Dingli BT18CRT2 Maintenance Checklist
Daily pre-start checks · Service schedule by operating hours · Warning alerts and immediate actions · Fluids & lubricants
Daily Pre-Start Inspection Checklist
Complete before every shift. Allow approximately 15–20 minutes. Do not operate the machine with a safety-critical defect.
Engine Oil Level
Engine off, level ground; dipstick between upper/lower marks.
Act if: Below MIN — do NOT start. Add SAE 10W-40 API CF oil.
Coolant Level
Recovery tank between FULL and LOW with engine cold. Never open a hot radiator cap.
Act if: Below LOW — check for leaks and top up with 50/50 ethylene-glycol LLC of the same brand.
Fuel Level
Check fuel gauge or visually; refuel with engine off.
Act if: Below 1/4 tank — refuel with ULSD diesel (ASTM D975).
Air Cleaner Indicator
Check restriction indicator if fitted.
Act if: Red flag = clogged element. Clean or replace outer 10002943 / inner 10009453 before operating.
Engine Leaks & Belt
Check under engine for puddles; fan belt should have no cracks or glazing.
Act if: Oil/coolant puddle — investigate. Cracked/glazed belt — replace before operating.
Telescope Boom Sliding Blocks
Check sliding blocks for wear, damage and proper contact.
Act if: Worn/damaged blocks can cause boom judder and structural stress. Replace before operating.
Hydraulic Oil Level
Check sight gauge with cold oil, machine stowed and all cylinders retracted.
Act if: Below MIN — do NOT operate at height. Check leaks and add ISO VG 32 or VG 46.
Hydraulic Leak Inspection
Walk around hoses, fittings, cylinder rods, pump area, turret and underneath machine.
Act if: Any active leak — do NOT operate. Hydraulic failure at height can cause uncontrolled descent.
Platform Guardrails & Gate
Check mid/top rails, gate latch and entry chain.
Act if: Loose/missing rail or faulty gate — do NOT allow personnel on platform.
Boom Sections & Pins
Check boom, jib and turntable for cracks, dents or distortion; check visible pin retention.
Act if: Any crack/deformation — STOP and tag out machine.
Tyre Condition (315/55D20)
Check all four tyres for damage, cuts, inflation and wheel-nut tightness.
Act if: Flat/damaged tyre — do NOT travel. Instability risk, especially on grades.
Ground Control Box
Power on ground box 92048954; test boom, telescope, jib, turret and drive functions.
Act if: Any function non-responsive — do NOT use until diagnosed. Check fuses and harness.
Emergency Stop
Test E-stop at ground and platform; verify all motion stops immediately.
Act if: E-stop does not stop motion — CRITICAL. Machine must NOT be used.
Horn, Descent Alarm & Flash
Test horn 00002326, descent alarm and flash/strobe beacon during movement.
Act if: Any alarm/flash missing — repair before use; collision risk.
Overload / Tilt System
Verify tilt sensor 00002917 and overload cut-out; test platform load sense system.
Act if: Bypassed/non-functional — do NOT operate. Tip-over risk.
Self-Leveling Platform
Verify platform remains level during boom articulation and check leveling-cylinder response.
Act if: Platform does not level — do NOT allow personnel until corrected.
Anti-Crushing Protection
Test operator anti-crushing protection; sensor must detect obstruction and stop motion.
Act if: Detection fails — CRITICAL. Do not operate until repaired.
Fault Diagnosis System
Check controller for active fault codes and clear only resolved codes.
Act if: Active fault code — diagnose before operating; auto engine fault shutdown may activate.
Drive Enable & Steer
Test drive enable, proportional joystick and thumb-rocker steering.
Act if: Drive/steer fault — do NOT travel until corrected.
Service Schedule by Operating Hours
At each interval, do everything shown in that column plus everything from shorter intervals. Engine intervals are from the Kubota D1105 workshop manual; machine-level intervals are from Dingli guidelines and the BT-series maintenance guide.
