

)G

ND

-8 B

K(18

)G

ND

-7 B

K(18

)G

ND

-2 B

K(16

)

3B B

N/B

K(18

)

7C W

H/B

U(1

6)

7B W

H/B

U(1

6)

6A V

T/YE

(16)

7A B

N/W

H(1

6)

6C B

N/G

Y(16

)

8C W

H/V

T(16

)

8B B

N/R

D(1

6)

8A-1

BN

/GN

(16)

9A B

N/B

K(16

)

1B G

N/Y

E(16

)

1C G

N/R

D(1

6)2B 1A 2C 4A 5A 9B 12

C

11B

10B

12B

12A

11C

4B 11A

3C 6B 3A

1C 1B 9A 8A 8B 8C 6C 7A 6A 7B 7C 3B

GN

D-1

3 BK

(16)

GN

D-1

2 BK

(16)

GN

D-1

1 BK

(16)

GN

D-5

BK(

16)

GN

D-4

BK(

16)

GN

D-3

BK(

16)

GN

D-6

BK(

16)

B- B

K(1

4)

B1 YV7

YV5

YV6

YV1

YV3

YV4

8A-2

BN

/GN

(16)

8A-3

BN

/GN

(16)

JS1

SB4

S2

SB5

SB6

SB7

SB8

B3

CAN

_H

CAN

_L

SB3

PC

U

EC

U

21

B2

12

3

12

3

CA

B

TILT

AS1

LS1

SA2

YV2

HL2

YV8

BK(

2)

BK(

2)

RD

(2)

HM

B+

J1J3

M-

B-

21

MC

1M

1

GND-10 BK(16)

RD(2)

GND-1 BK(16)

RD

(2)

BK(

2)

K F 2

=16

Pos

ition

DE

LPH

I Con

nect

or L

OC

24

=16

Pos

ition

DE

LPH

I Con

nect

or L

OC

3

=2 P

ositi

on A

MP

Con

nect

or L

OC

4

=5 P

ositi

on S

IBAS

Con

nect

or L

OC

7

NO

TE:A

LL W

IRE

S A

RE

18A

WG

OR

0.8

mm

2 UN

LESS

NO

TED

OTH

ERW

ISE

SB2

Gro

und

E-S

TOP

010-

1 B

U/R

D(1

6)

010-1 BU/RD(16)

010 BN/GN(16)

SA1

GB2

GB1

GB3

GB4

010-3 RD(14)

010-2 RD/BU(16)

010-5 RD/BU(16)

010-4 YE(14)

010-3 RD(14)

010A-2 YE(16)

001 RD(14) 001 RD(14)FU2 7A

FU1 300A

A

KA1

SB1

Pow

erS

witc

h

RD(2)

BK(2)Bat

teryK

ey S

witc

h

Rel

ay

Bea

con

Up

Dow

n Tilt

Sen

sor Ang

le S

enso

r Pre

ssur

e Se

nsor

Lift

Dow

n V

alve

Lift

Dow

n V

alve

Ove

rload

Indi

cato

r

Left

Poth

ole

Switc

hR

ight

Pot

hole

Sw

itch

Lift

Up

Lim

it Sw

itch

Lift

Dow

n Li

mit

Switc

h

Foot

Sw

itch(

optio

n)

Buz

zer

Tem

pera

ture

sen

sor

mod

ule

(opt

iona

l)

Pla

tform

Ccn

trol M

odul

e

Joys

tick

Driv

e Jo

ystic

kD

eadm

anS

teer

Lef

tS

teer

Rig

ht

Lift

Enab

le

Driv

e E

nabl

e

Low

Spe

ed

Hor

n Sw

itch

Pla

tform

E-S

TOP

Buz

zer

Low

Spe

ed In

dica

tor

Driv

e In

dica

tor

Lift

Indi

cato

r

LED H

orn

Low

Spe

ed V

alve

Forw

ard

Val

ve

Rev

erse

Val

ve

Lift

Up

Valv

e

Ste

er L

eft V

alve

Ste

er R

ight

Val

ve

Hou

rmet

er

Pum

p M

otor

LED

Ant

i-col

lisio

n Sw

itch

(Opt

ion)


