DINGLI JCPT2825RT Operator's Manual

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Operator's Manual

with Maintenance Information

JCPT2825RT

JCPT3225RT

Part Number: SM012110141

Original Instructions

Version Number: Rev1.1

July 2022 Printing

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Summary of Contents for DINGLI JCPT2825RT

Page 1 Operator’s Manual with Maintenance Information JCPT2825RT JCPT3225RT Part Number: SM012110141 Original Instructions Version Number: Rev1.1 July 2022 Printing...
Page 3 OPERATOR’S MANUAL with Maintenance Information Version of the Record Version of the Record Version Number Create Date SM012110141_Rev1.0 ………………………………………………………………………… 2022-07 SM012110141_Rev1.1 ………………………………………………………………………… 2022-08...
Page 5 Comply with employer, job site and the machine at all times. If you have any governmental rules. questions, please call DINGLI Machinery. Read, understand and follow the instructions in this and other manuals supplied with this machine.
Page 6 Pre-operation Inspection Workplace Inspection Function Tests Operating Instructions Transport and Lifting Instructions Maintenance Schematic Inspection and Repair Log Contact us: Zhejiang Dingli Machinery Co., Ltd. No.188 Qihang Road. Deqing Zhejiang P.R. China 313219 Tel: +86-572-8681688 Fax: +86-572-8681690 Web: www.cndingli.com E-mail:market@cndingli.com...
Page 7 OPERATOR’S MANUAL with Maintenance Information Safety Rules Hazard Classification Danger DINGLI 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.
Page 8 OPERATOR’S MANUAL with Maintenance Information Safety Rules The relevant conditions of using this type of machinery. the equipment An operator must not use drugs or alcohol that can change his/her alertness or coordination. The surface of work ground should be flat and An operator on prescription or hard with no obstacles in air and the safety over-the-counter drugs needs medical advice...
Page 9 Increasing the area exceed the maximum platform capacity or the exposed to the wind will decrease machine maximum capacity of the platform extension. stability. Maximum capacity – JCPT2825RT Maximum occupants Platform allowable maximum load 1000kg Maximum capacity – JCPT3225RT...
Page 10 Do not transport tools and materials unless Outdoor 400N they are evenly distributed and can be safely JCPT2825RT handled by person(s) in the platform. Indoor 400N Do not use the machine on a moving or mobile Outdoor 400N JCPT3225RT surface or vehicle.
Page 11 Collision Hazard Maximum Maximum Model slope rating side slope rating stowed position stowed position JCPT2825RT 40% (22°) 30% (17°) JCPT3225RT 40% (22°) 30% (17°) Be aware of limited sight distance and blind Note: Slope rating is subject to ground spots when driving or operating.
Page 12 OPERATOR’S MANUAL with Maintenance Information Safety Rules only in an open, well-ventilated area away from sparks, flames and lighted tobacco. Do not operate the machine in hazardous locations or locations where potentially flammable or explosive gases or particles may be present. Do not spray ether into engines equipped with glow plugs.
Page 13 OPERATOR’S MANUAL with Maintenance Information Safety Rules Outrigger Safety Battery Safety Do not lower the outriggers unless the Burn Hazard machine is on a firm surface. If the ground Batteries contain acid. Always wear protective does not meet the requirements specified of clothing and eye wear when working with the relevant regulations, sufficient ground batteries.
Page 14 OPERATOR’S MANUAL with Maintenance Information Safety Rules Lockout after Each Use Select a safe parking location - firm level surface, clear of obstructions and traffic. Lower the platform. Turn the key switch to the off position and remove the key to secure from unauthorized use.
Page 15 OPERATOR’S MANUAL with Maintenance Information Legend Legend Platform entry gate Engine(behind cover) Manual storage containers 10 Rear wheel Platform controls 11 Hydraulic tanks, Fuel tanks (behind cover) Main Platform 12 Lift Cylinder 5 Lanyard anchorage point 13 Ground controls Platform guard rails 14 Front wheel Platform extensions 15 Outrigger...
Page 16 Decal, Instructions-Lift point 09420005 Decal, Warning-Collision hazard 09310050 Decal, Instructions-Tie down point 09410069 Decal, Warning-Crushing hazard, outrigger Decal, Instructions-Maximum outrigger load 09310498 JCPT2825RT 8300kg Decal, Instructions-Maximum outrigger load 09310500 JCPT3225RT 10000kg 09410157 Decal, Symbols-Outrigger using warning Decal, Instructions-Maximum wheel load...
Page 17 Description Qty. Remark 09410071 Decal, Warning-Injection hazard 09410001 Decal, Danger-Explosion/burn hazard Decal, Warning-Inspected and operation 09410003 properly 09910094 Decal, Label-JCPT2825RT JCPT2825RT 09910096 Decal, Label-JCPT3225RT JCPT3225RT Decal, Danger-Do not alter or disable limit 09410005 switch 09330012 Decal, Instructions-Grease filling port 09440007 Decal, Caution-Max.
