Dino lift DINO 185XTS User manual

DINO
®
185XTS
OPERATING INSTRUCTIONS
Dealer:Manufacturer
Raikkolantie 145
FI-32210 LOIMAA
T. [phone]
F. [phone]
[email protected]
www.dinolift.com

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ORIGINAL OPERATING INSTRUCTIONS
VALID FROM SERIAL NUMBER 540016

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TABLE OF CONTENTS
OPERATION AND SAFETY ................................................................................................ 7
1.EU DECLARATION OF CONFORMITY..................................................................... 7
2.REACH DIAGRAM..................................................................................................... 8
3.DIMENSION DRAWING ............................................................................................ 9
4.TECHNICAL SPECIFICATION .................................................................................10
4.1Example of the machine’s nameplate................................................................10
4.2General description of the machine...................................................................11
4.3Description of the machine’s intended use ........................................................12
5.GENERAL SAFETY REGULATIONS........................................................................12
6.INSPECTIONS..........................................................................................................16
7.DAILY INSPECTION (START-UP INSPECTION).....................................................17
8.WORKSITE INSPECTION........................................................................................19
9.OPERATION OF THE SAFETY DEVICES................................................................20
9.1Lifting the boom/ articulated arms (RK3) ...........................................................20
9.2Boom extensions retracted (RK8)......................................................................20
9.3Emergency stop buttons (S1 and S4)................................................................20
9.4Platform load control (MRV)...............................................................................21
9.5inclination sensors RK30a and RK30b...............................................................23
10.OPERATING CONTROLS.....................................................................................24
10.1LCB – CONTROLS IN THE CHASSIS PANEL – XTS......................................24
10.2UCB – OPERATING CONTROLS ON THE PLATFORM – XTS .......................25
11.MEASURES TO BE TAKEN IN CASE OF EMERGENCY/AT RISK OF LOSING
THE STABILITY...............................................................................................................27
12.STARTING UP ......................................................................................................28
12.1Familiarise yourself with the machine and these instructions ............................28
12.2Starting the engine.............................................................................................28
12.2.1From the chassis control panel LCB...........................................................28
12.2.2From the platform control panel UCB .........................................................29
12.3Transferring, driving and steering......................................................................31
12.3.1Driving to the front and to the rear..............................................................31
12.3.2Steering......................................................................................................32
12.3.3Using the differential lock............................................................................32
12.4Operating the boom...........................................................................................32
12.4.1Operating the boom from the platform control centre UCB.........................33
12.4.2Operating the boom from the chassis control centre LCB ..........................35
12.5Socket outlets on the platform. ..........................................................................36
12.6General driving instructions ...............................................................................36
13.EMERGENCY DESCENT SYSTEM......................................................................38
13.1General information...........................................................................................38
13.2Using the emergency descent system...............................................................39
13.2.1From the chassis control centre LCB..........................................................39
13.2.2Emergency descent from the platform control panel UCB..........................39
13.3Testing the operation of the emergency descent system...................................39
14.SPECIAL INSTRUCTIONS FOR WINTER USE ....................................................40
15.MEASURES TO BE TAKEN AT THE END OF THE WORKING DAY.....................40
16.PREPARING THE LIFT FOR TRANSPORT..........................................................41