Schematic

89

JCPT1412HD JCPT1612HDB JCPT1612HDS

+ - B

COM K

110-

220V

AC

Inpu

t

Cha

rger

L N PE

+-

S C

010A

-7 B

U/R

D(1

6)

010-

5 R

D/B

U(1

6)

J K

010A

-1 G

N/W

H(1

6)

010B

BU

/RD

(16)

1C G

N/R

D(1

6)

1B G

N/Y

E(1

6)

GN

D-1

BK

(16)

4 3 5 2 1

GN

(18)

RD

(18)

BU

(18)

YE

(18)

WH

(18)

4 3 5 2 1

010A-6 BU/RD(16)

2B G

N/R

D(1

8)1A

WH

(18)

5A-2

RD

(18)

010A

-2 R

D(1

8)01

0A-3

RD

(18)

010A

-4 R

D(1

8)01

0A-5

RD

(18)

B+

VT/

YE

(16)

B S F A B C D

2B G

N/R

D(1

8)1A

WH

(18)

2C R

D(1

6)4A

RD

(16)

5A-1

RD

(16)

010A

-4 R

D(2

0)01

0A-5

RD

(20)

010A

BN

/RD

(16)

010A

-2 Y

E(1

6)

010A

-12

RD

(20)

010A

-13

RD

(20)

010A

-10

RD

(20)

SQ

5S

Q6

SQ

7S

Q8

SQ

1

SQ

2

SQ

3S

Q4

010A

-1 B

N/W

H(1

6)

010A

-11

RD

(18)

RD

(22)

RD

(22)

B-3

BK

(20)

B-2

BK

(20)

GN

D-1

BK

(16)

GN

D B

K(1

4)

010A

-14

RD

(20)

9B W

H/B

K(1

6)

12C

GN

/BU

(18)

11B

BU

/RD

(18)

10B

WH

/BU

(16)

12B

BN

/WH

(18)

12A

BN

/GY

(18)

11C

GN

/VT(

18)

4B W

H/V

T(18

)

3C G

N/Y

E(1

8)

3C G

N/R

D(1

8)

6B W

H/B

U(1

8)

3A B

N/Y

E(1

8)

F J E D E H G L K M L

12B

BN

/WH

(16)

12A

BN

/GY

(16)

11C

GN

/VT(

18)

HL1

B-1

WH

(20)

10B

-2 W

H/B

U(2

0)

11B

WH

(20)

12C

GN

(20)

WH

+GN

(22)

WH

+GN

(22)

BK

(22) B

U(2

0)R

D(2

0)

3A B

N(1

8)

SA

2

GN

D-2

BK

(16)

GN

D-3

BK

(16)

BU

(20)

B B

K(2

0)B

K(2

2)

M N N P RG

ND

-9 B

K(1

8)G

ND

-8 B

K(1

8)G

ND

-7 B

K(1

8)G

ND

-2 B

K(1

6)

3B B

N/B

K(1

8)

7C W

H/B

U(1

6)

7B W

H/B

U(1

6)

6A V

T/Y

E(1

6)

7A B

N/W

H(1

6)

6C B

N/G

Y(1

6)

8C W

H/V

T(16

)

8B B

N/R

D(1

6)

8A-1

BN

/GN

(16)

9A B

N/B

K(1

6)

1B G

N/Y

E(1

6)

1C G

N/R

D(1

6)2B 1A 2C 4A 5A 9B 12

C

11B

10B

12B

12A

11C

4B 11A

3C 6B 3A

1C 1B 9A 8A 8B 8C 6C 7A 6A 7B 7C 3B

GN

D-1

3 B

K(1

6)

GN

D-1

2 B

K(1

6)

GN

D-1

1 B

K(1

6)

GN

D-5

BK

(16)

GN

D-4

BK

(16)

GN

D-3

BK

(16)

GN

D-6

BK

(16)

B- B

K(1

4)

