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DINGLI JCPT0307 Operators Manual With Maintenance Information

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SELF-PROPELLED SCISSOR LIFTS
OPERATOR'S MANUAL
with Maintenance Information

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Summary of Contents for DINGLI JCPT0307

  • Page 1 SELF-PROPELLED SCISSOR LIFTS OPERATOR’S MANUAL with Maintenance Information...
  • Page 2 Comply with employer, job site and part of your machine and should remain with governmental rules. the machine at all times. If you have any questions, please call DINGLI Machinery. Read, understand and follow the instructions in this and other manuals supplied with this machine.
  • Page 5 OPERATOR’S MANUAL with Maintenance Information Safety Rules Decal Legend Danger Our product decals use symbols, color Failure to obey the instructions and coding and signal words to identify the safety rules in this manual will following: result in death or serious injury. Safety alert symbol—used to alert Do Not Operate Unless: personnel to potential personal injury hazards.
  • Page 6 OPERATOR’S MANUAL with Maintenance Information Safety Rules Intended Use Allow for platform movement, electrical line sway or sag and beware of strong or gusty This machine is intended to be used only to lift winds. personnel, along with their tools and materials Keep away from the machine if it contacts to an aerial work site.
  • Page 7 OPERATOR’S MANUAL with Maintenance Information Safety Rules drop-offs. Do not drive the machine on or near uneven terrain, unstable surfaces or other hazardous conditions with the platform raised. Do not push off or pull toward any object outside of the platform. Do not depend on the tilt alarm as a level indicator.
  • Page 8 Model slope rating side slope rating stowed position stowed position Check the work area for overhead obstructions or other possible hazards. JCPT0307 25% (14°) 25% (14°) JCPT0407 25% (14°) 25% (14°) Note: Slope rating is subject to ground...
  • Page 9 OPERATOR’S MANUAL with Maintenance Information Safety Rules Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present. Damaged Machine Hazard Be aware of crushing hazards when grasping Do not use a damaged or malfunctioning the platform guard rail.
  • Page 10 OPERATOR’S MANUAL with Maintenance Information Safety Rules Battery Safety Avoid electrical shock from contact with battery terminals. Remove all rings, watches Burn Hazard and other jewelry. Tip-over Hazard Do not use batteries that weigh less than the original equipment. Batteries are used as counterweight and are critical to machine stability.
  • Page 11 OPERATOR’S MANUAL with Maintenance Information Decals Legend Legend 10 Emergency lowering knob Manual storage container 11 Ground Control Panel Platform guard rails 12 Pump & Ground Control Drawer Platform controller 13 Batteries charger Platform extension release pedal 14 Swivel Wheel Platform entry gate 15 Scissor Main Platform...
  • Page 12 9414121 Warning – Crushing Hazard / Falling Hazard 9514301 Cosmetic – IPAF 9413013 Danger – Crushing Hazard 9514201 Cosmetic – CE For: JCPT0307 9913011 Cosmetic – Warning（Right） 12 For: JCPT0407 For: JCPT0307 9913013 Cosmetic – Warning（Left） 12 For: JCPT0407 9313011 Instructions –...
  • Page 13 OPERATOR’S MANUAL with Maintenance Information Decals...
  • Page 14 OPERATOR’S MANUAL with Maintenance Information Specifications JCPT0307 Maximum hydraulic pressure 180bar Height, working maximum 5.0 m (functions) (indoor use) Height, platform maximum System voltage 24V/10A 3.0 m (indoor use ) Driving wheels Φ230×80mm Height, working maximum 4.5 m Front wheels Φ152mm...
  • Page 15 OPERATOR’S MANUAL with Maintenance Information Specifications JCPT0407 Maximum hydraulic pressure 180bar Height, working maximum 5.9 m (functions) (indoor use) Height, platform maximum System voltage 24V/10A 3.9 m (indoor use ) Driving wheels Φ230×80mm Height, working maximum 4.5 m Front wheels Φ152mm (outdoor use) Height, platform maximum...
  • Page 16 OPERATOR’S MANUAL with Maintenance Information Control Panel Platform Control Panel ○ ○ ○ ○ ○ ○ ○ ○ Drive function select button Horn button Drive speed button Lift function select button Red Emergency Stop button Proportional control handle Function enable switch for lift and drive functions...
