Dino lift Dino 180XT User manual

Raikkolantie 145
FI-32210 LOIMAA
Tel. [phone]
Fax. [phone]
[email protected]
www.dinolift.com
DINO 180XT
OPERATION INSTRUCTIONS

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DINO 180XT
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OPERATION INSTRUCTIONS
Valid from serial number 18154

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CONTENTS
REACH DIAGRAM (M, KG)...........................................................................................................6
TECHNICAL SPECIFICATION (M, KG).....................................................................................7
REACH DIAGRAM (FT, LBS)........................................................................................................8
TECHNICAL SPECIFICATION (FT, LBS) ..................................................................................9
GENERAL SAFETY DIRECTIVES .............................................................................................10
REGULAR INSPECTION..............................................................................................................12
INSPECTION ON THE WORKSITE...........................................................................................13
SAFETY DEVICES.........................................................................................................................15
OPERATING CONTROLS............................................................................................................17
CONTROLS MOUNTED ON THE CHASSIS..............................................................................17
PLATFORM PANEL CONTROLS ...............................................................................................18
MEASURES TO BE TAKEN IF STABILITY IS THREATENED............................................19
STARTING UP THE LIFT.............................................................................................................21
OPERATING THE UNIT FROM THE CHASSIS CONTROL PANEL........................................26
OPERATING THE UNIT FROM THE WORK PLATFORM.......................................................27
EMERGENCY DESCENT SYSTEM............................................................................................31
DRIVING DEVICE .........................................................................................................................32
SPECIAL INSTRUCTIONS FOR WINTER USE.......................................................................34
ENDING THE DAYS WORK........................................................................................................35
PREPARING THE LIFT FOR TRANSPORT.............................................................................36
CONNECTING TO THE TOWING VEHICLE..........................................................................37
SERVICE AND MAINTENANCE.................................................................................................38
GENERAL......................................................................................................................................38
INSPECTIONS AND SERVICE....................................................................................................39
LUBRICATION PLAN..................................................................................................................40
HOLD- AND LOAD REGULATING VALVES ...........................................................................43
WHEEL BRAKES AND BEARINGS............................................................................................44
SERVICE, PLATFORM STABILIZATION SYSTEM.................................................................47
REGULAR SERVICING ...............................................................................................................48
TESTING THE LOAD LIMITS....................................................................................................54
SETTING THE OVERLOAD DEVICES......................................................................................56

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INSPECTING THE LIFT...............................................................................................................60
FIRST INSPECTION .....................................................................................................................60
DAILY INSPECTIONS..................................................................................................................61
INSPECTIONS ONCE AMONTH................................................................................................62
REGULAR INSPECTION (ANNUAL).........................................................................................63
EXTRAORDINARY INSPECTION..............................................................................................66
TEST LOADING IN CONJUNCTION WITH THE REGULAR SERVICE.................................67
FAULT FINDING............................................................................................................................68
HYDRAULIC SYSTEM, GENERAL INFORMATION.............................................................74
ELECTRIC COMPONENTS' FUNCTION..................................................................................75
LOWER CONTROL PANEL (PK), RELAYS...............................................................................75
LOWER CONTROL PANEL (PK), SWITCHES ..........................................................................77
UPPER CONTROL PANEL (OK), RELAYS................................................................................78
UPPER CONTROL PANEL (OK), SWITCHES............................................................................78
LIMIT SWITCHES ........................................................................................................................79
DRIVING DEVICE........................................................................................................................79
OTHER MARKINGS.....................................................................................................................80
PROPO -CONTROL CARD...........................................................................................................81
MAINBOARD................................................................................................................................82
PROCESSOR CARD......................................................................................................................83
ELECTRIC COMPONENTS.........................................................................................................84
ELECTRIC SCHEMA; 230VAC...................................................................................................85
ELECTRIC SCHEMA; 110/ 230VAC...........................................................................................86
ELECTRIC SCHEMA; 110VAC...................................................................................................87
ELECTRIC SCHEMA; DRIVE UNIT, OPERATING PANEL .................................................88
ELECTRIC SCHEMA; DRIVE UNIT, REMOTE CONTROL.................................................89
ELECTRIC SCHEMA; 12VDC, (230VAC, PETROL/ GASOLINE AGGREG.).....................90
ELECTRIC SCHEMA; 12VDC, (110/ 230VAC, PETROL/GASOLINE AGGR.)...................91
ELECTRIC SCHEMA; 12VDC, (230VAC, DIESEL AGGREGATE) ......................................92
ELECTRIC SCHEMA; 12VDC, (110/ 230VAC, DIESEL AGGREGATE)..............................93
ELECTRIC SCHEMA; PETROL/ GASOLINE AGGREGATE...............................................95
ELECTRIC SCHEMA; DIESEL AGGREGATE........................................................................96
HYDRAULIC COMPONENTS 230VAC......................................................................................98
HYDRAULIC SCHEME 230VAC.................................................................................................99
HYDRAULIC COMPONENTS 110VAC...................................................................................100
HYDRAULIC SCHEME 110VAC..............................................................................................101

