Dino lift 160XT Instruction Manual

DIN
O
®
160XT
180XT
210XT
Dealer:Manufacturer:
Raikkolantie 145
FI-32210 LOIMAA
Tel. [phone]
[e-mail]
www.dinolift.com
OPERATING INSTRUCTIONS
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160XT 180XT 210XT
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160XT 180XT 210XT
TRANSLATION OF THE ORIGINAL OPERATING INSTRUCTIONS
Valid from serial number
160XT 16931,17008 ->
180XT 19029,19034 ->
210XT 3265 ->
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TABLE OF CONTENTS
1EU DECLARATION OF CONFORMITY ....................................................................6
2REACH DIAGRAM.....................................................................................................7
2.1160XT..................................................................................................................7
2.2180XT..................................................................................................................8
2.3210XT..................................................................................................................9
3DIMENSION DRAWING...........................................................................................10
3.1160XT................................................................................................................10
3.2180XT................................................................................................................11
3.3210XT................................................................................................................12
4TECHNICAL SPECIFICATION................................................................................13
4.1GENERAL DESCRIPTION OF THE MACHINE...............................................................14
4.2DESCRIPTION OF THE MACHINE’S INTENDED USE.....................................................15
4.3EXAMPLE OF THE MACHINE’S NAMEPLATE...............................................................15
5GENERAL SAFETY REGULATIONS......................................................................16
5.1INSTRUCTIONS FOR SAFE OPERATION ....................................................................19
6INSPECTIONS.........................................................................................................20
7WORKSITE INSPECTION .......................................................................................21
8OPERATION OF THE SAFETY DEVICES ..............................................................22
9OPERATING CONTROLS IN THE CHASSIS CONTROL CENTRE .......................24
9.1OPERATING CONTROLS OF DRIVE SYSTEM................................................25
9.2OPERATING CONTROLS OF OUTRIGGERS..................................................25
9.3OPERATING CONTROLS IN PLATFORM CONTROL CENTRE ......................26
10MEASURES TO BE TAKEN IN THE CASE OF EMERGENCY/IF THE LIFT IS AT
RISK OF LOSING ITS STABILITY .................................................................................28
11STARTING THE USE...........................................................................................30
11.1OPERATING THE LIFT FROM THE CHASSIS CONTROL CENTRE................33
11.2OPERATING THE LIFT FROM THE PLATFORM CONTROL CENTRE............35
12EMERGENCY DESCENT SYSTEM.....................................................................42
13DRIVING DEVICE.................................................................................................43
14DRIVING DEVICE.................................................................................................44
15SPECIAL INSTRUCTIONS FOR WINTER USE...................................................46
16MEASURES TO BE TAKEN AT THE END OF THE WORKING DAY.................47
17PREPARING THE LIFT FOR TRANSPORT........................................................48
18CONNECTING TO THE TOWING VEHICLE........................................................49
19INSTRUCTIONS FOR SERVICE AND MAINTENANCE......................................50
19.1GENERAL SERVICE INSTRUCTIONS.............................................................50
19.2SERVICE AND INSPECTION INSTRUCTIONS................................................51
19.3LUBRICATION PLAN........................................................................................52
19.4LONG-TERM STORAGE...................................................................................53
19.5LOAD HOLDING AND LOAD REGULATION VALVES......................................55
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19.6WHEEL BRAKES AND BEARINGS...................................................................56
19.7LEVELLING SYSTEM OF THE PLATFORM .....................................................58
19.8REGULAR SERVICE.........................................................................................59
19.8.1TESTING THE LOAD LIMIT SWITCHES RK4 AND RK5 .........................66
20INSPECTION INSTRUCTIONS............................................................................72
20.1FIRST INSPECTION .........................................................................................72
20.2DAILY INSPECTION (START-UP INSPECTION)..............................................73
20.3MONTHLY INSPECTION (MAINTENANCE INSPECTION) ..............................74
20.4ANNUAL INSPECTION (REGULAR INSPECTION)..........................................75
20.5EXTRAORDINARY INSPECTION.....................................................................78
20.6TEST LOADING INSTRUCTIONS FOR REGULAR INSPECTION....................79
21FAULT FINDING ..................................................................................................80
22GENERAL INFORMATION OF HYDRAULICS....................................................87
23ELECTRIC COMPONENTS .................................................................................88
23.1CHASSIS CONTROL CENTRE (LCB), RELAYS...............................................88
23.2CHASSIS CONTROL CENTRE (LCB), SWITCHES..........................................93
23.4CHASSIS CONTROL CENTRE (LCB), OTHER ITEMS.....................................94
23.5PLATFORM CONTROL CENTRE (UCB), RELAYS ..........................................95
23.6PLATFORM CONTROL CENTRE (UCB), SWITCHES......................................95
23.7PLATFORM CONTROL CENTRE (UCB), OTHER ITEMS ................................97
23.8LIMIT SWITCHES .............................................................................................98
23.9CONTROL CENTRE FOR THE DRIVING DEVICE (DCB).................................99
23.10OTHER MARKINGS ......................................................................................99
25ADJUSTMENT OF THE MOVEMENT SPEEDS ................................................100
26ELECTRIC DIAGRAM........................................................................................103
27HYDRAULIC DIAGRAM.....................................................................................123
27.1STANDARD MACHINE ..........................................................................................123
27.2AUTOMATIC LEVELLING (OPTION).........................................................................124
27.2.1Sample of inspection protocol for the access platform......................126

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1 EU Declaration of Conformity
Manufacturer:
Dinolift Oy
Raikkolantie 145
FI-32210 Loimaa, FINLAND
which has authorised the Chief Engineer Mr. Seppo Kopu, Dinolift Oy, Raikkolantie
145, 32210 Loimaa, FINLAND, to draw up the Technical Construction File,
declares that
DINO 160XT Aerial Work Platform no YGC D160XT X X XXXXX
DINO 180XT Aerial Work Platform no YGC D180XT X X XXXXX
DINO 210XT Aerial Work Platform no YGC D210XT X X XXXXX
complies with the provisions of the Machine Directive 2006/42/EC and its
amendments as well as the national decree (VNA 400/2008), through which they
have been brought into effect as well as the regulations of the Low Voltage Directive
2000/14/EC, the Directive 2000/14/EC and the EMC Directive 2004/108/EC
To the assessment procedure of conformity has been applied: 2000/14/EC, Annex V:
Internal control of production.