  • Page 17 OPERATOR’S MANUAL with Maintenance Information Control Panel Platform Control Panel Proportional control handle Drive function select button Function enable switch for lift and drive Press this button to activate the drive functions function. Lift function: Press and hold the function Drive speed button enable switch to enable the lift function on Press this button to activate the slow or...
  • Page 18 OPERATOR’S MANUAL with Maintenance Information Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. Do Not Operate Unless: The pre-operation inspection is a visual inspection performed by the operator prior to You learn and practice the principles of √...
  • Page 19 OPERATOR’S MANUAL with Maintenance Information Pre-operation Inspection Pre-operation Inspection Check entire machine for: Be sure that the operator’s manual are  complete, legible and in the storage Cracks in welds or structural  container located in the platform. components Be sure that all decals are legible and in Dents or damage to machine ...
  • Page 20 OPERATOR’S MANUAL with Maintenance Information Workplace Inspection Fundamentals Do Not Operate Unless: The workplace inspection helps the operator You learn and practice the principles of √ determine if the workplace is suitable for safe safe machine operation contained in this machine operation.
  • Page 21 OPERATOR’S MANUAL with Maintenance Information Function Tests Fundamentals Do Not Operate Unless: The function tests are designed to discover You learn and practice the principles of √ any malfunctions before the machine is put safe machine operation contained in this into service.
  • Page 22 OPERATOR’S MANUAL with Maintenance Information Function Tests Select a test area that is firm, level and 12 Move down and hold the platform up / free of obstruction. down switch. Be sure the battery pack is connected. ⊙ Result: The platform should lower then stop at the height is 1.2 m.
  • Page 23 OPERATOR’S MANUAL with Maintenance Information Function Tests direction indicated by the blue arrow, then 31 Press and hold the function enable switch in the direction indicated by the yellow on the control handle. arrow. 32 Slowly move the control handle in the direction indicated by the blue up arrow on ⊙...
  • Page 24 ⊙ Result: The platform should rise to 3.0 m ⊙ Result: The drive function should not work for JCPT0307 Model and 3.9 m for in either direction. JCPT0407 Model. 42 Lower the platform and drive the machine 55 Press and hold the function enable switch.
  • Page 25 OPERATOR’S MANUAL with Maintenance Information Operating Instructions Do Not Operate Unless: The Operating Instructions section provides instructions for each aspect of machine You learn and practice the principles of √ operation. safe machine operation contained in this It is the operator's responsibility to follow all operator's manual.
  • Page 26 OPERATOR’S MANUAL with Maintenance Information Operating Instructions Emergency Stop To Position Platform Press the lift function select button. Push in the red Emergency Stop button to the off position at the ground controls or the Press and hold the function enable switch platform controls to stop all machine functions.
  • Page 27 OPERATOR’S MANUAL with Maintenance Information Operating Instructions Operation from Ground with button light is on, slow drive speed mode is active. When the button light is off, fast drive Controller speed mode is active. Maintain safe distances between operator, Press the drive speed button to select the machine and fixed objects.
  • Page 28 OPERATOR’S MANUAL with Maintenance Information Operating Instructions pins. 10 Fold down the right rail assembly. Keep hands clear of pinch points. 11 Replace the removed pin back into rear rail bracket. 12 Remove the left rear main deck wire lock pins.
  • Page 29 OPERATOR’S MANUAL with Maintenance Information Operating Instructions Error indicator readout If the LED diagnostic readout displays an error code, such as LL, push in and pull out the red Emergency Stop button to reset the system. List of Fault Codes Display Description Lift Reaction...
  • Page 30 OPERATOR’S MANUAL with Maintenance Information Operating Instructions Display Description Lift Reaction Motor Controller SRO Fault Controller Dependent ZAPI Steering or Speed Input Voltages out of ”Acquired” Controller Dependent range Unsafe Power Conditions or Interruptions Disable All Motion High Neutral Current Fault Disable All Motion Steering Input out of Range Disable All Motion...
  • Page 31 OPERATOR’S MANUAL with Maintenance Information Operating Instructions Troubleshooting Guide Display Description System Initialization Fault: ECU may be malfunctioning, replace it. System Communication Fault: Check communications cable connections and other wiring. If that does not resolve the problem, try replacing the PCU or ECU. Invalid Option setting Fault: Set appropriate option for this lift.
  • Page 32 OPERATOR’S MANUAL with Maintenance Information Operating Instructions Display Description Unsafe Power Conditions or Interruptions: Check battery voltage and charge batteries if necessary. Check the battery and power switch connections and tighten or clean. Check the voltage to the ECU and PCU. This fault can also be generated when the power switch or relays experience a sudden jolt.