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16.1Transporting on flatbed of a vehicle...................................................................41
16.2Lifting.................................................................................................................42
16.3Towing...............................................................................................................43
17.NOTES..................................................................................................................45
SERVICE AND MAINTENANCE.........................................................................................46
18.INSTRUCTIONS FOR SERVICE AND MAINTENANCE........................................46
18.1General service instructions...............................................................................46
18.2Service and inspection instructions....................................................................47
19.LUBRICATION INSTRUCTIONS...........................................................................49
19.1Lubrication table ................................................................................................50
20.LONG-TERM STORAGE ......................................................................................51
21.AXLES AND TYRES..............................................................................................51
21.1Tightening torques of the bolts:..........................................................................51
21.2Tyres..................................................................................................................51
21.3Axles..................................................................................................................52
21.3.1Checking the levels/change of transmission oil..........................................52
22.LOAD HOLDING AND LOAD REGULATION VALVES..........................................53
22.1Location of the load regulation valves................................................................53
22.2Checking the operation of the load regulation valves ........................................54
22.3Service instructions for the load regulation valves.............................................55
23.LEVELLING SYSTEM OF THE WORK PLATFORM..............................................56
24.CALIBRATION OF THE CONTROL SENSOR FOR THE PLATFORM LOAD........57
25.DPF- DIESEL PARTICLE FILTER (OPTION)........................................................58
26.REGULAR SERVICING.........................................................................................59
26.1Schedule for regular servicing ...........................................................................59
26.2Schedule for regular servicing ...........................................................................59
26.2.1Cleaning the lift...........................................................................................59
26.2.2Changing the hydraulic oil and the filters....................................................60
26.2.3Hydraulic hoses, connectors and pipes......................................................62
26.2.4Chassis, transmission, axles and wheels ...................................................62
26.2.5Checking the boom cylinders......................................................................63
26.2.6Inspecting the boom and the chassis .........................................................64
26.2.7Checking the operation of the load control system for the platform (MRV).68
26.2.8Measuring the pressure..............................................................................70
26.2.9Check the operating controls on the work platform (UCB) and in the lower
control centre (LCB)..................................................................................................71
26.2.10Warning stickers and instructions ...........................................................71
26.2.11Deutz (D 2011 L03 i) Diesel power unit...................................................71
26.2.12Check the anti-corrosive/paint coat.........................................................73
26.2.13Test run in accordance with the loading instructions...............................73
26.2.14Draw up a protocol of the service............................................................73
27.TEST LOADING INSTRUCTIONS FOR REGULAR INSPECTION........................74
28.INSPECTION INSTRUCTIONS.............................................................................76
28.1FIRST INSPECTION .........................................................................................76
28.1.1Sample of inspection protocol for the access platform ...............................77
28.2MONTHLY INSPECTION (MAINTENANCE INSPECTION)..............................79
28.3ANNUAL INSPECTION (REGULAR INSPECTION)..........................................80
28.3.1Perform the measures of the daily and monthly inspection ........................80
28.3.2thoroughly inspect the hydraulic system.....................................................80

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28.3.3Thorough inspection of the electric system.................................................82
28.3.4Thorough inspection of the steel structures................................................83
28.4EXTRAORDINARY INSPECTION.....................................................................85
29.FAULT FINDING ...................................................................................................86
29.1Error codes of the electric control system..........................................................86
29.1.1Error codes of the control system for the boom..........................................86
29.1.2Error codes of the control system for the transmission...............................87
29.2Fault finding table ..............................................................................................88
30.DIAGRAMS AND COMPONENTS ........................................................................92
30.1ELECTRIC SAFETY COMPONENTS 540001...............................................92
30.1.1CHASSIS CONTROL CENTRE (LCB), RELAYS .......................................92
30.1.2CHASSIS CONTROL CENTRE (LCB), SWITCHES...................................92
30.1.3CONTROL CENTRE ON PLATFORM (UCB), SWITCHES AND SIGNAL
LIGHTS 92
30.1.4LIMIT SWITCHES AND SAFETY DEVICES ..............................................93
30.1.5OTHER MARKINGS...................................................................................94
30.2DINO 185 XTC ELECTRIC COMPONENTS 540003.....................................95
30.3ELECTRIC DIAGRAMS 540003.....................................................................97
30.4HYDRAULIC COMPONENTS 540003.........................................................117
30.5HYDRAULIC DIAGRAMS 540003................................................................118
31.NOTES................................................................................................................121

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OPERATION AND SAFETY
1. EU DECLARATION OF CONFORMITY
Manufacturer:
Dinolift Oy
Raikkolantie 145
FI-32210 Loimaa, FINLAND
which has authorised Chief Engineer Mr. Seppo Kopu, Dinolift Oy, Raikkolantie 145, 32210
Loimaa, Finland to draw up the Technical Construction File
declares that
DINO 185XTS Access Platform no YGC185XTSD05400XX
is in conformity with the provisions of Machinery Directive 2006/42/EC as amended and
with national implementing legislation and also fulfils the requirements of the following EEC
directives: Low Voltage Directive (2006/95/EC), directive (2000/14/EC), and EMC Directive
(2004/108/EC).
Conformity assessment procedure followed: 2000/14/EC, Annex V: Internal control of
production.
Measured sound power level Lwa ( 95,5 + 1,5 ) 97 dB
Quaranteed sound power level Lwa 97 + 0,5 dB
Notified body nr. 0044,
RWTÜV
Postfach 10 32 61
DE-45032 Essen
has granted the certificate no. TÜV 44 205 12 399100
In designing the machine, the following harmonized standards have been applied:
SFS-EN 280/A1+A2; SFS-EN 60204-1/A1
Loimaa 22.05.2013
(place) (date)
-----------------------------------------
(signature)
Seppo Kopu, Chief Engineer
(name in block letters, position)