Measured sound power level Petrol/Diesel Lwa (96 + 1,5) 97,5 / (98,5+1,5) 100 dB
Guaranteed sound power level Petrol/Diesel Lwa (97.5 + 0,5) 97,5 / (100+0,5) 100 dB
Notified body no. 0537,
VTT
P.O.Box 1300
FI-33101 Tampere
FINLAND
has granted the certificate no.VTT 176 / 524 / 09
In designing the machine, the following harmonised standards have been applied:
SFS-EN 280/A1+A2; SFS-EN 60204-1/A1
LoimaaXX.XX.XXXX
(place) (date)
-----------------------------------------
(signature)
Seppo Kopu
Chief Engineer
(name in block letters, position)
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160XT 180XT 210XT
2 REACH DIAGRAM
2.1 160XT
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2.2 180XT
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2.3 210XT
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3 DIMENSION DRAWING
3.1 160XT
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3.2 180XT
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3.3 210XT
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4 TECHNICAL SPECIFICATION
160XT 180XT 210XT
Max. working height 16.0 m 18.0 m 21.0 m
Max. platform height 14.0 m 16.0 m 19.0 m
Max. outreach 9.1 m 10.9 m 11.7 m
Boom rotation continuous
Platform rotation 90°
Turn area refer to the reach diagram
Support width 3.80 m 3.80 m 4.30 m
Transport width 1.78 m 1.78 m 1.92 m
Transport length 5.91 m 6.55 m 7.88 m
Transport height 2.20 m 2.20 m 2.18 m
Weight (incl. Honda power unit) 1,990 kg 2,115 kg 2,465 kg
Max. allowed load on platform 215 kg
Max. number of persons + additional load 2 persons + 55 kg
Max. allowed sideways load (caused by
persons) 400 N
Max. lateral inclination (chassis) ±0,3°
Max. wind speed during operation 12,5 m/s
Min. ambient temperature when working -20 °C
Max. support force on the outriggers 16,800 N 16,800 N 22,800 N
Platform size 0.7 x 1.3 m
Gradeability 25 %
Power supply
mains current 230V/50Hz/10A
Sound pressure level Under 70 dB
petrol-driven power unit (option) 4.8 kW (6.5 hp)/3,600 rpm
Sound pressure level 98 dB
diesel-driven power unit (option) 4.4 kW (6 hp)/2,800 rpm
Sound pressure level 101 dB
Socket outlets on the platform 230V/50Hz/16A
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4.1 General description of the machine
The denominations of the machine’s essential parts and concepts, which are used
later in these instructions, are described on this page.
Platform
Boom extension 1
Boom extension 2
Boom extension 3
Levelling cylinder of
the platform (slave)
Articulated arms
Telescope cylinder
Lifting cylinder
Turning device
Outrigger cylinder
Outrigger
Mastercylinder
Chassis
Driving
device
drive direction
Right
Left Turning
Counter-clockwise (to the left)
Turning
Clockwise (to the right)
Jockey
wheel
Coupling
Boom support
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4.2 Description of the machine’s intended use
The intended use of the Aerial Work Platform is exclusively limited to
transferring people and tools and acting as a work platform within its
permissible load-bearing capacity and reach (refer to the table “Technical
Specifications” and the “Reach Diagram”).
The intended use also covers:
- Following all the instructions in the Operating Instructions
- Performance of the inspections and maintenance operations
4.3 Example of the machine’s nameplate
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5 GENERAL SAFETY REGULATIONS
Make yourself familiar with these operating instructions before using the lift!
- Keep these operating instructions in the place reserved for them.
- Make sure that all users of the lift are familiar with these instructions.
- Advise new users and strictly follow all instructions given by the manufacturer.