  • Page 33 OPERATOR’S MANUAL with Maintenance Information Operating Instructions Battery and Charger Instructions To Charge Battery Be sure the battery is connected before Observe and Obey: charging. Open the battery compartment. The Do not use an external charger or booster √ compartment should remain open for the battery.
  • Page 34 OPERATOR’S MANUAL with Maintenance Information Transport and Lifting Instructions Observe and Obey: Brake Release Operation Chock the wheels to prevent the machine Common sense and planning must be √ from rolling. applied to control the movement of the machine when lifting it with a crane or Pull out the red Emergency Stop button on both the ground and platform controls forklift.
  • Page 35 OPERATOR’S MANUAL with Maintenance Information Transport and Lifting Instructions Securing to Truck or Trailer for Lifting the Machine with a Transit Forklift Always chock the machine wheels in Be sure the extension deck, controls and preparation for transport. component trays are secure. Turn the key switch to the off position and Remove all loose items on the machine.
  • Page 36 OPERATOR’S MANUAL with Maintenance Information Maintenance Pre-delivery Preparation Report Observe and Obey: The pre-delivery preparation report contains Only routine maintenance items specified in √ checklists for each type of scheduled this manual shall be performed by the inspection. operator. Make copies of the Pre-delivery Preparation Scheduled maintenance inspections shall √...
  • Page 37 OPERATOR’S MANUAL with Maintenance Information Maintenance Pre-delivery Preparation Report Fundamentals Instructions It is the responsibility of the dealer to perform Use the operator’s manual on your machine. the Pre-delivery Preparation. The Pre-delivery Preparation consists of The Pre-delivery Preparation is performed completing the Pre-operation Inspection, the prior to each delivery.
  • Page 38 OPERATOR’S MANUAL with Maintenance Information Maintenance Maintenance Inspection Report Model Checklist A Y N R A-1 Inspect the manuals and Serial number decals Date A-2 Pre-operation inspection Hour meter A-3 Check the Batteries Machine owner A-4 Check the Hydraulic Oil Level Inspected by (print) A-5 Function tests Inspector signature...
  • Page 39 OPERATOR’S MANUAL with Maintenance Information Maintenance Checklist A Procedures Inspect the Manuals and Decals Maintaining the operator’s and safety manuals ⊙ Result: The machine is equipped with all in good condition is essential to safe machine required decals, and all decals are legible and operation.
  • Page 40 OPERATOR’S MANUAL with Maintenance Information Maintenance Perform Pre-operation Inspection Check the Batteries Completing a Pre-operation Inspection is essential to safe machine operation. The Pre-operation Inspection is a visual inspection Proper battery condition is essential to good performed by the operator prior to each work machine performance and operational safety.
  • Page 41 OPERATOR’S MANUAL with Maintenance Information Maintenance Check the Hydraulic Oil Level Perform Function Tests Completing the function tests is essential to safe machine operation. Function tests are designed to discover any malfunctions before Maintaining the hydraulic oil at the proper level the machine is put into service.
  • Page 42 OPERATOR’S MANUAL with Maintenance Information Maintenance Perform 30 Day Service The 30 day maintenance procedure is a one time procedure to be performed after the first 30 days or 40 hours of usage. After this interval, refer to the maintenance tables for continued scheduled maintenance.
  • Page 43 OPERATOR’S MANUAL with Maintenance Information Maintenance Checklist B Procedures Inspect the Batteries Remove the battery vent caps and check the specific gravity of each battery cell with We require that this procedure be performed a hydrometer. Note the results. every 250 hours or quarterly, whichever Check the ambient air temperature and comes first.
  • Page 44 OPERATOR’S MANUAL with Maintenance Information Maintenance readings between cells is greater than 0.1 sounds and the LEDs blink , correct the OR the specific gravity of one or more cells charger connections at the fuse and battery. is less than 1.177. Replace the battery. The charger will then operate correctly and begin charging the batteries.
  • Page 45 OPERATOR’S MANUAL with Maintenance Information Maintenance Inspect the Electrical Wiring We require that this procedure be performed Crushing hazard. Keep every 250 hours or quarterly, whichever hands clear of the safety arm when lowering comes first. the platform. Maintaining electrical wiring in good condition Inspect the center chassis area and is essential to safe operation and good scissor arms for burnt, chafed and pinched...