B1 YV

7

YV

5

YV

6

YV

1

YV

3

YV

4

8A-2

BN

/GN

(16)

8A-3

BN

/GN

(16)

JS1

SB

4

S2

SB

5

SB

6

SB

7

SB

8

B3

CA

N_H

CA

N_L

SB

3P

CU

EC

U

21

B2

12

3

12

3

CA

B

TILT

AS

1

LS1

SA

2

YV

2

HL2

YV

8

BK

(2)

BK

(2)

RD

(2)

HM

B+

J1J3

M-

B-

21

MC

1M

1

GND-10 BK(16)

RD(2)

GND-1 BK(16)

RD

(2)

BK

(2)

K F 2

=16

Pos

ition

DE

LPH

I Con

nect

or L

OC

24

=16

Pos

ition

DE

LPH

I Con

nect

or L

OC

3

=2 P

ositi

on A

MP

Con

nect

or L

OC

4

=5 P

ositi

on S

IBA

S C

onne

ctor

LO

C7

NO

TE:A

LL W

IRE

S A

RE

18A

WG

OR

0.8

mm

2 UN

LES

S N

OTE

D O

THE

RW

ISE

SB

2G

roun

dE

-STO

P

010-

1 B

U/R

D(1

6)

010-1 BU/RD(16)010 BN/GN(16)

SA

1

010-3 RD(14)

010-2 RD/BU(16)

010-5 RD/BU(16)

010-4 YE(14)

010-3 RD(14)

010A-2 YE(16)

001 RD(14) 001 RD(14)FU2 7A

FU1 300A

A

KA

1

SB

1P

ower

Sw

itch

RD(2)

BK(2)Bat

tery

Key

Sw

itch

Rel

ay

Bea

con

Up

Dow

n Tilt

Sen

sor

Ang

le S

enso

r Pre

ssur

e S

enso

r

Lift

Dow

n V

alve

Lift

Dow

n V

alve

Ove

rload

Indi

cato

r

Left

Pot

hole

Sw

itch

Rig

ht P

otho

le S

witc

h

Lift

Up

Lim

it S

witc

h

Lift

Dow

n Li

mit

Sw

itch

Foot

Sw

itch(

optio

n)

Buz

zer

Tem

pera

ture

sen

sor

mod

ule

(opt

iona

l)

Pla

tform

Ccn

trol M

odul

e

Joys

tick

Driv

e Jo

ystic

kD

eadm

anS

teer

Lef

tS

teer

Rig

ht

Lift

Ena

ble

Driv

e E

nabl

e

Low

Spe

ed

Hor

n S

witc

h

Pla

tform

E-S

TOP

Buz

zer

Low

Spe

ed In

dica

tor

Driv

e In

dica

tor

Lift

Indi

cato

r

LED H

orn

Low

Spe

ed V

alve

Forw

ard

Val

ve

Rev

erse

Val

ve

Lift

Up

Val

ve

Ste

er L

eft V

alve

Ste

er R

ight

Val

ve

Hou

rmet

er

Pum

p M

otor

LED

Ant

i-col

lisio

n S

witc

h (O

ptio

n)

GB

2G

B1

GB

3G

B4


Schematic

90

JCPT0808DC JCPT1008DC JCPT1012DC JCPT1212DC

Pump Motor

Drive Motor

Drive Motor

Excitation

Excitation

刹车线圈

刹车线圈

10B WH/BU(16)

B+-B RD(16)

EXCITATION BU/

RD(16)BK(2)

BK(2)

BU(16)

BK(2)

BU(16)

RD(2)

BU(16)

RD(2)

BU(16)

M1M2M3

RD(2)

RD(16)

BK(16)

BK(16)

RD(16)

4 7 2 13

58

6

109

BM1

2k? R2

2k? R1

010A-6 RD(16)

GND-11 BK(16)

GND-1 BK(16)

=16 Position DELPHI Connector LOC2


=2 Position AMP Connector LOC4

=5 Position SIBAS Connector LOC7

NOTE:ALL WIRES ARE 18AWG OR 0.8mm2 UNLESS NOTED OTHERWISE

k F 2

4

Pothole Switch

1A RD/BU(18)

