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Operation Service Manual

1. N E Platform Overload Option gi S1 S2 BRK M ACC M14x1 5 Pb Ti M18x1 5 H L D1 D2 D3 D4 M16x1 5 ry st s2 L 8 Sv38 20 4 gman EN svos 47A 2 4 y F AT RV08 22 1 DiS a n I an S CV08 20 e D rh Bea ie Fi 13 ls pm i nee SV10 47B 1 Ser IA 8 bar SV10 31 T Mas Rv08 22 ES SV10 24 aL A 4 1 1 D2 1 4 SIT F 1 i J HE ed RV08 22 8 5 4 1 A ji 2 F 1 D1 sl 1 5mm SV08 25 P T BRK ACC 47 JCPT1212DC Lift Cylinder Platform Overload Option a Ka E Si ER L 2 gt V38 20 TT ES SV08 47A 214 4 e a f I 4 ue CV08 20 3 1 CV08 20 5 Y Be 1 1 hi 2 1 a FRRV10 41F SV10 40 2 Lei 4 Li La al e Lal 4 4 1 i i 2 2 TS 1 RV08 22 SV08 25 48 Schematic JCPT1012DC JCPT1008DC JCPT0808DC Schematic Lift Cylinder Platform gt Overload Option on Si s2 2 l SV38 20 SV08 47A 24 1 7 4 CV08 20 4 4
2. Wear pads Tires and wheels Ground strap Limit switches alarms and horn Nuts bolts and other fasteners Platform overload components Platform entry gate Beacon and alarms if equipped Safety arm Platform extension s Scissor pins and retaining fasteners Pre operation Inspection Platform control joystick Brake release components Check entire machine for Cracks in welds or structural components Dents or damage to machine Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened Be sure side rails are installed and rail pins and bolts are fastened Be sure that the chassis trays are closed and latched and the batteries are properly connected Note If the platform must be raised to inspect the machine make sure the safety arm is in place See Operating Instructions section Observe and Obey Only routine maintenance items specified in this manual shall be performed by the operator Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual Maintenance Symbols Legend NOTICE fm following symbol
3. Hydraulic Schematic JCPT1212HD Upper Lift Cylinder Lift Cylinder I Platform S Overload Y Option S1 S2 BRK M ACC M14x1 5 Vv P T M18x1 5 4 a a L D1 D2 D3 D4 M16x1 5 I d st s2 L 2 V38 20 TT ES SS dates e CV08 20 SVOB 47A 2 4 Y Bu 4 RVO8 22 1 D F 1 2 Hol S TES 3 1 CVe8 20 pom ay E PEER z ST P ja 3 ei a FRRV10 41F pl i 2 S o 1 H Z SE SV10 47B LA s 8 bar SV10 31 i el GZ RV08 22 E SV10 24 o Si D2 E a fea H ell E I y J 1 4 PO RVO8 22 LA D1 oH s cl H 1 5mm 2 v i 4 H H SV08 25 P T BRK ACC 46 Schematic JCPT1012HD JCPT1008HD JCPTO808HD Lift Cylinder
4. 3 1 CV88 20 e if CAAA 1 1 2 a FRRV10 41F SV10 40 LA 4 P l me l a IS 1 e S 4 2 2 1 3 RV08 22 2 m 1 a i M 1 SV08 25 P T 2 ES bag a gt I 49 Schematic Electrical Schematic JCPT0808HD JCPT1008HD JCPT1012HD JCPT1212HD Alan Horr 88 ae i tor latforn Controller a Not use E 8 load signal output ower ower Platform Left up signal output ropel Reverse signal output tor Control output tor Control output Not used ressure sensor Input Chassis Down Rocker Switch Input CAN Hich Key Switch Power Platforr ower Scissor Angle Sensor Input ot Used latform Down Output Steering Turn left Signal Output Horn Signal QuiPut Alarm Output thole Limit Switch Input Platform Full Up Limit Switch Input hassis Up Rocker Switch Input control wer 4 IE ox essure Sensor Input ot use ot use Propel Forward Output teering Turn Right Output rive Control interlocking Signal Output e 3rake Output 4 Not use cl Tit Alarm Input n Limit Switch Input Full Up Limit Switch lo lt ol oa Pothole Limit Switct 50 Schematic JCPT0808DC JCPT1008DC JCPT1012DC JCPT1212DC 7A Fus 250A Fuse Pump Moto Platform E Stoj Plattorr S
5. Raise the platform Result Before the platform is raised 2 m from the ground an alarm should sound and the drive function should not Work 47 Lower the platform and remove the 2x4 wood block Do Not Operate Unless V You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace Know and understand the workplace inspection before going on to the next section 5 Only use the machine as it was intended Workplace Inspection Fundamentals The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation lt should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Workplace Inspection Be aware of and avoid the following hazardous situations Drop offs or holes Bumps floor obstructions or debris Sloped surfaces Unstable or slippery surfaces Overhead obstructions and high voltage conductors Hazardous locations Inadequate surface support to withstand all load forces imposed by the machine Wind and weather conditions The presence of unauthorized personn
6. Tilt Operation instruction Capacity Decal N Series Name Decal Model Name Decal Notice Side Force Safety Arm Danger Crush Hazard VVarning Crush Hazard AINININININ Crane Hole Decal E Tie Hole Decal N VVarning Pre Operation N Danger Explosion burn Hazard Nameplate Emergency Lovver VVarning Battery Charging VVarning Crush Hazard Forklift Pocket Harness Decal Niaai ajfjaj a gt Notice Keyswitch 36 Decals JCPTO808HD JCPT1008HD JCPT1012HD JCPT1212HD JCPT0808DC JCPT1008DC JCPT1012DC JCPT1212DC 37 Model JCPT0808HD Height working maximum 8m Height platform maximum 6m Height stowed maximum 2 21m Rails up Height stovved maximum 1 75 m Rails lowered Width 0 81 m Length platform retracted 2 48 m Length platform extended 3 38 m Platform length x width 2 27 x 0 81 m Platform extension length 0 9m Maximum load capacity 380 kg Maximum wind speed 12 5 m s Wheelbase 1 87 m Turning radius outside 2 19 m Turning radius inside 0 Ground clearance 10cm Ground clearance 1 9 cm Pothole guards deployed Weight 1950kg Machine weights vary with option configurations Specifications Maximum hydraulic pressure 241 3 bar functions System voltage 24V Tire size d 381x127 Airborne noise emissions lt 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not ex
7. button 6 7 8 LED Horn button Lift function select button Proportional control handle and function enable switch for lift and drive functions Platform Control Panel 1 Thumb rocker switch for steer functions Press the thumb rocker switch in either direction to activate steer function Drive function select button Press this button to activate the drive function Drive speed button Press this button to activate the slow or fast drive function Red Emergency Stop button Push in the red Emergency Stop button to the off position to stop all functions Pull out the red Emergency Stop button to the on position to operate the machine LED Diagnostic read out and battery charge indicator Horn Button Push the horn button and the horn will sound Release the horn button and the horn will stop 7 Lift function select button Control Panel Press this button to activate the lift function 8 Proportional control handle and function enable switch for lift and drive functions Lift function Press and hold the function enable switch to enable the lift function on the platform control handle Move the control handle in the direction indicated by the blue arrow and the platform will raise Move the control handle in the direction indicated by the yellow arrow and the platform will lower The descent alarm should sound while the platform is lowering Drive function Press and h