Engine Oil Level
Check
Coolant Level
Check
Hydraulic Oil Level
Check (sight gauge)
System Leak Inspection
Check
Boom Sections — Visual
Inspect
Telescope Sliding Blocks [BT-MG]
Check
Platform Guardrails & Gate
Check
Tyres (315/55D20)
Inspect
E-Stop (Ground + Platform)
Test
Horn & Motion Alarm (00002326)
Test
Descent Alarm [OEM]
Test
Flash/Strobe Beacon [OEM]
Test
Ground Control Box (92048954)
Test all functions
Anti-restart System [OEM]
Test
Anti-reverse Engine [OEM]
Test
Anti-crushing System [OEM]
Test
Self-Leveling Platform [OEM]
Test
Fault Diagnosis System [OEM]
Check codes
Engine Oil + Filter
Change (break-in)
Fuel Pre-Filter (water drain) [BT-MG]
Drain water
Fuel Hoses & Clamps
Check
Radiator — Reverse Clean [BT-MG]
Clean (reverse fan)
System Leak Inspection
Check
Telescope Sliding Blocks [BT-MG]
Lubricate
Turntable Bearing & Slew
Lube ring gear
Chassis & Wheel Hubs
Lube pivots
Axle Oscillation Bushes [BT-MG]
Lubricate
Steering Components [BT-MG]
Lubricate
Wheel Lug Nuts
Check
Air Cleaner Element
Clean (dry air)
Fuel Pre-Filter (water drain) [BT-MG]
Drain water
Fuel Filter (element type)
Clean (kerosene)
Fan Belt
Check tension (7-9mm)
Battery
Check electrolyte
Engine Oil + Filter
Change
Air Cleaner Element
Clean
Fuel Pre-Filter (water drain) [BT-MG]
Drain water
Fuel Hoses & Clamps
Check
Fuel Filter (element type)
Clean
Fan Belt
Check
Battery
Check
Radiator — Reverse Clean [BT-MG]
Clean
Coolant System (LLC)
Check hoses/clamps
Intake Air Line
Check hoses
System Leak Inspection
Check
Hydraulic Oil Level Indicator (90015911)
Check
Hydraulic Hose Connections
Check/tighten
Boom Sections — Visual
Inspect
Telescope Sliding Blocks [BT-MG]
Lubricate
Turntable Bearing & Slew
Lube ring gear
Boom Pivot Pins & Retention
Check
Chassis & Wheel Hubs
Lubricate pivots
Axle Oscillation Bushes [BT-MG]
Lubricate
Steering Components [BT-MG]
Lubricate
Wheel Lug Nuts
Torque check
Engine Harness (00009591)
Inspect
Main Boom Harness (00009594)
Inspect
Overload / Load Sense [OEM]
Test
Anti-crushing System [OEM]
Test
Fault Diagnosis System [OEM]
Check codes
Auto Fault Shutdown [OEM]
Test
Lubrication — All Grease Points
Grease
Engine Oil + Filter
Change
Air Cleaner Element
Clean
Fuel Pre-Filter (water drain) [BT-MG]
Drain water
Fuel Hoses & Clamps
Check
Fuel Filter (element type)
Clean
Fuel Filter Cartridge
REPLACE (400hr)
Fan Belt
REPLACE
Battery
Check
Radiator — Reverse Clean [BT-MG]
Clean
Coolant System (LLC)
Flush radiator
System Leak Inspection
Check
Return Oil Filter
REPLACE
Suction Filter (90028620)
Check
Hydraulic Hose Connections
Check
Boom Sections — Visual
Inspect
Telescope Sliding Blocks [BT-MG]
Lubricate
Turntable Bearing & Slew
Inspect+Lube
Boom Pivot Pins & Retention
Check
Lifting Cylinder (50008064)
Inspect
Telescope Cyl (50008014)
Inspect
JIB Leveling Cyl (50007730)
Inspect
JIB Lifting Cyl (50010163)
Inspect
Chassis & Wheel Hubs
Check
Axle Oscillation Bushes [BT-MG]
Lubricate
Steering Components [BT-MG]
Lubricate
Wheel Lug Nuts
Torque check
Tyres (315/55D20)
Inspect
Fuse Panel (all ratings)
Check
Overload / Load Sense [OEM]
Test
Anti-crushing System [OEM]
Test
Self-Leveling Platform [OEM]
Test
Fault Diagnosis System [OEM]
Check codes
Auto Fault Shutdown [OEM]
Test
Lubrication — All Grease Points
Grease
Engine Oil + Filter
Change
Air Cleaner Element
REPLACE (1yr)
Fuel Pre-Filter (water drain) [BT-MG]