1As

Right Pothole Switch

10B-2 WH/BU(18)

B2Buzzer

21

E

F J D E H G L K M L

010A-1 BN/WH(16)

010A-11 RD(18) RD

(22)

RD(22)

B-3 BK(20)

010-5 RD/BU(16)

010-2 RD/BU(16)

010-3 RD(14)

SA1

Key Switch

GB1

GB2

GB3

GB4

Battery

6V

RD(2)

BK(2)

FU1 300A

001 RD(14) 001 RD(14)010-3 RD(14)

010-4 YE(14)

010A-2 YE(16)

FU2 7A

KA1

Relay

SB1

Power

Switch

A

HL1

010A-14 RD(20)

B-2 BK(20)

Beacon

GND-1 BK(16)

GND BK(14)

RD(2)

BK(2)

Anti-Collision Switch(Option)

Up Down

SA2

1

32

TILT

Tilt Sensor Angle Sensor

AS1

Pressure Sensor

LS1A

B

C

1

32

BK(22)

Lift Down Valve

YV2

HL2

Overload Indicator

M N N P R

SQ2

Lift Down Limit Switch

Lift Up Limit Switch

12C GN/BU(18)

11B BU/RD(18)

12B BN/WH(18)

12A BN/GY(18)

11C GN/VT(18)

4B WH/VT(18)

11A GN/YE(18)

3C GN/RD(18)

6B WH/BU(18)

3A BN/YE(18)

3B BN/BK(18)

10B-1 WH/BU(16)

10B WH/BU(16)

9B WH/BK(16)

12C GN(20)

11B WH(20)

12A BN/GY(16)

12B BN/WH(16)

11C GN/VT(18)

WH+GN(22)

WH+GN(22)

BU(20)

RD(20)

3A BN(18)

BK(22)

B BK(20)

BU(20)

GND-3 BK(16)

GND-2 BK(16)

1B 1C 2B 2C 4A 5A 9B 10B

12C

11B

12B

12A

11C

4B 11A

3C 6B 3A 3B

10C

9C 10A

8C 6C 9A 4C 7A 5B 5C 8A 6A 7B 7C 8B

GND-2 BK(18)

GND-7 BK(18)

GND-8 BK(18)

GND-9 BK(18)

数字指示

ECU

10C GN/VT(16)

9C BU/RD(16)

10A GN/BU(16)

8C WH/VT(16)

6C BN/GY(16)

9A BN/BK(16)

4C GN/WH(16)

7A BN/WH(16)

5B GN/RD(16)

5C BN/YE(16)

8A-1 BN/GN(16)

8A-2 BN/GN(16)

12

Hourmeter

HM

6A VT/YE(16)

7B WH/BU(16)

7C WH/BU(16)

8B BN/RD(16)

B- BK(14)

BK(2)

YV1

YV3

YV4

B1

GND-3 BK(16)

GND-4 BK(16)

GND-5 BK(16)

GND-6 BK(16)

Lift Up Valve

Steer Left Valve

Steer Right Valve

Horn

GND-3 BK(16)GND-10 BK(16)

CONTROL+ RD/BU(16)

CONTROL- BU(16)

KM1 DC

Contactor

GND-11 BK(16)

GND-1 BK(16)

RD(2)

B+B-

Trac Enable

Forward

Reverse

Trac Speed

MC Speed

Brake

Blink Code Input

MC Enable

8C WH/VT(16)

6C BN/GY(16)

9A BN/BK(16)

4C GN/WH(16)

7A BN/WH(16)

5B GN/RD(16)

5C BN/YE(16)

8A BN/GN(16)

11101534251454329817

1

12PT2F2T1F1

MC1

Power

Temperature sensor

module (optional)

+ - B

COM K

110-220VAC Input

L N PE

Charger

+-

010A-7 BU/RD(16)

010-5 RD/BU(16)

010A-1 GN/WH(16)

010B BU/RD(16)

1C GN/RD(16)