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2. REACH DIAGRAM

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3. DIMENSION DRAWING

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4. TECHNICAL SPECIFICATION
Max. working height (18.5 m)
Max. platform height (16.5 m)
Max. outreach (11.7 m)
Boom rotation continuous
Platform rotation 180°
Work area refer to the reach diagram
Swing radius (1.75 m)
Transport width (2.29 m)
Transport length driving / transportation 7.17m / 5.27m
Transport height (2.56 m)
Weight 8000 kg
Fuel tank capacity 100 litres
Fuel left for 20 more hours
Max. allowed load on platform 250kg
Max. number of persons + additional load 2 persons + 90 kg
Max. allowed sideways load (caused by persons) 400 N
Max. lateral inclination of chassis ±5°
Max. wind speed during operation 12,5 m/s
Min. ambient temperature when working -20 °C
Tyres IN315/55D20. (Foam filling)
Maximum possible tyre load 35.000 N (3.570 kg)
Max. ground pressure 3.2 kg/cm2
Platform size 0.8 x 1.8 m
Driving speed high/low 1 km/h / 6 km/h
Gradeability 45 %
Power supply: DIESEL
Combustion engine (Deutz D2011 L03 i) 36.3 kW (48 h.p.)
Sound pressure level 98 dB
Socket outlets on the platform 230V / 50Hz / 16A
Filling capacity of the hydraulic oil tank: 86 litres
Pressure of the hydraulic system:
Drive hydraulics: 400 bar
Boom system hydraulics: 210 bar
4.1 Example of the machine’s nameplate

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4.2 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.
Left Turning
counter-clockwise
Platform
Axle
Boom extension 1
Boom extension 2
Boom extension 3
Right Turning
clockwise
Levelling cylinder of
platform
Articulated arms
Boom cylinder
Lifting cylinder
Turning device
Arm cylinder
Mastercylinder
Chassis
Boom support
Locking cylinder
Jib cylinder
Jib
Chassis control
centre (LCB)
Platform control
centre (UCB)

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4.3 Description of the machine’s intended use
The Dino 185 XTS Access Platform is exclusively intended for lifting and
transferring people and tools and acting as a work platform to the limit of its
load-bearing capacity and reach (see Technical specifications and Reach
diagram).
The intended use also covers:
- Following all the instructions in the Operating Instructions
- Performance of the inspections and maintenance operations
5. GENERAL SAFETY REGULATIONS
Make yourself familiar with these operating instructions before using the lift!
Keep these operating instructions carefully with the lift 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.
Only specially trained personnel with authorisation in writing from their employer and
who have good familiarity with the device and are at least 18-years old are allowed
to operate the lift
The max. allowed load on the platform is two (2) persons and at maximum ninety
(90) kg of additional load, however, the total load must not exceed two hundred fifty
(250) kg.
.
The work platform may only be used, whilst the chassis is well supported, i.e. the
tyres are supported on sufficiently firm and level ground. Refer to the Technical
specification and the decals affixed to the machine for max. load on the tyres.
Take into account the gradient of the terrain, when selecting the worksite.
The weather conditions, such as wind, visibility and rain, must always be taken into
account so that these factors will not adversely affect the safe performance of the
lifting operations.
The lift must not be used if the temperature drops below -20°C or the wind speed
exceeds 12.5 m/s.
Protect your hearing when you operate the lift from the chassis control panel (LCB)
(91 dB).
While on the platform, always wear the safety harness and fix it to the prescribed
fixing loops.

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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.
Always exercise utmost caution while driving with the platform raised.
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 servicing 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 lift must not be used when located on the bed of a lorry, on a trailer, on board a
vessel or in any other similar location.
Never load the platform while in the upper position.
Never exceed the maximum load of the work platform (250 kg).

The lift MUST NOT be used as a crane.
Before starting the operation, make sure that the turning device's tail overhang can
spin around without obstruction.
Always check the level position of the machine. The warning light (H17)
on the platform indicates that the inclination is too great.
Ensure that the lift cannot slide while on a gradient.
Check that there are no outsiders in the work area.

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Stepping on or off the platform in motion is prohibited.
Familiarise yourself with the terrain before starting the operation. The max. allowed
inclination of 20 ° must not be exceeded while transferring the lift. If the inclination is
more than 5° during the transfer, the work platform must be in the transport position.
Before starting the operation, always ensure that the safety devices and the
emergency descent system are working properly.
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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The device must not be altered without the manufacturer’s consent nor
used under conditions that do not meet the requirements set by the
manufacturer.
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.
Beware of the live aerial power lines in the area – observe the minimum
safety distances:
Use a safety harness while on the platform.
Weight 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
Fixing points for
the safety
harness.