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REACH DIAGRAM (m, kg)

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TECHNICAL SPECIFICATION (m, kg)
Max. working height 18,0 m
Max. platform height 16,0 m
Max. outreach 10,9 m
Boom rotation continuous
Platform rotation 90°
Reach when turned refer to reach diagram
Support width 3,80 m
Transport width 1,78 m
Transport length 6,55 m
Transport height 2,20 m
Weight (with power pack) 2050 kg
Lifting capacity 215 kg
Max. number of persons + load 2 persons + 55 kg
Max. allowed sideways load (caused by persons) 400 N
Max. sideways inclination (chassis) ±0,3°
Max. wind force when working 12,5 m/s
Min. ambient temperature when working - 20 °C
Max. support force on the outriggers 16800 N
Platform size 0,7 x 1,3 m
Gradeability 25%
Power supply:
- internal combustion engine (gasoline/petrol) 4,8 kW (6,5 hp)/ 3600 r/min
- internal combustion engine (diesel) 4,4 kW (6 hp)/ 2800 r/min
-mains current 230V/ 50Hz/ 16A
-mains current (GB) 110V/ 50Hz/ 16A or 230V/ 50Hz/ 16A
-mains current (US) 110V/ 60Hz/ 16A
Socket outlets on the platform 230V/ 50Hz / 10A
Socket outlets on the platform (GB) 110V/ 50Hz / 10A
Socket outlets on the platform (US) 110V/ 60Hz / 10A

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REACH DIAGRAM (ft, lbs)

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TECHNICAL SPECIFICATION (ft, lbs)
Max. working height 59'1"
Max. platform height 52'6"
Max. outreach 35'9"
Boom rotation continuous
Platform rotation 90°
Reach when turned refer to reach diagram
Support width 12'6"
Transport width 5'10"
Transport length 21'6"
Transport height 7'3"
Weight (with power pack) 4520 lbs
Lifting capacity 474 lbs
Max. number of persons + load 2 persons + 120 lbs
Max. allowed sideways load (caused by persons) 88 lbs
Max. sideways inclination (chassis) ±0,3°
Max. wind force when working 41 ft/s
Min. ambient temperature when working - 4 °F
Max. support force on the outriggers 3800 lbs
Platform size 2'4" x 4'3"
Gradeability 25%
Power supply:
- internal combustion engine (gasoline/petrol) 6,5 hp/ 3600 r/min
- internal combustion engine (diesel) 6 hp/ 2800 r/min
-mains current 230V/ 50Hz/ 16A
-mains current (GB) 110V/ 50Hz/ 16A or 230V/ 50Hz/ 16A
-mains current (US) 110V/ 60Hz/ 16A
Socket outlets on the platform 230V/ 50Hz / 10A
Socket outlets on the platform (GB) 110V/ 50Hz / 10A
Socket outlets on the platform (US) 110V/ 60Hz / 10A