  • Page 46 OPERATOR’S MANUAL with Maintenance Information Maintenance Inspect the Tires and Wheels Test the Emergency Stop (including lock nut torque) We require that this procedure be performed every 250 hours or quarterly, whichever comes first. We require that this procedure be performed A properly functioning Emergency Stop is every 250 hours or quarterly, whichever essential for safe machine operation.
  • Page 47 OPERATOR’S MANUAL with Maintenance Information Maintenance Test the Key Switch Test the Automotive-style Horn (if equipped) We require that this procedure be performed every 250 hours or quarterly, whichever We require that this procedure be comes first. performed every 250 hours or quarterly, whichever comes first.
  • Page 48 OPERATOR’S MANUAL with Maintenance Information Maintenance Test the Drive Brakes We require that this procedure be Choose a point on the machine; i.e., performed every 250 hours or quarterly, contact patch of a tire, as a visual whichever comes first. reference for use when crossing the test line.
  • Page 49 OPERATOR’S MANUAL with Maintenance Information Maintenance Test the Drive Speed - Stowed Position Choose a point on the machine; i.e., We require that this procedure be performed contact patch of a tire, as a visual every 250 hours or quarterly, whichever reference for use when crossing the start comes first.
  • Page 50 OPERATOR’S MANUAL with Maintenance Information Maintenance Test the Drive Speed - Raised Position Press and hold the function enable switch We require that this procedure be performed on the joystick. every 250 hours or quarterly, whichever comes first. Raise the platform approximately 1.2 m from the ground.
  • Page 51 OPERATOR’S MANUAL with Maintenance Information Maintenance B-10 Test the Slow Drive Speed We require that this procedure be performed Choose a point on the machine; i.e., contact patch of a tire, as a visual every 250 hours or quarterly, whichever reference for use when crossing the start comes first.
  • Page 52 OPERATOR’S MANUAL with Maintenance Information Maintenance B-11 B-12 Perform Hydraulic Oil Analysis Inspect the Hydraulic Tank Cap Venting System We require that this procedure be performed every 250 hours or quarterly, whichever comes We require that this procedure be performed first.
  • Page 53 OPERATOR’S MANUAL with Maintenance Information Maintenance B-13 Test the Down Limit Switch Rotate the roller arm of the limit switch 90 We require that this procedure be performed degrees in an upwards direction. Activate every 250 hours or quarterly, whichever comes the switch contacts.
  • Page 54 OPERATOR’S MANUAL with Maintenance Information Maintenance B-14 controls, push the arm of the up limit switch towards the drive end of the Test the Up Limit Switch and the machine to activate the limit switch. Indoor/outdoor limit switch ⊙ Result: The platform stops raising. The machine is functioning properly.
  • Page 55 OPERATOR’S MANUAL with Maintenance Information Maintenance Checklist C Procedures Test the Platform Overload System (if equipped) We require that this procedure be performed every 500 hours or six months, whichever comes first OR when the machine fails to lift the maximum rated load. Testing the platform overload system regularly is essential to safe machine operation.
  • Page 56 OPERATOR’S MANUAL with Maintenance Information Maintenance machine is functioning properly ¤ Result: The alarm does not sound. Replace the Hydraulic Tank Breather Calibrate the platform overload system. Lower the platform onto the safety arm. Crushing hazard. Keep We require that this procedure be performed hands clear of the safety arm when lowering every 500 hours or semi-annually, whichever the platform.
  • Page 57 OPERATOR’S MANUAL with Maintenance Information Maintenance Checklist D Procedures Check the Scissor Arm Wear Pads We require that this procedure be performed Measure the distance between the number every 1000 hours or annually, whichever one inner arm cross tube and the chassis comes first.
  • Page 58 OPERATOR’S MANUAL with Maintenance Information Maintenance Checklist E Procedure Test or Replace the Hydraulic Oil We require that this procedure be Bodily injury hazard. performed every 2000 hours or every two Spraying hydraulic oil can penetrate and burn years, whichever comes first. skin.
  • Page 59 OPERATOR’S MANUAL with Maintenance Information Schematic Hydraulic Schematic L ift C y lin d e r P la t fo rm O v e rlo a d (O p tio n ) s o lin o id v a lv e , w ith o u t E m e rg e n c y lo w e r in g h a n d le P u m p...