Page 18 OPERATOR’S MANUAL with Maintenance Information Decals Safety tape 8 8 8 8 Safety tape Safety tape 8 8 8 8 8...
Page 19 OPERATOR’S MANUAL with Maintenance Information Decals JCPT2825RT...
Page 20 OPERATOR’S MANUAL with Maintenance Information Decals JCPT2825RT...
Page 21 OPERATOR’S MANUAL with Maintenance Information Decals JCPT3225RT...
Page 22 OPERATOR’S MANUAL with Maintenance Information Decals JCPT3225RT...
Page 23 It should be used only with adequate safety factors. AC outlet in platform Standard Continuous improvement of our products is a Maximum hydraulic pressure 250 bar (functions) DINGLI policy. Product specifications are subject to change without notice or obligation. Tire size 355/55D625...
Page 24 It should be used only with AC outlet in platform Standard adequate safety factors. Maximum hydraulic pressure Continuous improvement of our products is a 250 bar (functions) DINGLI policy. Product specifications are subject to change without notice or obligation. Tire size 15-625...
Page 25 OPERATOR’S MANUAL with Maintenance Information Controls Ground Control Panel Display Red Emergency Stop button Engine idle select button Platform down button Overload indicator light 10 Lift function enable button Engine start/flameout button Emergency lowering down button Standstill-Regeneration button 12 Platform up button Engine fault alarm indicator 13 Emergency lowering down enable button Key switch...
Page 26 OPERATOR’S MANUAL with Maintenance Information Controls Ground Control Panel Red Emergency Stop button Display Push in the red Emergency Stop button to Diagnostic readout the off position to stop all functions. Pull Engine idle select button out the red Emergency Stop button to the Press this button to select the engine idle on position to operate the machine.
Page 27 OPERATOR’S MANUAL with Maintenance Information Controls Platform Control Panel Red Emergency Stop button Steer mode select button Drive function select button 10 LED readout screen Power platform button 11 Engine start / flameout button Engine idle select button 12 Generator select button (if equipped) Horn button 13 Lift function select button Standby...
Page 28 OPERATOR’S MANUAL with Maintenance Information Controls Platform Control Panel Red Emergency Stop button Steer mode select button Push in the red Emergency Stop button to Press this button to select steer mode: FS the off position to stop all functions. Pull mode (Front Steer mode), bS mode (Rear out the red Emergency Stop button to the Steer mode).
Page 29 OPERATOR’S MANUAL with Maintenance Information Controls control panel and the machine will move in the direction that the yellow arrow points. Outrigger extendable / retractable function: Press and hold the function enable switch to enable the Outrigger extend/ retract function on the platform control handle. Move the control handle in the direction indicated by the yellow arrow and the outrigger will extend.
Page 30 OPERATOR’S MANUAL with Maintenance Information Pre-operation Inspection Fundamentals Do Not Operate Unless: It is the responsibility of the operator to √ You learn and practice the principles of perform a pre-operation inspection and routine safe machine operation contained in this maintenance.
Page 31 OPERATOR’S MANUAL with Maintenance Information Pre-operation Inspection Pre-operation Inspection  Be sure that the operator’s manual are □ Beacon (if equipped) complete, legible and in the storage □ Safety arm container located in the platform. □ Platform extension(s)  Be sure that all decals are legible and in □...
Page 32 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 33 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 34 OPERATOR’S MANUAL with Maintenance Information Function Tests Select a test area that is firm, level and button. Press and hold the platform up free of obstruction. button. ⊙ Result: The platform should rise. At the Ground Controls 10 Press and hold the lift function enable button.
Page 35 OPERATOR’S MANUAL with Maintenance Information Function Tests down enable button. Press and hold the ⊙ Result: The platform should raise. emergency lowering down button. 28 Release the control handle. ⊙ Result: The platform should lower. ⊙ Result: The platform should stop raising. 18 Turn the key switch to platform control and 29 Press and hold the function enable switch.
Page 36 OPERATOR’S MANUAL with Maintenance Information Function Tests 35 Push the steer mode select button for ⊙ Result: The machine should move in the steer FS mode (Rear Steer mode). direction that the yellow arrow points on the control panel, then come to an abrupt stop. 36 Press and hold the function enable switch on the proportional control handle.