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GENERAL SAFETY DIRECTIVES
Make yourself familiar with the operators manual before using the lift!
The operator's manual should be stored in the space reserved for it.
Make sure that all persons working with the lift are familiar with the operator's manual.Inform new
users about the operation of the lift and the manual.
All the manufacturers directions and recommendations should be followed strictly.
Make sure you know well all directions that deal with the operating safety of the lift.
Always use the brake beams when leaving the lift from the tow vehicle.
Only personnel who have received training in the use of the lift and are at least 18 years of age is
allowed to use the lift.
AT LEAST YEARS + TRAINING
No more than two persons and max. additional load of 55 kg (120 lbs) or max. total load of 215 kg
(474 lbs) are allowed on the platform.
When the chassis is supported by the outriggers, the carrying capacity of the ground and any
possible inclination of the support area must always be considered.
On soft ground the outriggers should be additionally supported by adequately sized support plates.
When choosing additional support plates or other aids, always make sure that the outrigger feet
cannot slip when resting on them.
The lift may be moved only when it is in transport position. When moving the lift no persons or
workloads are allowed on the platform.
Weather factors, ie. wind, visibility, outdoor temperature, rain and so on, must always be taken into
consideration when using the lift, so that the necessary precautions to eliminate dangers caused by
these are always taken.
It is not allowed to use the lift under following conditions:
-temperatures below -20 °C (-4 °F)
-wind speed over 12,5 m/s (41’/s)
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No ladders, steps or other similar equipment may be used on the platform.
Objects may under no circumstances be thrown out from the platform.
The lift must not be used to move persons or objects between floors or different work levels.
The safety devices must not in any circumstances be put out of function.
Before lowering the platform, always make sure that there are no obstacles on the chassis. The
platform must not be lowered onto the ground, or brought in contact with other objects, as this will
constitute a risk for damages.
If the lift is used in areas where there is other traffic, the working area must be equipped with
warning lights and, if necessary, fenced in.
All regulations concerning road traffic and working safety must always be respected.
Always be especially careful when working in the vicinity of open-wire power lines.
Do not forget the stipulated minimum safety distances (refer to table).
The lift must be regularly cleaned, so that dirt does not influence the operational safety, or make
regular inspections inconvenient and unreliable.
The lift must be inspected and serviced regularly. Service and repairs may be performed only by
trained personnel, who are familiar with the operating-, service- and repair manuals.
The lift may never be used if it is not in faultless condition.
No technical, constructional or other changes may be made to the unit without written
permission from the manufacturer.
Voltage Min. under distance
m (ft) Min. sideways distance m (ft)
100 – 400 V hanging cables 0,5 (2) 0,5 (2)
100 – 400 V open-wire cable 2 (7) 2 (7)
6 – 45 kV 2 (7) 3 (10)
110 kV 3 (10) 5 (17)
220 kV 4 (13) 5 (17)
400 kV 5 (17) 5 (17)

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REGULAR INSPECTION
A thorough inspection must be made at least once every twelve (12) months.
The inspection should be made by a person who is technically trained and is familiar with the
function, use and construction of the lift.
Inspections should be recorded in a protocol that should always follow the unit and be stored in the
space reserved for it.
The inspections must be made regularly throughout the operative life of the lift.
The inspections must be made within twelve (12) months from the first or the previous inspection.
If the lift is used in especially severe conditions, inspection intervals should be shorter than
mentioned above.
The general operating conditions of the lift, and safety- and control devices should be established
through regular inspections. Special attention should be paid to factors that influence the operating
safety.
It should also be established if the findings of the previous inspection, or the experiences gained
when using the unit could give cause to further improve the operational safety of the unit.
ATTENTION! Primarily the national legislation must be followed!
Regular inspections and service measures are described more thoroughly in the chapter "Service-
and maintenance".

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INSPECTION ON THE WORKSITE
1. General
-Is the lift suited for the job at hand?
-Is the performance of the lift sufficient for the job (reach, loadability etc.)?
-Is the lift located safely on a site so that no negative influence on work safety is possible?
-Is there enough illumination for safe working?
2. Documents
-Are the operating and service instructions for this particular lift present? (Manufacturers
manual)
-Have the inspections and service measures mentioned in the instructions been made and
defects that could influence safety been repaired? (Inspection protocols)
3. Structures and construction (Optical inspection and functional test)
-General condition of the lift
-Functioning and protection of controls
-Emergency stop, signal horn and limit switches
-Electrical devices and cables
-Oil leaks
-Load markings and signs
4. Operator
-Is the lift operator old enough?
-Has the operator recieved the necessary training?
5. Special circumstances on the work site
-Are there factors connected with the work site or work task that demand special attention or
additional instructions / directives?