  • Page 60 P L A T F O R M C O N T R O L B O X M C 1 E C U P C U 7 S E G M E N T 0 0 7 G N / V T ( 1 6 ) J S 1 D IS P L A Y D R IV E J O Y S T IC K...
  • Page 63 OPERATOR’S MANUAL with Maintenance Information Parts List Item Part Number Description Qty. Remark GB/T 818-2000 Screw M4×10 JCPT5007MQ-113003 Cover plate JCPT5007MQ-113004 Cover plate2 Alarm beacon JCPT5007MQ-213100 Chassis AAZ8104 Travel switch JCPT3707M-00018 Shield sleeve 6 Shield sleeve 12 GB/T 70.1-2000 Screw M10×30 GB/T 97.1-2002 Washer 10 HX-SHCS 3/8-24x1...
  • Page 64 OPERATOR’S MANUAL with Maintenance Information Parts List Item Part Number Description Qty. Remark QQE240-7CH23-A-MO0 Charger 1-01 Key switch 24VDC Indicator light Up-Down switch Emergency stop Button Hour meter GB/T 818-2000 Screw M4×10 JCPT5007MQ-115210 Ground control panel welding ECU Module GB/T 818-2000 Screw M6×20 JCPT0630-12012 Lock...
  • Page 65 OPERATOR’S MANUAL with Maintenance Information Parts List Item Part Number Description Qty. Remark 7602-20“ Glide track JCPT5007MQ-113007 Lock GB/T 6182-2000 Nut M8 GB/T 70.1-2000 Screw M5×8 GB/T 97.1-2002 Washer 8 GB/T 5782-2000 Bolt M10×45 GB/T 97.1-2002 Washer 10 GB/T 93-1987 Washer 10 6’’...
  • Page 66 OPERATOR’S MANUAL with Maintenance Information Parts List Scissors Arms Assembly JCPT0307...
  • Page 67 OPERATOR’S MANUAL with Maintenance Information Parts List Item Part Number Description Qty. Remark JCPT5007MQ-131100 Inner arm11 JCPT5007MQ-131200 Out arm 1 JCPT5007MQ-131009 Axis JCPT5007MQ-131010 Axis Flange GB894.2-1986 Circle D20 JCPT5007MQ-131006 Safety arm JCPT5007MQ-131007 Safety holder GB/T 97.1-2002 Washer 6 GB/T 5783-2000 Bolt M6×20 GB/T 889.1-2000 Nut M6...
  • Page 68 OPERATOR’S MANUAL with Maintenance Information Parts List Scissors Arms Assembly JCPT0407...
  • Page 69 OPERATOR’S MANUAL with Maintenance Information Parts List Item Part Number Description Qty. Remark JCPT5007MQ-131100 Inner 1 arm JCPT5007MQ-131200 Outer 1 arm JCPT5007MQ-131009 Axle 1 JCPT5007MQ-131010 Axle 2 JCPT5007MQ-131012 Bead flange GB894.2-1986 Circlip D20 JCPT5007MQ-131006 Safety arm JCPT5007MQ-131007 Safety Arm Spacer GB/T 97.1-2002 Spacer 6 GB/T 5783-2000...
  • Page 70 OPERATOR’S MANUAL with Maintenance Information Parts List...
  • Page 71 OPERATOR’S MANUAL with Maintenance Information Parts List Item Part Number Description Qty. Remark Controller TYSBZ-001 Hold of console GB/T 97.1-2002 Washer 5 GB/T 6182-2000 Nut M5 GB/T 818-2000 Bolt M5×16 GTBZ16A-43500 Manual storage container JCPT5007MQ-412200 Platform extension JCPT5007MQ-412400 Platform guard rails JCPT5007MQ-412300 Platform guard rails GB/T 6182-2000...
  • Page 72 OPERATOR’S MANUAL with Maintenance Information OPERATOR’S MANUAL with Maintenance Information Parts List Parts List Item Part Number Description Qty. Remark JCPT0808HD-141640 Hinge B GB/T 5782-2000 Bolt M6×50 JCPT5007MQ-412610 Door JCPT3707M-43302 Spring GB/T97.1-2002 Washer 6 JCPT3707M-43301 Handle JCPT5007MQ-412700 Platform guard rails GB/T 6182-2000 Nut M6 JCPT5007MQ-412100...
  • Page 73 OPERATOR’S MANUAL with Maintenance Information Inspection and Repair Log Inspection and Repair Log Date Comments...

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