- Make sure you clearly understand all instructions relating to the operational safety of
the lift.
Always use chocks under the wheels when disconnecting the lift from the car.
Only specially trained personnel with authorisation in writing, who are well
familiarised with the device, and at least 18-years old, are allowed to operate the
unit.
- The max. allowed load on the platform is two (2) persons and at maximum fifty five
(55) kg of additional load, however, the total load must not exceed two hundred fifteen
(215) kg.
- The platform may only be operated when the chassis is well supported, and the
wheels are off the ground.
- The load-bearing capacity and the gradient of the base must be taken into account
when supporting the chassis.
- Additional support plates of adequate size must be used under the outriggers, when
working on soft ground. Only use such additional support plates, on which the metallic
outriggers will not slide.
The lift may only be moved in the transport position. No persons or load are
allowed on the platform during the transportation.
The weather conditions, such as wind, visibility and rain, must always be taken into
account so that these will not adversely affect safe performance of the lifting operations.
The use of the lift is prohibited if
- the temperature drops under -20 °C or
- the wind speed exceeds 12.5 m/s
Protect your hearing while using the power unit (option)(92 dB)
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Use the safety harness
Do not use ladders, steps or other similar equipment on the platform.
Never throw any objects from the platform.
The lift must not be used for transferring goods or persons between different floors or
working levels.
Never disable the operation of any safety device.
Always make sure, before lowering the platform, that the area on the underside is clear of
any obstructions.
Avoid damaging the platform by lowering it on the ground, or bringing it in contact with
any structures.
When working in busy areas, the operating range of the lift must be clearly marked by
using either warning lights or fencing.
Also observe the regulations of the Road Traffic Act.
Connecting
points for the
safety harness.
1 person/lug
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Beware of the live aerial power lines in the area –
observe the minimum safety distances:
Voltage Min. distance below
(m) Min. distance at the side (m)
100 – 400 V hanging spiral
cable 0.5 0.5
100 – 400 V open-wire cable 2 2
6 - 45 kV 2 3
110 kV 3 5
220 kV 4 5
400 kV 5 5
Keep the lift free of any dirt, which may impair safe operation, and impede the inspection
of the structures.
The device must be serviced and inspected regularly.
Only skilled persons, familiar with the service and repair instructions, are allowed to carry
out servicing and repair work.
It is strictly prohibited to use a lift which is out of order.
The device must neither be altered without the manufacturer’s
consent nor be used under conditions, which do not meet the
manufacturer's requirements.
The operator must be given instructions and consent from the
manufacturer for all such specific work methods or conditions
that the manufacturer has not explicitly defined.
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5.1 Instructions for safe operation
- Use a safety harness while on the platform.
- Use hearing protectors when operating the power unit. Sound pressure level at
the lower control unit 92 dB.
- Never add load onto the platform while in the upper position.
- The lift must not be used when the temperature is below -20°C, and the wind
speed exceeds 12.5 m/s.
- Beware of live power lines within the work area.
- The lift MUST NOT be used as a crane.
- Always ensure the load-bearing capacity of the standing surface.
- Ensure the unobstructed range of movement before operating the outriggers.
- While in the support position, ensure that the wheels are off the ground.
- Always verify the horizontal position of the machine.
- Ensure that the outriggers cannot slide while on a gradient.
- Always ensure that the work area is clear of outsiders. Danger of getting
squeezed between rotating and fixed structures.
- Stepping on or off the platform in motion is prohibited.
- The maximum-allowed gradient during transfers is 5°. During transfer in rough
terrain, try to stay above the machine.
- While operating the boom from the control centre on the turning device, beware
of getting pressed against the outriggers or other structures that do not turn
with the boom.
- When the boom is in its lowest positions, make sure it cannot clash during
rotation with structures that do not turn with the boom.
- Before operating, always ensure that the safety devices and the emergency
descent system are in working order.
- Do not take tools/material of large surface area onto the platform. The increase
in wind load may jeopardize the stability of the device.
- Always keep the lift free from dirt, snow and ice.
- Ensure that the lift is inspected and serviced, before use.
- Never use a defective lift.
- Never use a lift alone. Make sure that there is always someone on the ground,
who can call for help in case of an emergency.
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6 INSPECTIONS
A thorough inspection of the lift must be carried out at least once every twelve (12)
months.
The inspection shall be carried out by a technically trained person who is familiar with the
operation and structure of the lift.
Draw up a protocol of the inspections and always keep it with the unit stored in the space
reserved for it.
Carry out the inspections regularly throughout the service life of the lift.
The inspection must be carried out within twelve (12) months of the first inspection or
previous regular inspection.
If the lift is used under extreme conditions, intervals between the inspections shall be
reduced.
The overall operating condition of the lift as well as the condition of the safety-related
control devices shall be established in the regular inspections. Particular attention shall
be paid to changes, which affect the operational safety.
In connection with the regular inspection shall be established to what extent the lessons
and practical experience gained since the previous inspection could be utilized to
improve the safety even more.
National legislation must be followed first of all.
Regular inspections and service measures are described more thoroughly in the chapter
“Service- and maintenance”.
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