Page 37 OPERATOR’S MANUAL with Maintenance Information Function Tests Test Platform extendable / retractable 50 Move the proportional control handle in the direction indicated by the blue arrow, then Functions move the proportional control handle in the 60 Push and hold the Power platform button. direction indicated by the yellow arrow.
Page 38 OPERATOR’S MANUAL with Maintenance Information Operating Instructions Do Not Operate Unless: √ You learn and practice the principles of Reliability data, diagnostic coverage [DC], the system architecture [Category], common safe machine operation contained in this cause failure and, where relevant, operator's manual.
Page 39 OPERATOR’S MANUAL with Maintenance Information Operating Instructions To Position Platform Emergency Stop Press the lift function enable button. Push in the red Emergency Stop button to the off position at the ground controls or the Press the platform up/down button to platform controls to stop all machine functions activate the up function or the down and turn the engine off.
Page 40 OPERATOR’S MANUAL with Maintenance Information Operating Instructions To Drive You will need: Carpenter’s level Press the drive function select button. Straight piece of wood, at least 1 m long Press and hold the function enable switch tape measure on the control handle. Lay the piece of wood on the slope Increase speed: Slowly move the control handle off center.
Page 41 OPERATOR’S MANUAL with Maintenance Information Operating Instructions Operation from Ground with The outriggers will extend and level the machine. Controller Cannot use the outrigger Maintain safe distances between operator, directly on uneven surface, soft ground, pit machine and fixed objects. edges and slopes greater ground, To avoid the Be aware of the direction the machine will risk of machine tipping, casualties and...
Page 42 OPERATOR’S MANUAL with Maintenance Information Operating Instructions further action is needed. 1) Drive machine to a flat and well-ventilated position. 1 Heat Mode 1, “Level 1” 2) Turn the key switch to ground control. Active when: relative Soot load > 62%: 3) Press and hold Standstill-Regeneration If the operating conditions of the machine do button 2 seconds.
Page 43 OPERATOR’S MANUAL with Maintenance Information Operating Instructions performed by the operator. ○ 6 Replace DPF Required, “Level 6” Active when: relative Soot load > 156%: Soot load has reached a critical level where safe regeneration in machine no longer can be ensured.
Page 44 OPERATOR’S MANUAL with Maintenance Information Operating Instructions Emergency operating with hand ○ pump Emergency Lowering ○ Unplug the lever and put it into the hand pump (1). Press and hold the button (2). Operate the hand pump with the lever, the platform should lower.
Page 45 OPERATOR’S MANUAL with Maintenance Information Operating Instructions A B C D 4 retract, Press the corresponding knob in the direction of the arrow. Operate the hand pump with the lever, the outrigger emergency retract Retracting Platform After Each Use Select a safe parking location - firm level surface, clear of obstructions and traffic.
Page 46 OPERATOR’S MANUAL with Maintenance Information Transport and Lifting Instructions Observe and Obey: Free-wheel Configuration for Winching √ Common sense and planning must be applied to control the movement of the Chock the wheels to prevent the machine from machine when lifting it with a crane or rolling.
Page 47 OPERATOR’S MANUAL with Maintenance Information Transport and Lifting Instructions Securing to Truck or Trailer for Transit Turn the key switch to the off position and Always chock the machine wheels in remove the key before transporting. preparation for transport. Inspect the entire machine for loose or Retract and secure the extension deck(s).
Page 48 Center of gravity X Axis Y Axis Lifting Instructions Fully lower the platform. Be sure the extension JCPT2825RT 2.3m 1.0m decks, controls and covers are secure. Remove all loose items on the machine. JCPT3225RT 2.7m...
Page 49 OPERATOR’S MANUAL with Maintenance Information Maintenance Make copies of the Pre-delivery Preparation Observe and Obey: report to use for each inspection. Store √ Only routine maintenance items specified in completed forms as required. this manual shall be performed by the operator.
Page 50 OPERATOR’S MANUAL with Maintenance Information Maintenance Pre-delivery Preparation Report Fundamentals Legend It is the responsibility of the dealer to perform the Pre-delivery Preparation. Y = yes, completed N = no, unable to complete The Pre-delivery Preparation is performed prior to each delivery. The inspection is R = repaired designed to discover if anything is apparently Comments...
Page 51 OPERATOR’S MANUAL with Maintenance Information Maintenance Maintenance Inspection Report Model Checklist A Serial number A-1 Manuals and decals Date A-2 Pre-operation inspect Hour meter A-3 Check the Batteries Machine owner A-4 Check the Engine Oil Level Inspected by (print) A-5 Check the Hydraulic Oil Level Inspector signature A-6 Check the Engine Coolant Inspector title...