8. follow the step by step instructions to test all machine functions A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection and function tests again before putting the machine into service Function Tests 1 Select a test area that is firm level and free of obstruction 2 Be sure the battery pack is connected At the Ground Controls 3 Pull out the platform and ground red Emergency Stop buttons to the on position Turn the key switch to ground control Observe the diagnostic LED readout on the platform controls 6 Push in the ground red Emergency Stop button to the off position O Result The LED should look like the picture at right Test Emergency Stop Result No functions should operate 7 Pull out the red Emergency Stop button to the on position Test Up Down Functions The audible warnings on this machine and the standard horn all come from the same central alarm The horn is a constant tone The descent alarm sounds at 60 beeps per minute The alarm that goes off when the pothole guards have not deployed sounds at 300 beeps per minute The alarm that goes off when the machine is not level sounds at 600 beeps per minute An o
9. in hazardous locations where potentially flammable or explosive gases or particles may be present A Damaged Machine Hazards Do not use a damaged or malfunctioning machine Conduct a thorough pre operation inspection of the machine and test all functions before each work shift Immediately tag and remove from service a damaged or malfunctioning machine Be sure all maintenance has been performed as specified in this manual and the appropriate DINGLI service manual Be sure all decals are in place and legible Be sure the operator s safety and responsibilities manuals are complete legible and in the storage container located in the platform A Bodily Injury Hazard Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Improper contact with components under any cover will cause serious injury Only trained maintenance personnel should access compartments Access by the operator is only advised when performing a pre operation inspection All compartments must remain closed and secured during operation Safety Rules A Battery Safety Burn Hazards yA Batteries contain acid Alvvays vvear protective clothing and eye vvear when working with batteries Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Explosion Hazard Keep sparks flames and lighted tobacco away from
10. piece of wood is level While holding the piece of wood level measure the distance from the bottom of the piece of Operating Instructions wood to the ground Divide the tape measure distance rise by the length of the piece of wood run and multiply by 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 or side slope rating the machine must be winched or transported up or down the slope See Transport and Lifting section Operation from Ground with Controller Maintain safe distances between operator machine and fixed objects Be aware of the direction the machine will travel when using the controller Battery Level Indicator Full Use the LED diagnostic readout to determine the battery level How to use the Safety Arm 1 Raise the platform approximately 3 m from the ground 2 Rotate the safety arm away from the machine and let it hang down 3 Lower the platform until the safety arm rests securely on the link Keep clear of the safety arm when lowering the platform A DANGER Don t engage the safety arm unless unload the platform 28 Operating Instructions How to Fold Down the Guardrails The platform railing system consists of three fold down rail section for the extension deck and three section for the main deck All sections are held in place by four wire lock pins 1 Fully lower the platform and retract the pl
11. points on the control panel Test Drive and Braking 31 Press and hold the function enable switch on the control handle 32 Slowly move the control handle in the direction indicated by the blue up arrow on the control panel until the machine begins to move then return the handle to the center position O Result The machine should move in the direction that the blue up arrow points on the control panel then come to an abrupt stop 33 Press and hold the function enable switch on the control handle 34 Slowly move the control handle in the direction indicated by the yellow down arrow on the control panel until the machine begins to move then return the handle to the center position O Result The machine should move in the direction that the yellow down arrow points on the control panel then come to an abrupt stop Note The brakes must be able to hold the machine on any slope it is able to climb 22 Function Tests Test Limited Drive Speed 35 Press and hold the lift function enable switch Raise the platform approximately 2 1 m from the ground O Result The pothole guards should deploy 36 Press and hold the function enable switch on the control handle 37 Slowly move the control handle to the full drive position Result The maximum achievable drive speed with the platform raised should not exceed 20 cm s If the drive speed with the platform raised exceeds 20 cm s immediately tag and remove
12. the control handle in the direction indicated by the blue arrow then in the direction indicated by the yellow arrow Result No functions should operate 22 Press the lift function select button 23 Press and hold the function enable switch on the control handle 24 Slowly move the control handle in the direction indicated by the blue arrow Result The platform should raise The pothole guards should deploy 25 Release the control handle Result The platform should stop raising 26 Press and hold the function enable switch Slowly move the control handle in the direction indicated by the yellow arrow Result The platform should lower The descent alarm should sound while the platform is lowering 21 Function Tests Test the Steering Note When performing the steer and drive function tests stand in the platform facing the steer end of the machine 27 Press the drive function select switch 28 Press and hold the function enable switch on the control handle 29 Depress the thumb rocker switch on top of the control handle in the direction identified by the blue left arrow on the control panel Result The steer wheels should turn in the direction that the blue left arrow points on the control panel 30 Depress the thumb rocker switch in the direction identified by the white right arrow on the control panel Result The steer wheels should turn in the direction that the white right arrow