1B GN/YE(16)

GND-1 BK(16)

GN(18)

RD(18)

BU(18)

YE(18)

WH(18)

JS1

SB4

S2 SB5

SB6

SB7

SB8

Joystick

Drive Joystick Deadman

Steer Left

Steer Right

Lift Enable

Drive Enable

Low Speed

Horn Switch

Platform Ccntrol Module

PCU

LED

Lift Indicator

Drive Indicator

Low Speed Indicator

SB3

Platform E-STOP

CAN_L

CAN_H

B3Buzzer

s CKJ

4 3 5 2 1

4 3 5 2 1

010A-6 BU/RD(16)

SB2

Ground E-STOP

010-1 BU/RD(16)

010A BN/RD(16)

010A-2 YE(16)

010A-4 RD(20)

010A-5 RD(20)

010A-10 RD(20)

Left Pothole Switch

SQ4

B-1 WH(20)

SQ3

5A-2 RD(18)

010A-2 RD(18)

010A-3 RD(18)

010A-4 RD(18)

010A-5 RD(18)

B+-A RD(16)

FootSwitch（Option）

B F A B C D

010-1 BU/RD(16)

010 BN/GN(16)

1B GN/YE(16)

1C GN/RD(16)

2B GN/RD(18) 01

0A-6 RD(16)

B+-B RD(16) 2C RD(16)

4A RD(16)

5A-1 RD(16)

010A-12 RD(20)

010A-13 RD(20)

SQ5

SQ6

SQ7

SQ8

SQ1

10B-2 WH/BU(20)


Schematic

91

JCPT1412DC JCPT1612DCB JCPT1612DCS

1A RD/BU(18)

1As

Temperature sensor

module (optional)

+ - B

COM K

110-220VAC Input

L N PE

Charger

+-

010A-7 BU/RD(16)

010-5 RD/BU(16)

010A-1 GN/WH(16)

010B BU/RD(16)

1C GN/RD(16)

1B GN/YE(16)

GND-1 BK(16)

GN(18)

RD(18)

BU(18)

YE(18)

WH(18)

JS1

SB4

S2 SB5

SB6

SB7

SB8

Joystick

Drive Joystick Deadman

Steer Left

Steer Right

Lift Enable

Drive Enable

Low Speed

Horn Switch

Platform Ccntrol Module

PCU

LED

Lift Indicator

Drive Indicator

Low Speed Indicator

SB3

Platform E-STOP

CAN_L

CAN_H

B3Buzzer

s CKJ

4 3 5 2 1

4 3 5 2 1

010A-6 BU/RD(16)

SB2

Ground E-STOP

010-1 BU/RD(16)

010A BN/RD(16)

010A-2 YE(16)

010A-4 RD(20)

010A-5 RD(20)

010A-10 RD(20)

Left Pothole Switch

SQ4

B-1 WH(20)

SQ3

5A-2 RD(18)

010A-2 RD(18)

010A-3 RD(18)

010A-4 RD(18)

010A-5 RD(18)

B+-A RD(16)

FootSwitch（Option）

B F A B C D

010-1 BU/RD(16)

010 BN/GN(16)

1B GN/YE(16)

1C GN/RD(16)

2B GN/RD(18) 01

0A-6 RD(16)

B+-B RD(16) 2C

RD(16)

4A RD(16)

5A-1 RD(16)

010A-12 RD(20)

010A-13 RD(20)

SQ5

SQ6

SQ7

SQ8

SQ1

10B-2 WH/BU(20)

Right Pothole Switch

10B-2 WH/BU(18)

B2Buzzer

21

E

F J D E H G L K M L

010A-1 BN/WH(16)

010A-11 RD(18) RD

(22)

RD(22)

B-3 BK(20)

010-5 RD/BU(16)

010-2 RD/BU(16)

010-3 RD(14)

SA1

Key Switch

Battery

12V

RD(2)

BK(2)

FU1 300A

001 RD(14) 001 RD(14)010-3 RD(14)

010-4 YE(14)

010A-2 YE(16)