Drain water
Fuel Hoses & Clamps
Check
Fuel Filter (element type)
Clean
Fuel Filter Cartridge
REPLACE
Fan Belt
REPLACE
Battery
Check
Radiator — Reverse Clean [BT-MG]
Clean
Coolant System (LLC)
Flush
Valve Clearance (0.145-0.185mm)
Check & Adjust (800hr)
Injection Nozzle (13.73 MPa)
Check pressure (800hr)
System Leak Inspection
Check
Return Oil Filter
REPLACE
Suction Filter (90028620)
REPLACE
Charge Filter (00001870)
REPLACE
Pressure Filter (00001871)
REPLACE
Hydraulic Hose Connections
Check
Drive Pump (00010226)
Inspect
Function Pump (00010229)
Inspect
Hydraulic Oil (full system)
Sample & Analyse
Boom Sections — Visual
Inspect
Telescope Sliding Blocks [BT-MG]
Lubricate
Turntable Bearing & Slew
Inspect+Lube
Boom Pivot Pins & Retention
Check
Lifting Cylinder (50008064)
Inspect
Telescope Cyl (50008014)
Inspect
JIB Leveling Cyl (50007730)
Inspect
JIB Lifting Cyl (50010163)
Inspect
Chassis & Wheel Hubs
Check
Axle Oscillation Bushes [BT-MG]
Lubricate
Steering Components [BT-MG]
Lubricate
Wheel Lug Nuts
Torque check
Tyres (315/55D20)
Inspect
Tilt Sensor (00002917)
Calibrate
Controller (85000135)
Inspect
Power Distribution (00006155)
Inspect
Fuse Panel (all ratings)
Check
Overload / Load Sense [OEM]
Test
Anti-crushing System [OEM]
Test
Self-Leveling Platform [OEM]
Test
Fault Diagnosis System [OEM]
Check codes
Auto Fault Shutdown [OEM]
Test
Lubrication — All Grease Points
Grease
Engine Oil + Filter
Change
Air Cleaner Element
REPLACE
Fuel Pre-Filter (water drain) [BT-MG]
Drain water
Fuel Hoses & Clamps
REPLACE (2yr)
Fuel Filter (element type)
Clean
Fuel Filter Cartridge
REPLACE
Fan Belt
REPLACE
Battery
REPLACE (2yr)
Radiator — Reverse Clean [BT-MG]
Clean
Coolant System (LLC)
Change coolant (2yr)
Intake Air Line
REPLACE (2yr)
Valve Clearance (0.145-0.185mm)
Check & Adjust
Injection Nozzle (13.73 MPa)
Check pressure
Injection Pump & Timing
Check (1500hr)
System Leak Inspection
Check
Return Oil Filter
REPLACE
Suction Filter (90028620)
REPLACE
Charge Filter (00001870)
REPLACE
Pressure Filter (00001871)
REPLACE
Filter Cartridges (90029476, 00000519)
REPLACE
Hydraulic Hose Connections
Check
Drive Pump (00010226)
Inspect/Service
Function Pump (00010229)
Inspect/Service
Hydraulic Oil (full system)
Change (145L)
Boom Sections — Visual
Full NDT
Telescope Sliding Blocks [BT-MG]
REPLACE (if worn)
Turntable Bearing & Slew
Full inspection
Boom Pivot Pins & Retention
Check
Lifting Cylinder (50008064)
Seal kit check
Telescope Cyl (50008014)
Seal kit check
JIB Leveling Cyl (50007730)
Seal kit check
JIB Lifting Cyl (50010163)
Seal kit check
Chassis & Wheel Hubs
Full inspection
Axle Oscillation Bushes [BT-MG]
Lubricate
Steering Components [BT-MG]
Lubricate
Wheel Lug Nuts
Torque check
Tyres (315/55D20)
REPLACE (if worn)
Tilt Sensor (00002917)
Calibrate
Controller (85000135)
Inspect
Power Distribution (00006155)
Inspect
Engine Harness (00009591)
REPLACE (if dmg)
Main Boom Harness (00009594)
REPLACE (if dmg)
Fuse Panel (all ratings)
Check
Overload / Load Sense [OEM]
Recalibrate
Anti-crushing System [OEM]
Test
Self-Leveling Platform [OEM]
Test
Fault Diagnosis System [OEM]
Full diagnostics
Auto Fault Shutdown [OEM]
Test
Lubrication — All Grease Points
Grease
Warning Alerts & Immediate Actions
RED = stop all operations immediately. AMBER = take action before continuing. GREEN = monitor and schedule service.