13. 5m s Maximum slope rating O Stowed position SE Maximum side slope rating A pe 25 Stowed position Note Slope rating is subject to ground conditions and adequate traction Maximum working slope 3 Drive speeds Stowed maximum 5 0 km h Platform raised maximum 0 8 km h Floor loading information Tire load maximum 1000 kg Tire contact pressure 6 96 kg cm 682 kPa Occupied floor pressure 1142 kg m 11 19 kPa Power source Controls 4 Batteries 6V 210AH Proportional AC outlet in platform Standard 43 Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a DINGLI policy Product specifications are subject to change without notice or obligation Model JCPT1012DC Height working maximum 10m Height platform maximum 8m Height stowed maximum 2 33 m Rails up Height stowed maximum 1 86 m Rails lowered Width 1 15m Length platform retracted 2 48 m Length platform extended 3 38 m Platform length x width SE Platform extension length 0 9m Maximum load capacity 450 kg Maximum wind speed 12 5 m s Wheelbase 1 87 m Turning radius outside 2 33 m Turning radius inside 0 Ground clearance 10cm Ground clearance 1 9 cm Pothole guards deployed Weight 2300kg Machine weights vary with
14. CPT1012HD Maximum occupants 2 Platform retracted 450 kg Only platform 337 kg Only extension deck 113 kg Maximum capacity JCPT1212HD Maximum occupants 2 Platform retracted 320 kg Only platform 207 kg Only extension deck 113 kg Platform retracted Platform extended A El Extension Platform only only Maximum capacity JCPT0808DC Maximum occupants 2 Platform retracted 380 kg Only platform 267 kg Only extension deck 113 kg Maximum capacity JCPT1008DC Maximum occupants 2 Platform retracted 230 kg Only platform 117 kg Only extension deck 113 kg Maximum capacity JCPT1012DC Maximum occupants 2 Platform retracted 450 kg Only platform 337 kg Only extension deck 113 kg Maximum capacity JCPT1212DC Maximum occupants 2 Platform retracted 320 kg Only platform 207 kg Only extension deck 113 kg Platform retracted Platform extended t Extension Platform only only Safety Rules Work Area Safety Do not raise the platform unless the machine is on a firm level surface Do not drive over 0 8 km h with the platform raised Do not depend on the tilt alarm as a level indicator The tilt alarm sounds on the chassis and in the platform when the machine is on a slope If the tilt alarm sounds Lower the platform Move the machine to a firm level surface If the tilt alarm sounds when the platform is raised use extreme caution to lower the platform Do not raise the platform when wind speeds
15. CPT1212HD Height working maximum 12m Height platform maximum 10m Height stowed maximum 2 46 m Rails up Height stowed maximum 1 99 m Rails lowered Width 1 15m Length platform retracted 2 48 m Length platform extended 3 38 m Platform length x width 227x142 m Platform extension length 0 9m Maximum load capacity 320 kg Maximum wind speed 12 5 m s Wheelbase 1 87 m Turning radius outside 2 33 m Turning radius inside 0 Ground clearance 10cm Ground clearance 1 9 cm Pothole guards deployed Weight 2730kg Machine weights vary with option configurations Specifications Maximum hydraulic pressure 241 3 bar functions System voltage 24V Tire size d 381x127 Airborne noise emissions lt 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s Maximum slope rating O Stowed position SE Maximum side slope rating A a 25 Stowed position Note Slope rating is subject to ground conditions and adequate traction Maximum working slope 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 7 44 kg cm 729 kPa Occupied floor pressure 1045 kg m 10 25 kPa Power source Controls 4 Batteries 6V 210AH Proportional AC outlet in platform Standard 41 Note Floo
16. ELECTRIC SCISSOR LIFTS Operation Service Manual JCPT0808HD JCPT1008HD JCPT1012HD JCPT1212HD JCPT0808DC JCPT1008DC JCPT1012DC JCPT1212DC A WARNING THE MANUFACTURER SHALL NOT BE HELD LIABLE IN CASE OF FAULTS OR ACCIDENTS DUE TO NEGLIGENCE INCAPACITY INSTALLATION BY UNQUALIFIED TECHNICIANS AND IMPROPER USE OF THE MACHINE DO NOT OPERATE THIS MACHINE UNTIL YOU READ AND UNDERSTAND ALL THE DANGERS WARNINGS AND CAUTIONS IN THIS MANUAL Important Read understand and obey these safety rules and operating instructions before operating this machine Only trained and authorized personnel shall be permitted to operate this machine This manual should be considered a permanent part of your machine and should remain with the machine at all times If you have any questions please call DINGLI Machinery Contents Page Safety Rules 1 Control panel 12 Pre operation Inspection 15 Maintenance 17 Function Tests 19 Workplace Inspection 24 Operating Instructions 25 Transport and Lifting Instructions 32 Decals 36 Specifications 38 Schematic 46 Owners Users and operators We appreciate your choice of our machine for your application Our number one priority is user safety which is best achieved by our joint efforts We feel that you make a major contribution to safety if you as the equipment users and operators 1 Comply with employer job site and governmental rules 2 Read understand and follow the instructions i
17. S PAY Mf NA Switch gt Controller Forward Raise Platform Rai Platform Down C Turn Left coil Turn Right co CEJA i dicator ensor 2 1243 Contriller Contro ignal Output gt Main Relay tll 1 94 r Sianal lt fi up signal output gt signal output ccelerat Brak ntr Forware Signal o16 Key Switch Power Platfor sensor Input Steering Turn left Signal Output Horn Signal OutPut Alarm Output Pothole Limit Switch Input form Full Up Limit Switch Input Chas Rocker Switch Input LED I DCH a O Sensor Input 1 ontrol O 5V Accelerator Signal Output Not_used ropel Forward Output steering Turn Right Out ontrol interlockir A it Jri Signal Output Not us Not us 1 Tilt Alarma Input lt Down Limit Switch Input
18. ary with option configurations Specifications Maximum hydraulic pressure 241 3 bar functions System voltage 24V Tire size d 381x127 Airborne noise emissions lt 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s Maximum slope rating O Stowed position SE Maximum side slope rating A pe 25 Stowed position Note Slope rating is subject to ground conditions and adequate traction Maximum working slope 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 6 96 kg cm 682 kPa Occupied floor pressure 1142 kg m 11 19 kPa Power source Controls 4 Batteries 6V 210AH Proportional AC outlet in platform Standard 39 Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a DINGLI policy Product specifications are subject to change without notice or obligation Model JCPT1012HD Height working maximum 10m Height platform maximum 8m Height stowed maximum 2 33 m Rails up Height stowed maximum 1 86 m Rails lowered Width 1 15m Length platform retracted 2 48 m Length platform extended 3 38 m Platform le
19. atform extension 2 Remove the platform controls 3 From inside the platform remove the two front extension deck wire lock pins 4 Fold down the front rail assembly Keep hands clear of pinch points 5 Replace the two removed pins back into each side rail bracket 6 Fold down the extension platform right rail assembly Keep hands clear of pinch points 7 Fold down the extension platform left rail assembly Keep hands clear of pinch points 8 Carefully open the gate and move to the rear step or the ground 9 From the rear step or from the ground remove the right rear main deck wire lock 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 13 Fold down the left rail assembly Keep hands clear of pinch points 14 Replace the removed pin back into rear rail bracket How to Raise the Guardrails Follow the fold down instructions but in reverse order 29 Operating Instructions To Extend and Retract Platform 1 Press the platform lock pin pedal on the extension deck by foot Push the platform extension guardrail to extend the platform to the desired position Do not stand on the platform extension while trying to extend it Error indicator readout If the LED diagnostic readout displays an error code such as LL push in and pull out the red Emerge