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LIMIT SWITCHES
RK4 AND RK5
PRESSURE
SPRING
LINK
LIFT
CYLINDER

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SAFETY DEVICES
1. Support outriggers (fig A)
A safety limit switch RK3 prevents use of the outriggers and the drive mechanism when the boom
is lifted off the transport support.
The limit switch is mounted on the tow bar boom support point.
2. Lifting the boom (fig B)
Lifting of the boom is prevented by safety limit switches when the wheels are not lifted off the
ground, ie. when the lift is not supported by the supporting outriggers.
The limit switches RK11, RK12, RK13 and RK14 are in the outriggers.
3. Overload protection switches (fig A and C)
The safety limit switches prevent overloading the lift. When arriving at a certain preset reach, the
overload switch RK4 stops extending or lowering the telescopic boom. The overload switch RK5
has a back-up function, for the case that the overload switch RK4 is not working.
When the lift is working within the permissible reach zone the green light in the control panel is lit.
If the movement is stopped by the limit switches, a red light is lit. When the red light is lit the boom
can be moved in the direction where it stays within the allowed reach zone.
The limit switch RK5 backs up the RK4 and switches the platform alarm horn on.
4. The EMERGENCY STOP pushbutton immediately stops the movement and shuts off the
power unit. The power unit can not be restarted before the EMERGENCY STOP pushbutton
is lifted (fig D and E, buttons 3 and 22).
Do not prevent the function of safety devices - the cover of the chassis control panel must not
be locked with key when using the lift.

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OPERATING CONTROLS
CONTROLS MOUNTED ON THE CHASSIS
1. Operating switch 0 = Off
1 = Operation of support outriggers, moving the lift by
hydraulic power (driving device) and platform inclination
2 = Controlling the boom from the platform
3 = Controlling the boom from the chassis
2. Start -pushbutton
3. Emergency stop - stop by pushing
- release by lifting
4A. Yellow signal light, outrigger limit switches
4B. Red signal light, safety device (RK4)
4C. Red signal light, outrigger limit switches
5. Start -pushbutton, emergency descent
6.
7. Turning lever
8. Boom movement lever
9. Telescopic movement lever
10. Voltage meter
11. Fuse
12. Right rear support outrigger
13. Left rear support outrigger
14. Left front support outrigger
15. Right front support outrigger
16. Levelling gauge (chassis)
27. Hydraulic movement, current on
28A. Hydraulic movement, forwards -pushbutton
28B. Hydraulic movement, backwards -pushbutton
28L. Hydraulic movement, to the left -pushbutton
28R. Hydraulic movement, to the right -pushbutton
29. Stop -pushbutton
31. Operating control, platform inclination (pushbutton)
32. Platform inclination, operating lever
33. Lifting arms movement lever
34. Hour meter
35. Motor running speed adjustment (diesel engine)

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PLATFORM PANEL CONTROLS
Close the chassis control panel cover before using the platform
controls (the cover must not be locked when using the lift).
17. Operating lever
18. Warning lights green = inside the reach limits
red = at the reach limit
20. Start -pushbutton, emergency descent
21. Fuse
22. Emergency stop - stop by pushing
- release by lifting
23. Signal horn
24. Socket 2 pcs. (230VAC)
25. Motor OFF
26. Motor START
30. Lifting arms -switch 0 = boom
1 = lifting arms

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MEASURES TO BE TAKEN IF STABILITY IS THREATENED
The following factors can lead to loss of standing stability:
-a technical fault in the lift
-wind or other factors that can create sideways forces
-a decrease in ground firmness
-negligence when positioning and raising the lift
A decrease in standing stability is mostly perceived as an increase in the inclination of the lift and
boom.
1. If there is enough time, you should try to find out the cause of the instability and ascertain in
which direction the destabilizing forces are working.
Warn persons in the vicinity by using the alarm horn.
2. Retract the telescope, so that the sideways reach is reduced.
Carefully avoid all sudden movements.
3. Turn the boom away from the dangerous zone/direction, that is, in the direction where it acts
towards increased stability.
4. Lower the boom.
If the destabilization is caused by a technical fault in the lift, the fault must be rectified
immediately.
The lift must not be used before the fault has been rectified and the lift properly inspected.

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Notes