Engine Oil Pressure Warning
Immediate action: STOP engine. Check oil level. If level is OK, do NOT restart; call service.
Risk if ignored: Engine seizure and major internal damage.
Engine Overheating
Immediate action: Stop engine. Do NOT open radiator cap. Let cool for 30+ minutes; check coolant, belt and radiator.
Risk if ignored: Head-gasket failure, warped head or cracked block.
Hydraulic System Failure
Immediate action: Stop all boom movement. Use emergency descent to lower platform. Do NOT operate until repaired.
Risk if ignored: Uncontrolled platform descent and fall-from-height risk.
Tilt / Overload Alarm
Immediate action: Stop movement. Do NOT extend boom further. Reduce load and move to level ground if safe.
Risk if ignored: Tip-over and crushing hazard.
E-Stop Not Functioning
Immediate action: Cut engine, evacuate via emergency descent, tag out machine. Do NOT use.
Risk if ignored: No emergency stopping capability.
Hydraulic Oil Level Low
Immediate action: Lower platform, check leaks, top up ISO VG 32/46 and check suction filter 90028620.
Risk if ignored: Pump cavitation and accelerated pump wear.
Engine Hard Start / No Start
Immediate action: Check fuel, bleed fuel system, check glow plugs and air filter.
Risk if ignored: Injector damage, power loss and incomplete combustion.
Boom Drift / Slow Movement
Immediate action: Lower platform. Check telescope valve 00000513, cylinder seals, hydraulic temperature and level.
Risk if ignored: Worsening drift and possible platform descent.
Unusual Noise / Vibration
Immediate action: Stop and identify source; inspect drive pump 00010226, function pump 00010229, turret bearing and wheel hubs.
Risk if ignored: Bearing/gear damage or structural fatigue.
Electrical Warning / Fuse Blown
Immediate action: Replace only with the SAME fuse rating. If it blows again, inspect harness 00009591/00009594.
Risk if ignored: Short circuit and fire risk.
Anti-Crushing System Alert
Immediate action: Stop boom movement. Check sensor zone and clear obstruction. If sensor fault, do NOT operate.
Risk if ignored: Crushing hazard to operator.
Fault Diagnosis Code Active
Immediate action: Read controller code 85000135, diagnose root cause and clear only after repair. Do NOT bypass.
Risk if ignored: Auto shutdown during operation and personnel stranded at height.
Engine Oil Change Due — 200 h
Immediate action: Schedule oil + filter change. 5.1 L, SAE 10W-40 API CF.
Risk if ignored: Accelerated wear and shortened engine life.
Hydraulic Filter Change Due — 500 h
Immediate action: Replace return filter at 500 h; suction filter 90028620 at 1,000 h.
Risk if ignored: Contaminated oil accelerates pump and valve wear.
Air Cleaner Service Due — 100 h
Immediate action: Clean with dry compressed air below 30 psi from inside out; replace outer 10002943 / inner 10009453 as scheduled.
Risk if ignored: Restricted air causes power loss and higher fuel consumption.
Self-Leveling Platform Service
Immediate action: Test platform leveling and inspect JIB leveling cylinder 50007730 and seals.
Risk if ignored: Load slide, falling tools and operator instability at height.
Fluids, Lubricants & Capacities
Use the specified grade and keep filling/lubrication equipment clean. Capacities are nominal; confirm by level indication.
Fuel Tank
ULSD diesel, ASTM D975 / EN 590; cetane >45 preferred >50; sulfur <15 ppm.
Engine Oil
SAE 10W-40, API CF or higher. SAE 10W-30, SAE 20 or SAE 30 may be used per ambient temperature.
Engine Coolant
50/50 ethylene-glycol LLC + soft water. Never mix brands.
Hydraulic Oil
ISO VG 32 or VG 46 anti-wear hydraulic oil, HL-HLP grade per DIN 51524. VG 46 preferred for India.
Grease
Multipurpose lithium EP grease, NLGI Grade 2 — boom pins, turret bearing, cylinder pins and chassis pivots.
Battery
12 V, 65 Ah. Check electrolyte every 100 h; top up only with distilled water; replace every 2 years.