20. batteries Batteries emit explosive gas The battery tray should remain open during the entire charging cycle Do not contact the battery terminals or the cable clamps with tools that may cause sparks Component Damage Hazard Do not use any battery charger greater than 24V to charge the batteries Safety Rules Electrocution Burn Hazard Connect the battery charger to a grounded AC 3 wire electrical outlet only w Inspect daily for damaged cords cables and wires Replace damaged items before operating Avoid electrical shock from contact with battery terminals Remove all rings watches 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 Each battery must weigh 33 kg Battery tray including batteries must weigh a minimum of 165 kg Lifting Hazard Use the appropriate number of people and proper lifting techniques when lifting batteries Lockout After Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Lower the platform 3 Turn the key switch to the off position and remove the key to secure from unauthorized use 4 Chock the wheels 5 Charge the batteries Safety Rules Legend 7 6 5 E 4 2 4 SC SCH 16 15 14 13 eck as 48 12 17 40 UV 1 Lanyard anchorage point 10 Battery charger 2 Platform guard rail
21. ceed 2 5m s Maximum slope rating O Stowed position SE Maximum side slope rating A pe 25 Stowed position Note Slope rating is subject to ground conditions and adequate traction Maximum working slope 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 6 96 kg cm 682 kPa Occupied floor pressure 1060 kg m 10 39 kPa Power source Controls 4 Batteries 6V 210AH Proportional AC outlet in platform Standard 38 Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a DINGLI policy Product specifications are subject to change without notice or obligation Model JCPT1008HD Height working maximum 10m Height platform maximum 8m Height stowed maximum 2 33 m Rails up Height stowed maximum 1 88 m Rails lowered Width 0 81 m Length platform retracted 2 48 m Length platform extended 3 38 m Platform length x width SE Platform extension length 0 9m Maximum load capacity 230 kg Maximum wind speed 12 5 m s Wheelbase 1 87 m Turning radius outside 2 19 m Turning radius inside 0 Ground clearance 10cm Ground clearance 1 9 cm Pothole guards deployed Weight 2100kg Machine weights v
22. d used in accordance with the manufacturer s instructions A Electrocution Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current Maintain safe distances from electrical power lines and apparatus in accordance with applicable governmental regulations and the following chart Minimum Safe Voltage Approach Distance Phase to Phase 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 line sway or sag and beware of strong or gusty winds Keep away from the machine if it contacts energized power lines Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off Do not operate the machine during lightning or storms Do not use the machine as a ground for welding Safety Rules A Tip over Hazards Occupants equipment and materials must not exceed the maximum platform capacity or the maximum capacity of the platform extension Maximum capacity JCPT0808HD Maximum occupants 2 Platform retracted 380 kg Only platform 267 kg Only extension deck 113 kg Maximum capacity JCPT1008HD Maximum occupants 2 Platform retracted 230 kg Only platform 117 kg Only extension deck 113 kg Maximum capacity J
23. e entry is secured for operation Do not enter or exit the platform unless the machine is in the stowed position A Collision Hazards Be aware of limited sight distance and blind spots when driving or operating Be aware of extended platform position s when moving the machine Check the work area for overhead obstructions or other possible hazards Be aware of crushing hazards when grasping the platform guard rail Operators must comply with employer job site and governmental rules regarding use of personal protective equipment Observe and use color coded direction arrows on the platform controls and platform decal plate for drive and steer functions Do not operate a machine in the path of any crane or moving overhead machinery unless the controls of the crane have been locked out and or precautions have been taken to prevent any potential collision No stunt driving or horseplay while operating a machine Do not lower the platform unless the area below is clear of personnel and obstructions Safety Rules Limit travel speed according to the condition of the ground surface congestion slope location of personnel and any other factors which may cause collision A Component Damage Hazards Do not use any battery or charger greater than 24V to charge the batteries Do not use the machine as a ground for welding A Explosion and Fire Hazards Do not operate the machine or charge the batteries
24. el Other possible unsafe conditions Do Not Operate Unless v You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended 25 Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation It is the operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel along with their tools and materials to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected to use a machine at different times in the same work shift they must all be qualified operators and are all expected to follow all safety rules and instructions in the operator s safety and responsibilities manuals That means every new operator should perform a pre operation inspection function tests and a workplace inspection before using the machine Emergency Stop Push in the red Emergency Stop button to the off position at the ground controls or the platform controls to stop all machine functions Repair a
25. emove all loose items on the machine Fully lower the platform The platform must remain lowered during all loading and transport procedures Use the forklift pockets located on both sides of the ladder 34 Transport and Lifting Instructions Lifting Instructions Center of gravity Fully lower the platform Be sure the extension decks controls and covers are secure Remove I Model X Axis Y Axis all loose items on the machine Determine the center of gravity of your machine JCPTO808HD 90 5 cm 56 5cm using the table and the picture on this page JCPT0808DC Attach the rigging only to the designated lifting E 80 6cm 57 6cm points on the machine There are two lifting JCPT1008DG points on each end of the machine JCPT1012HD 89cm 64 4cm JCPT1012DC Adjust the rigging to prevent damage to the i machine and to keep the machine level ai 83cm 68 2cm JCPT1212DC Ladder te Lifting PRS o Lifting Points 2 35 Decals Decal Inspection Use 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 Part No Description Qty Notice Manual Box IPAF Decal CE Decal Logo Decal Danger Safety Rules Danger Tip over Hazard I sch sech Danger
26. ersonnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury TAWARNING orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Ae with safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury NOTICE PA without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage Intended Use This machine is intended to be used only to lift personnel along with their tools and materials to an aerial work site Safety Sign Maintenance Replace 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 because they may damage the safety sign material Safety Rules Personal Safety Fall Protection Personal fall protection equipment PFPE is not required when operating this machine If PFPE is required by job site or employer rules the following shall apply All PFPE must comply with applicable governmental regulations and must be inspected an
27. gli Service Manual 30 Battery and Charger Instructions Observe and Obey Y Do not use an external charger or booster battery y Charge the battery in a well ventilated area V Use proper AC input voltage for charging as indicated on the charger Y Use only a Dingli authorized battery and charger To Charge Battery 1 Be sure the batteries are connected before charging the batteries 2 Open the battery compartment The compartment should remain open for the entire charging cycle Maintenance free batteries 3 Connect the battery charger to a grounded AC circuit 4 The charger will indicate when the battery is fully charged 31 Operating Instructions Standard Batteries 3 Remove the battery vent caps and check the battery acid level If necessary add only enough distilled water to cover the plates Do not overfill prior to the charge cycle 4 Replace the battery vent caps 5 Connect the battery charger to a grounded AC circuit 6 The charger will indicate when the battery is fully charged 7 Check the battery acid level when the charging cycle is complete Replenish with distilled water to the bottom of the fill tube Do not overfill Dry Battery Filling and Charging Instructions 1 Remove the battery vent caps and permanently remove the plastic seal from the battery vent openings 2 Fill each cell with battery acid electrolyte unti
28. h 227x142 m Platform extension length 0 9m Maximum load capacity 320 kg Maximum wind speed 12 5 m s Wheelbase 1 87 m Turning radius outside 2 33 m Turning radius inside 0 Ground clearance 10cm Ground clearance 1 9 cm Pothole guards deployed Weight 2730kg Machine weights vary with option configurations Specifications Maximum hydraulic pressure 241 3 bar functions System voltage 24V Tire size d 381x127 Airborne noise emissions lt 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s Maximum slope rating O Stowed position SE Maximum side slope rating A a 25 Stowed position Note Slope rating is subject to ground conditions and adequate traction Maximum working slope 3 Drive speeds Stowed maximum 5 0 km h Platform raised maximum 0 8 km h Floor loading information Tire load maximum 1000 kg Tire contact pressure 7 44 kg cm 729 kPa Occupied floor pressure 1045 kg m 10 25 kPa Power source Controls 4 Batteries 6V 210AH Proportional AC outlet in platform Standard 45 Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a DINGLI policy Product specifications are subject to change without notice or obligation Schematic
29. l the level is sufficient to cover the plates Do not fill to maximum level until the battery charge cycle is complete Overfilling can cause the battery acid to overflow during charging Neutralize battery acid spills with baking soda and water 3 Install the battery vent caps 4 Charge the battery 5 Check the battery acid level when the charging cycle is complete Replenish with distilled water to the bottom of the fill tube Do not overfill Transport and Lifting Instructions Observe and Obey V Common sense and planning must be applied to control the movement of the machine when lifting it with a crane or forklift N Only qualified aerial lift operators should move the machine on or off the truck N The transport vehicle must be parked on a level surface N The transport vehicle must be secured to prevent rolling while the machine is being loaded N Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight See the serial label for the machine weight N The machine must be on a level surface or secured before releasing the brakes Y Do not allow the rails to fall when the snap pins are removed Maintain a firm grasp on the rails when the rails are lowered N Do not drive the machine on a slope that exceeds the slope or side slope rating See Driving on a Slope i
30. le toward center Stop Return the control handle to center or release the function enable switch Use the color coded direction arrows on the platform controls and on the platform to identify the direction the machine will travel Machine travel speed is restricted when the platform is raised Battery condition will affect machine performance Machine drive speed and function speed will drop when the battery level indicator is flashing To reduce drive speed The drive controls can operate in two different drive speed modes When the drive speed button light is on slow drive speed mode is active When the button light is off fast drive speed mode is active Press the drive speed button to select the desired drive speed A Driving on a slope Determine the slope and side slope ratings for the machine and determine the slope grade 0608 S0808 S0812 S1012 Maximum slope rating stowed position 25 Maximum side slope rating stowed position 25 Note Slope rating is subject to ground conditions and adequate traction Press the drive speed button to the fast drive speed mode To determine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need Carpenter s level straight piece of wood at least 1 m long tape measure Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood and lift the end until the
31. m perimeter Do not alter or disable machine components that in any way affect safety and stability Do not replace items critical to machine stability with items of different weight or specification Do not use batteries that weigh less than the original equipment Batteries are used as counterweight and are critical to machine stability Each battery must weigh 33 kg Battery box including batteries must weigh a minimum of 165 kg Do not modify or alter an aerial work platform without prior written permission from the manufacturer Mounting attachments for holding tools or other materials onto the platform toeboards or guard rail system can increase the weight in the platform and the surface area of the platform or the load Do not place ladders or scaffolds in the platform or against any part of this machine Do not transport tools and materials unless they are evenly distributed and can be safely handled by person s in the platform Do not use the machine on a moving or mobile surface or vehicle Be sure all tires are in good condition air filled tires are properly inflated and lug nuts are properly tightened Safety Rules Work Area Safety 4 Crushing Hazards Keep hands and limbs out of scissors Keep hands clear when folding rails Use common sense and planning when operating the machine with the controller from the ground Maintain safe distances between the operator the machine and fixed objects Mai