Page 52 OPERATOR’S MANUAL with Maintenance Information Maintenance B-14 Engine maintenance Checklist C C-1 Platform overload C-2 Engine maintenance Checklist D D-1 Return filter element D-2 Free-wheel configuration D-3 Engine maintenance Checklist E E-1 Test or replace hydraulic oil Perform every 2000 hours: E-2 Engine maintenance Perform every 3000 hours: E-3 Engine maintenance...
Page 53 Note: Contact your authorized DINGLI procedure or hazard and could result in unsafe distributor or DINGLI machinery if replacement operating conditions. manuals or decals are needed. Check to make sure that the operator’s manual is present and complete in the storage container on the platform.
Page 54 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 55 OPERATOR’S MANUAL with Maintenance Information Maintenance Check the Engine Oil Level Check the Hydraulic Oil Level Maintaining the proper engine oil level is Maintaining the hydraulic oil at the proper level essential to good engine performance and is essential to machine operation. Improper service life.
Page 56 OPERATOR’S MANUAL with Maintenance Information Maintenance Check the Engine Coolant 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 engine coolant at the proper the machine is put into service.
Page 57 OPERATOR’S MANUAL with Maintenance Information Maintenance A-10 Perform Engine Maintenance Perform Engine Maintenance Engine specifications require that this Engine specifications require that this one-time procedure be performed every 8 hours or daily, procedure be performed after 50 hours of whichever comes first. operation.
Page 58 Maintenance Checklist B Procedures Inspect the Batteries Remove the battery vent caps and check DINGLI requires that this procedure be the specific gravity of each battery cell with performed every 250 hours or quarterly, a hydrometer. Note the results. whichever comes first.
Page 59 0.1 OR the specific gravity of one or more cells is less than 1.177. Replace the battery. DINGLI requires that this procedure be 10 Check the battery acid level. If needed, performed every 250 hours or quarterly, replenish with distilled water to 1/8 inch I 3 whichever comes first.
Page 60 Emergency Stop button to the on position. Dingli requires that this procedure be Start the engine from the ground controls performed every 250 hours or quarterly, and raise the platform approximately 5.5m whichever comes first.
Page 61 OPERATOR’S MANUAL with Maintenance Information Maintenance Inspect the Tires and Wheels Check the Oil Level in the Drive Hubs Dingli requires that this procedure be Dingli requires that this procedure be performed every 250 hours or quarterly, performed every 250 hours or quarterly,...
Page 62 OPERATOR’S MANUAL with Maintenance Information Maintenance Test the Key Switch Test the Emergency Stop Dingli requires that this procedure be Dingli requires that this procedure be performed every 250 hours or quarterly, performed every 250 hours or quarterly, whichever comes first.
Page 63 OPERATOR’S MANUAL with Maintenance Information Maintenance Test the Automotive-style Horn Test the Drive Brakes Dingli requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Dingli requires that this procedure be A functional horn is essential to safe machine performed every 250 hours or quarterly, whichever comes first.
Page 64 Test the Drive Speed - Stowed Braking distance, maximum Position High range on paved surface 120cm Dingli requires that this procedure be performed every 250 hours or quarterly, whichever comes Proper drive function movement is essential to safe machine operation. The drive function should respond quickly and smoothly to operator control.
Page 65 Maintenance B-11 B-12 Test the Drive Speed -Raised Position Lubrication Dingli requires that this procedure be Dingli requires that this procedure be performed every 250 hours or quarterly, performed every 100 hours or month, whichever comes first. whichever comes first.
Page 66 OPERATOR’S MANUAL with Maintenance Information Maintenance Grease nipple Grease nipple Grease nipple Grease nipple Grease nipple Grease nipple Grease Grease nipple nipple Grease nipple Grease nipple Grease Grease nipple Grease nipple nipple The following points must be lubricated on Grease the platform in particular: nipple •...
Page 67 B-13 B-14 Perform Hydraulic Oil Analysis Perform Engine Maintenance Engine specifications require that this Dingli requires that this procedure be procedure be performed every 250 hours or performed every 250 hours or quarterly, quarterly, whichever comes first. whichever comes first.