FU2 7A

KA1

Relay

SB1

Power

Switch

A

HL1

010A-14 RD(20)

B-2 BK(20)

Beacon

GND-1 BK(16)

GND BK(14)

RD(2)

BK(2)

Anti-Collision Switch(Option)

Up Down

SA2

1

32

TILT

Tilt Sensor Angle Sensor

AS1

Pressure Sensor

LS1A

B

C

1

32

BK(22)

Lift Down Valve

YV2

HL2

Overload Indicator

M N N P R

SQ2

Lift Down Limit Switch

Lift Up Limit Switch

12C GN/BU(18)

11B BU/RD(18)

12B BN/WH(18)

12A BN/GY(18)

11C GN/VT(18)

4B WH/VT(18)

11A GN/YE(18)

3C GN/RD(18)

6B WH/BU(18)

3A BN/YE(18)

3B BN/BK(18)

10B-1 WH/BU(16)

10B WH/BU(16)

9B WH/BK(16)

12C GN(20)

11B WH(20)

12A BN/GY(16)

12B BN/WH(16)

11C GN/VT(18)

WH+GN(22)

WH+GN(22)

BU(20)

RD(20)

3A BN(18)

BK(22)

B BK(20)

BU(20)

GND-3 BK(16)

GND-2 BK(16)

1B 1C 2B 2C 4A 5A 9B 10B

12C

11B

12B

12A

11C

4B 11A

3C 6B 3A 3B

10C

9C 10A

8C 6C 9A 4C 7A 5B 5C 8A 6A 7B 7C 8B

GND-2 BK(18)

GND-7 BK(18)

GND-8 BK(18)

GND-9 BK(18)

数字指示

ECU

10C GN/VT(16)

9C BU/RD(16)

10A GN/BU(16)

8C WH/VT(16)

6C BN/GY(16)

9A BN/BK(16)

4C GN/WH(16)

7A BN/WH(16)

5B GN/RD(16)

5C BN/YE(16)

8A-1 BN/GN(16)

8A-2 BN/GN(16)

12

Hourmeter

HM

6A VT/YE(16)

7B WH/BU(16)

7C WH/BU(16)

8B BN/RD(16)

B- BK(14)

BK(2)

YV1

YV3

YV4

B1

GND-3 BK(16)

GND-4 BK(16)

GND-5 BK(16)

GND-6 BK(16)

Lift Up Valve

Steer Left Valve

Steer Right Valve

Horn

GND-3 BK(16)GND-10 BK(16)

CONTROL+ RD/BU(16)

CONTROL- BU(16)

KM1 DC

Contactor

GND-11 BK(16)

GND-1 BK(16)

RD(2)

B+B-

Trac Enable

Forward

Reverse

Trac Speed

MC Speed

Brake

Blink Code Input

MC Enable

8C WH/VT(16)

6C BN/GY(16)

9A BN/BK(16)

4C GN/WH(16)

7A BN/WH(16)

5B GN/RD(16)

5C BN/YE(16)

8A BN/GN(16)

11101534251454329817

1

12PT2F2T1F1

MC1

Power

Pump Motor

Drive Motor

Drive Motor

Excitation

Excitation

刹车线圈

刹车线圈

10B WH/BU(16)

B+-B RD(16)

EXCITATION BU/RD(16)BK

(2)

BK(2)

BU(16)

BK(2)

BU(16)

RD(2)

BU(16)

RD(2)

BU(16)

M1M2M3

RD(2)

RD(16)

BK(16)

BK(16)

RD(16)

4 7 2 13

58

6

109

BM1

2k? R2

2k? R1

010A-6 RD(16)

GND-11 BK(16)

GND-1 BK(16)



=2 Position AMP Connector LOC4

=5 Position SIBAS Connector LOC7

NOTE:ALL WIRES ARE 18AWG OR 0.8mm2

UNLESS NOTED OTHERWISE

k F 2

4

Pothole Switch

GB1

GB2

GB3

GB4


Inspection and Repair Log

92

Inspection and Repair Log

Date Comments

operator’smanual - premier platforms

Documents