32. may exceed 12 5 m s If wind speeds exceed 12 5 m s when the platform is raised lower the platform and do not continue to operate the machine Do not operate the machine in strong or gusty winds Do not increase the surface area of the platform or the load Increasing the area exposed to the wind will decrease machine stability Do not use the platform controls to free a Safety Rules platform that is caught snagged or otherwise prevented from normal motion by an adjacent structure All personnel must be removed from the platform before attempting to free the platform using the ground controls Use extreme care and slow speeds while driving the machine in the stowed position across uneven terrain debris unstable or slippery surfaces and near holes and drop offs Do not drive the machine on or near uneven terrain unstable surfaces or other hazardous conditions with the platform raised Do not use the machine as a crane Do not place or attach fixed or overhanging loads to any part of this machine Do not push the machine or other objects with the platform Do not operate the machine with the chassis trays open Do not contact adjacent structures with the platform Do not alter or disable the limit switches Do not push off or pull toward any object outside of the platform Maximum allowable manual force 400 N Do not tie the platform to adjacent structures Do not place loads outside the platfor
33. n the Operating Instructions section N If the slope of the transport vehicle bed exceeds the maximum slope rating the machine must be loaded and unloaded using a winch as described Brake Release Operation For the Hydraulic Motor Drive Model 1 Chock the wheels to prevent the machine from rolling 2 Be sure the winch line is properly secured to the drive chassis tie points and the path is clear of all obstructions 3 Push in the black brake release knob to open the brake valve 4 Pump the red brake release pump knob For the DC Motor Drive Model 1 Chock the wheels to prevent the machine from rolling 2 Pull out the red Emergency Stop button on both the ground and platform controls to the on position 3 Press and hold lift switch to down position in ground control meanwhile turn on the key switch to the Ground position The brake will be released after Alarm alerts 4 If you want to close the brake release just turn off the key switch in ground position Towing the Hydraulic Drive Model is not recommended If the machine must be towed do not exceed 3 5 km h Towing the DC Motor Drive Model is not recommended If the machine must be towed do not exceed 4 1 km h Transport and Lifting Instructions Securing to Truck or Trailer for Transit Always chock the machine wheels in preparation for transport Retract and secure the extension deck s Turn the key switch to the off posi
34. n this and other manuals supplied with this machine 3 Use good safe work practices in a commonsense way 4 Only have trained certified operators directed by informed and knowledgeable supervision running the machine If there is anything in this manual that is not clear or which you believe should be added please contact us Contact us Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless Y You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations Know and understand the safety rules before going on to the next section 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended W You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals N You read understand and obey employer s safety rules and worksite regulations N You read understand and obey all applicable governmental regulations W You are properly trained to safely operate the machine Safety Rules Decal Legend DINGLI product decals use symbols color coding and signal words to identify the following A Safety alert symbol used to alert p
35. ncy Stop button to reset the system Fault Codes Code Description Condition Normal 01 System initialization error 02 System communication error 03 Invalid option Setting 12 Chassis Up Down Switch ON at Power up 18 Pothole Guard Failure 31 Pressure Sensor Fault 32 Angle Sensor Fault 34 Mode Switch Failure 42 Platform Left Turn Switch ON at Power up 43 Platform Right Turn Switch ON at Power up 46 Platform Joystick Enable Switch ON at Power up 47 Platform Joystick not in neutral at power up 52 Drive Forward Coil Fault 53 Drive Reverse Coil Fault 54 Lift Up Coil Fault 55 Lift Down Coil Fault 56 Right Turn Coil Fault 57 Left Turn Coil Fault 58 Brake Fault Operating Instructions 59 Low Speed Coil Fault 61 Motor Controller Current Sensor Fault Motor Controller Hardware Failsafe 62 Fault 63 Motor Controller Motor Output Fault 64 Motor Controller SRO Fault 65 Motor Controller Throttle Fault Motor Controller Emergency Reverse 66 Fault 67 Motor Controller HPD Fault 68 Low Voltage Fault 71 Motor Controller Main Contactor Fault 72 Motor Controller Over Voltage Fault Motor Controller Thermal Cutback 73 Fault 74 Motor Controller Motor Fault 80 Over 80 Load 90 Over 90 Load 99 Over 100 Load OL Overloaded Platform LL Machine Tilted beyond safe limits For more information please consult the appropriate Din
36. ngth x width SE Platform extension length 0 9m Maximum load capacity 450 kg Maximum wind speed 12 5 m s Wheelbase 1 87 m Turning radius outside 2 33 m Turning radius inside 0 Ground clearance 10cm Ground clearance 1 9 cm Pothole guards deployed Weight 2300kg Machine weights vary with option configurations Specifications Maximum hydraulic pressure 241 3 bar functions System voltage 24V Tire size d 381x127 Airborne noise emissions lt 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s Maximum slope rating O Stowed position SE Maximum side slope rating A a 25 Stowed position Note Slope rating is subject to ground conditions and adequate traction Maximum working slope 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 7 09 kg cm 694 kPa Occupied floor pressure 881 kg m 8 63 kPa Power source Controls 4 Batteries 6V 210AH Proportional AC outlet in platform Standard 40 Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a DINGLI policy Product specifications are subject to change without notice or obligation Model J