Page 68 Maintenance Checklist C Procedures Test the Platform Overload System ¤ Result: The overload alarm at the platform Dingli specifications require that this procedure controls sounds. Calibrate the platform be performed every 500 hours or overload system. semi-annually, whichever comes first OR when...
Page 69 OPERATOR’S MANUAL with Maintenance Information Maintenance 10 Test all machine functions from the ground controls. Perform Engine Maintenance ⊙ Result: All ground control functions should operate. 11 Turn the key switch to platform control. Engine specifications require that this And start the engine from platform controls procedure be performed every 500 hours or 12 Test all machine functions from the semi-annually, whichever comes first.
Page 70 Checklist D Procedures Check the Free-wheel Configuration Replace the Hydraulic Tank Return Filter Element Dingli specifications require that this procedure be performed every 1000 hours or annually, DINGLI requires that this procedure be whichever comes first. performed every 1000 hours or annually, Proper use of the free-wheel configuration is whichever comes first.
Page 71 OPERATOR’S MANUAL with Maintenance Information Maintenance Chock the rear wheels. Center a lifting jack of ample capacity Perform Engine Maintenance (50,000 lbs / 25,000 kg) under the drive chassis between the front wheels. Lift the wheels off the ground and place Engine specifications require that this blocks under the drive chassis for support.
Page 72 Maintenance Checklist E Procedures Test or Replace the Hydraulic Oil Bodily injury hazard. DINGLI requires that this procedure be Spraying hydraulic oil can penetrate and burn performed every 2000 hours or every two skin. Loosen hydraulic connections very slowly years, whichever comes first.
Page 73 OPERATOR’S MANUAL with Maintenance Information Maintenance 11 Install a new oil filter onto the tank and install the tank cover. Perform Engine Maintenance 12 Install the breather cap onto the hydraulic tank. 13 Install the hydraulic tank and install and Engine specifications require that this tighten the hydraulic tank retaining procedure be performed every 2000 hours or...
Page 74 OPERATOR’S MANUAL with Maintenance Information Maintenance Perform Engine Maintenance Perform Engine Maintenance Engine specifications require that this Engine specifications require that this procedure be performed every 3000 hours, procedure be performed every 6000 hours. Required maintenance procedures and Required maintenance procedures and additional engine information is available in the additional engine information is available in the engine operator’s manual.
Page 75 OPERATOR’S MANUAL with Maintenance Information Maintenance Fault State In the fault state, a fault code from the list will be displayed flashing at a 1 Hz rate (0.5 seconds on, 0.5 off). List of Fault Codes Display Display for Ground Description Description Platform...
Page 76 OPERATOR’S MANUAL with Maintenance Information Maintenance Display Display for Ground Description Repair Platform Platform Drive Enable Switch Check the switch, PCU enable button fault ON at power-up replace the platform PCU joystick out of neutral Platform Joystick not in neutral Check the switch, fault ON at power-up...
Page 77 OPERATOR’S MANUAL with Maintenance Information Maintenance Display Display for Ground Description Repair Platform check the wiring, Brake valve fault Brake valve fault replace the valve Engine oil under pressure check the wiring, Oil Pressure Fault fault replace the sensor Engine water over check the wiring, Water Temperature Fault temperature fault...
Page 78 Drive reverse Prop Coil Fault replace the valve Remove the excess Overload fault Platform Overload Fault load immediately. Machine Tilted Beyond Safe check the wiring, Tilt fault Limits Fault replace the sensor For more information, please consult the appropriate Dingli Service Dept.
Page 79 OPERATOR’S MANUAL with Maintenance Information Schematic Hydraulic Schematic - Function model...
Page 80 OPERATOR’S MANUAL with Maintenance Information Schematic Hydraulic Schematic - Drive model...
Page 81 OPERATOR’S MANUAL with Maintenance Information Schematic Electrical Schematic...
Page 82 OPERATOR’S MANUAL with Maintenance Information Schematic...
Page 83 OPERATOR’S MANUAL with Maintenance Information Inspection and Repair Log The maintenance checks carried out on the machine must be recorded in a document called the Inspection Register. Replacements of the components of the hydraulic system, electrical system, mechanisms or structural elements, safety devices as well as faults of a certain entity and relative repairs must also be recorded in the Inspection Register.
Page 84 Zhejiang Dingli Machinery Co., Ltd. No.188 Qihang Road. Deqing Zhejiang P.R. China 313219 Tel: +86-572-8681688 Fax: +86-572-8681690 Web: www.cndingli.com E-mail:market@cndingli.com...

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