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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 basis throughout the service life of the lift.
The inspection must be carried out within twelve (12) months off the first or previous
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, it shall be established to what extent the lessons
and practical experience gained from the previous inspection can be implemented for even
better safety.
NOTE! 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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7. DAILY INSPECTION (START-UP INSPECTION)
To be always performed at a new worksite and in the beginning of every working day.
The inspection is performed by the user. In the inspection attention shall be paid to
the following issues:
Establish the load-bearing capacity of the ground (see point “General safety
regulations”).
Verify the standing stability of the lift.
Control the due operation of the indicator for level position.
Test the operation of the emergency stop system both from the platform and the
chassis control panels.
Test the operation of the emergency descent system both from the platform and the
chassis control panels (see point “Emergency descent system”).
Testing the sound signal and the signal lights.
Check that the lights and reflectors are in order and clean, and the warning and
instruction decals are clean.
Check the condition of the operating controls and test all the work movements.
Check the condition of the access routes, the platform gate and the handrails.
Check the operation of the safety devices.
Check the operation of the limit switches that prevent the movements of the boom.
Check the system for oil leaks.
Check the structures visually.
Observe the location of nearby power lines and overhead obstacles.
Inspect visually the tread of the tyres.
Cleanliness of the pre-filter/water trap of the fuel. Drain off the accumulated water
from the tap screw.
Check the element of the Diesel engine cooler for cleanliness.

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Check the operation of the control system for platform load. Check that, when there
is no load on the platform, both the green and the yellow LED indicators are
illuminated (see point “Operation of the safety devices”).
Check the element of the Diesel engine cooler for cleanliness

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8. WORKSITE INSPECTION
1. General information
- Is the lift suited for the intended job?
- Is the performance of the lift sufficient for the job? (reach, loadability etc.)
- Is the position of the lift safe?
- Is the terrain suitable for using the lift (evenness and load-bearing capacity)?
- Is the lighting on the worksite sufficient?
Permissible ground pressure for different soil types
2. Documents
- Are the Operation and Service Instructions for this lift present? (Manufacturer’s
instructions)
- Are inspections and servicing carried out in accordance with the instructions and
have the defects affecting the safety been checked as repaired?
(Inspection protocols)
3. Structure (Visual inspection and operational test)
- General condition of the lift
- Operation and protection of the controls
- Emergency stop, signal horn and limit switches
- Electrical appliances and wiring
- Oil leaks
- Load markings and signs
4. Operator
- Is the operator old enough?
- Has the operator received the required training?
5. Special issues on the worksite
- Are there any additional regulations relevant to the worksite or the work?
Soil material Density Permissible ground
pressure kg / cm ²
Gravel High density Medium density
Loose
6
4
2
Sand High density Medium density
Loose
5
3
1.5
Fine sand High density Medium density
Loose
4
2
1
Sand/ mud Fixed Tough
Soft
1
0.5
0.25

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9. OPERATION OF THE SAFETY DEVICES
9.1 Lifting the boom/ articulated arms (RK3)
The safety switch RK3 prevents driving at the maximum speed once the boom or the
articulated arms are lifted from the limit switch. The switch is located on the transport
support.
Test the operation by making a driving speed test with the lever S22 in the “high”
position, and the boom system at first in the transport position and the raised
position. Only the “low” speed must operate, while the boom system is raised.
9.2 Boom extensions retracted (RK8)
The limit switch RK8 for fully retracted boom extensions prevents driving at maximum
speed, when any of the boom extensions is extended. The switch is located at the rear end
of the 1st boom, behind the boom end cover.
Test the operation by making a driving speed test with the lever S22 in the “high”
position – the boom extensions at first fully retracted and then slightly extended. Only
the “low” speed must operate, while the boom extensions are extended.
9.3 Emergency stop buttons (S1 and S4)
Stops all the movements and turns off the power unit. The emergency stop pushbuttons
must be pulled up before starting the power unit. Once the emergency stop pushbuttons
have been depressed, the emergency descent system is operational.
The operation of the emergency descent buttons is tested by pressing the
button during transfer or operation the boom system. The Diesel unit and the
movements must then stop.
Emergency
descent in
UCB
Emergency
descent in LCB