37. ntain a firm grasp on the platform rail when removing the rail pins Do not allow the platform guard rails to fall A Operation on Slopes Hazards Do not drive the machine on a slope that exceeds the slope and side slope rating of the machine Slope rating applies to machines in the stowed position Maximum Maximum Model slope ratingside slope rating stowed position stowed position JCPT0808HD 25 14 25 14 JCPT1008HD 25 14 25 14 JCPT1012HD 25 14 25 14 JCPT1012HD 25 14 25 14 JCPT0808DC 25 14 25 14 JCPT1008DC 25 14 25 14 JCPT1012DC 25 14 25 14 JCPT1012DC 25 14 25 14 Note Slope rating is subject to ground conditions and adequate traction Safety Rules A Fall Hazards The guard rail system provides fall protection If occupant s of the platform are required to wear personal fall protection equipment PFPE due to job site or employer rules PFPE equipment and its use shall be in accordance with the PFPE manufacturer s instructions and applicable governmental requirements Do not sit stand or climb on the platform guard rails Maintain a firm footing on the platform floor at all times Do not climb down from the platform when raised Keep the platform floor clear of debris Close the entry gate before operating Do not operate the machine unless the guard rails are properly installed and th
38. ny function that operates when either red Emergency Stop button is pushed in Emergency Lowering 1 Pull the emergency lowering knob Operation from Ground 1 Turn the key switch to ground control 2 Pull out both ground and platform red Emergency Stop buttons to the on position 3 Be sure the battery pack is connected before operating the machine To Position Platform 1 Move the up down toggle switch according to the markings on the control panel Drive and steer functions are not available from the ground controls 26 Operating Instructions Operation from Platform 1 Turn the key switch to platform control 2 Pull out the ground and platform red Emergency Stop buttons to the on position 3 Be sure the battery pack is connected before operating the machine To Position Platform 1 Press the lift function select button 2 Press and hold the lift function enable switch on the control handle 3 Move the control handle according to the markings on the control panel To Steer 1 Press the drive function select button 2 Press and hold the function enable switch on the control handle 3 Turn the steer wheels with the thumb rocker switch located on the top of the control handle To Drive 1 Press the drive function select button 2 Press and hold the function enable switch on the control handle 3 Increase speed Slowly move the control handle off center Decrease speed Slowly move the control hand
39. old the function enable switch to enable the drive function on the platform control handle Move the control handle in the direction indicated by the blue arrow on the control panel and the machine will move in the direction that the blue arrow points Move the control handle in the direction indicated by the yellow arrow on the control panel and the machine will move in the direction that the yellow arrow points Do Not Operate Unless v You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection Know and understand the pre operation inspection before going on to the next section 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended Pre operation Inspection Fundamentals It is the responsibility of the operator to perform a pre operation inspection and routine maintenance The pre operation inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on
40. option configurations Specifications Maximum hydraulic pressure 241 3 bar functions System voltage 24V Tire size d 381x127 Airborne noise emissions lt 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s Maximum slope rating O Stowed position SE Maximum side slope rating A a 25 Stowed position Note Slope rating is subject to ground conditions and adequate traction Maximum working slope 3 Drive speeds Stowed maximum 5 0 km h Platform raised maximum 0 8 km h Floor loading information Tire load maximum 1000 kg Tire contact pressure 7 09 kg cm 694 kPa Occupied floor pressure 881 kg m 8 63 kPa Power source Controls 4 Batteries 6V 210AH Proportional AC outlet in platform Standard 44 Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a DINGLI policy Product specifications are subject to change without notice or obligation Model JCPT1212DC Height working maximum 12m Height platform maximum 10m Height stowed maximum 2 46 m Rails up Height stowed maximum 1 99 m Rails lowered Width 1 15m Length platform retracted 2 48 m Length platform extended 3 38 m Platform length x widt
41. ptional automotive style horn is also available 8 Turn the key switch to off or platform position 9 Move up and hold the platform switch Result No function should operate 10 Turn the key switch to ground control position 11 Move up and hold the platform up switch 20 Result The platform should raise 12 Move down and hold the platform down switch Result The platform should lower then stop at the height is 2 1 m The descent alarm should sound while the platform is lowering 13 Move down and hold the platform down switch Result The platform should lower to end The descent alarm should sound while the platform is lowering Test the Emergency Lowering 14 Activate the up function and raise the platform approximately 60 cm 15 Pull the emergency lowering knob located the ground control side Result The platform should lower The descent alarm will not sound 16 Turn the key switch to platform control At the Platform Controls Test Emergency Stop 17 Push in the platform red Emergency Stop button to the off position Result No functions should operate 18 Pull the red Emergency Stop button out to the on position Result The LED indicator light should come on Test the Horn 19 Push the horn button Result The horn should sound Test Function Enable and Up Down Functions 20 Do not hold the function enable switch on the control handle 21 Slowly move
42. r loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a DINGLI policy Product specifications are subject to change without notice or obligation Model JCPT0808DC Height working maximum 8m Height platform maximum 6m Height stowed maximum 2 21m Rails up Height stovved maximum 1 75 m Rails lowered Width 0 81 m Length platform retracted 2 48 m Length platform extended 3 38 m Platform length x width 2 27 x 0 81 m Platform extension length 0 9m Maximum load capacity 380 kg Maximum wind speed 12 5 m s Wheelbase 1 87 m Turning radius outside 2 19 m Turning radius inside 0 Ground clearance 10cm Ground clearance 1 9 cm Pothole guards deployed Weight 1950kg Machine weights vary with option configurations Specifications Maximum hydraulic pressure 241 3 bar functions System voltage 24V Tire size d 381x127 Airborne noise emissions lt 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2 5m s Maximum slope rating O Stowed position SE Maximum side slope rating A pe 25 Stowed position Note Slope rating is subject to ground conditions and adequate traction Maximum working slope 3 Drive speeds Stowed maximum 5 0 km h Platform
43. raised maximum 0 8 km h Floor loading information Tire load maximum 1000 kg Tire contact pressure 6 96 kg cm 682 kPa Occupied floor pressure 1060 kg m 10 39 kPa Power source Controls 4 Batteries 6V 210AH Proportional AC outlet in platform Standard 42 Note Floor loading information is approximate and does not incorporate different option configurations It should be used only with adequate safety factors Continuous improvement of our products is a DINGLI policy Product specifications are subject to change without notice or obligation Model JCPT1008DC Height working maximum 10m Height platform maximum 8m Height stowed maximum 2 33 m Rails up Height stowed maximum 1 88 m Rails lowered Width 0 81 m Length platform retracted 2 48 m Length platform extended 3 38 m Platform length x width SE Platform extension length 0 9m Maximum load capacity 230 kg Maximum wind speed 12 5 m s Wheelbase 1 87 m Turning radius outside 2 19 m Turning radius inside 0 Ground clearance 10cm Ground clearance 1 9 cm Pothole guards deployed Weight 2100kg Machine weights vary with option configurations Specifications Maximum hydraulic pressure 241 3 bar functions System voltage 24V Tire size d 381x127 Airborne noise emissions lt 70 dB Maximum sound level at normal operating workstations A weighted Vibration value does not exceed 2
44. s 11 Non steer tire 3 Platform extension release pedal 12 Entry ladder 4 Main Platform 13 Ground controls on opposite side of machine 5 Platform control 14 Lift Cylinder 6 Manual storage container 15 Safety arm 7 Platform extension 16 Platform entry gate 8 Scissor Arms 17 Pothole guard 9 Steer tire 18 Brake release pump 11 Control Panel GENCY SCA o Lu Ke SE 2 ES E A 4 ect O ls EN Ground Control Panel 1 Red Emergency Stop button Push in the red Emergency Stop button to the off position to stop all functions Pull out the red Emergency Stop button to the on position to operate the machine 2 Indicator light 3 7 amp breaker for electric circuits 4 Platform up down toggle switch Move the switch up and the platform will raise Move the switch down and the platform will lower 5 Key switch for platform off ground control selection Turn the key switch to the platform position and the platform controls will operate Turn the key switch to the off position and the machine will be off Turn the key switch to the base position and the ground controls will operate Control Panel Platform Control Panel 1 Thumb rocker switch for steer functions 2 Drive function select button 3 Drive speed button 4 Red Emergency Stop
45. s have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Maintenance Check the Batteries Proper battery condition is essential to operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions AWARNING etectrocution hazard Contact with hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry AWARNING aiy injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Be sure that the battery cable connections are tight and free of corrosion 3 Be sure that the battery hold down bars are secure 4 Remove the battery vent caps 5 Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 6 Install the vent caps Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to iden
46. the machine from service Test the Tilt Sensor Operation Note Perform this test from the ground with the platform controller Do not stand in the platform 38 Fully lower the platform 39 Place a 2x4 or similar piece of wood under both wheels on one side and drive the machine up onto them 40 Raise the platform at least 2 1 m O Result The platform should stop and the tilt alarm will sound at 600 beeps per minute 41 Move the drive control handle in the direction indicated by the blue up arrow then move the drive control handle in the direction indicated by the white down arrow Result The drive function should not work in either direction 42 Lower the platform and drive the machine off the block 23 Function Tests Test the Pothole Guards Note The pothole guards should automatically deploy when the platform is raised The pothole guards activate another limit switch which allows the machine to continue to function If the pothole guards do not deploy an alarm sounds and the machine will not drive 43 Raise the platform Result When the platform is raised 2 m from the ground the pothole guards should deploy 44 Press on the pothole guards on one side and then the other Result The pothole guards should not move 45 Lower the platform Result The pothole guards should return to the stowed position 46 Place a 2x4 or similar piece of wood under a pothole guard
47. the next page and check each of the items If damage or any unauthorized variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection again before going on to the function tests Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Pre operation Inspection Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located in the platform Be sure that all decals are legible and in place See Decals section Check for hydraulic oil leaks and proper oil level Add oil if needed See Maintenance section Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and anifolds 3 Battery pack and connections Drive motors
48. tify changes in oil level that might indicate the presence of hydraulic system problems NOTICE DR this procedure with the platform in the stowed position and the engine off 1 Visually inspect the sight gauge located on the side of the hydraulic oil tank Result The hydraulic oil level should be within the Lower and Full of the sight gauge 2 Add oil if necessary Do not overfill Hydraulic oil specifications 18C 5C 10W 18 C 99 10W 20 10W 30 Maintenance Scheduled Maintenance Maintenance performed quarterly annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service Do Not Operate Unless V You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use Know and understand the function tests before going on to the next section 4 Inspect the workplace 5 Only use the machine as it was intended Function Tests Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service The operator must
49. tion and remove the key before transporting Inspect the entire machine for loose or unsecured items Use the tie down points on the chassis for anchoring down to the transport surface Use a minimum of 2 chains or straps Use chains or straps of ample load capacity If the railings have been folded down secure them with straps before transporting Y Y 33 Transport and Lifting Instructions Observe and Obey Y ified ri ld ri lft th Position the forklift forks in position with the Only qualified riggers should rig and lift the forklift pockets machine Drive forward to the full extent of the forks N Only qualified forklift operators should lift the machine with a forklift Raise the machine 6 in 15 cm and then tilt the forks back slightly to keep the machine secure N Be sure the crane capacity loading surfaces and straps or lines are sufficient to Be sure the machine is level when lowering the withstand the machine weight See the serial forks plate for the machine weight NOTICE Lifting the machine from the side can result in component damage Lifting the Machine with a Forklift Be sure the extension deck controls and component trays are secure R

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