Dinolift DINO 105TL, Operating Instructions Manual

Page 1: ...OPERATING INSTRUCTIONS DINO 105TL Manufacturer Dinolift Oy Raikkolantie 145 FI 32210 LOIMAA Tel 358 20 1772 400 info dinolift com www dinolift com Dealer ...

Page 2: ...DINO 105TL 2 ...

Page 3: ...DINO 105TL 3 ORIGINAL OPERATING INSTRUCTIONS Valid from serial number 10196 ...

Page 4: ...OL CENTRE 19 9 2 OPERATING CONTROLS OF OUTRIGGERS 20 9 3 OPERATING CONTROLS IN THE PLATFORM CONTROL CENTRE UCB 21 10 MEASURES TO BE TAKEN IN THE CASE OF EMERGENCY IF THE LIFT IS AT RISK OF LOSING ITS STABILITY 22 11 STARTING UP 23 11 1 DRIVING FROM THE LCB CENTRE CHASSIS CONTROL CENTRE 26 11 2 DRIVING FROM THE UCB CENTRE PLATFORM CONTROL CENTRE 27 12 EMERGENCY DESCENT SYSTEM 30 13 DRIVING DEVICE O...

Page 5: ...Measuring pressure of the hydraulic system 49 18 9 13 Check the operating controls on the platform 50 18 9 14 Warning stickers and adhesive tapes 50 18 9 15 Inspect the brakes and the driving device 50 18 9 16 Traffic lighting 50 18 9 17 Anti corrosion treatment 50 18 9 18 Test run 51 18 9 19 Draw up an inspection protocol 51 19 INSPECTION INSTRUCTIONS 52 19 1 FIRST INSPECTION 52 19 1 1 SAMPLE OF ...

Page 6: ...DINO 105TL 6 HYDRAULIC DIAGRAM 10189 81 23 1 NOTES 82 ...

Page 7: ...C 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 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 Notified body no 0537 VTT P O Box 1300 FI 33101 Tampere FINLAND has granted ...

Page 8: ...DINO 105TL 8 2 REACH DIAGRAM ...

Page 9: ...DINO 105TL 9 3 DIMENSION DRAWING ...

Page 10: ...m 130 kg Max number of persons additional load 1 person 50 kg Max allowed sideways load caused by persons 200 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 7500 N Platform size 0 85 m x 0 7 m Gradeability using the driving device optional 15 Power supply 230V 50Hz 10A Sound pressure level...

Page 11: ...sed later in these instructions are described on this page Turning Counter clockwise to the Platform drive Boom extension 1 Boom extension 2 Right Left Turning Clockwise to the right Levelling cylinder of platform Telescope cylinder Lifting cylinder Turning device Outrigger cylinder Outrigger Master cylinder Chassi Coupling Boom ...

Page 12: ...ly 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 one 1 person and at maximum fifty 50 kg of additional load however the total load must not exceed one hundred thirty 130 kg The platform may only be operated when the chassis is wel...

Page 13: ...derside 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 Beware of the live aerial power lines in the area observe the minimum safety distan...

Page 14: ...rom the manufacturer for all such specific work methods or conditions that the manufacturer has not explicitly defined The device must neither be altered without the manufacturer s consent nor be used under conditions which do not meet the requirements set by the manufacturer 5 1 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 cabl...

Page 15: ...f 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 panel on the turning device beware of getting pressed against the outriggers or other structures that do not turn with the boom Whe...

Page 16: ...umented evidence of competence or an expert with documented evidence of competence A protocol must be drawn up of the executed inspections The protocols of the start up and periodic inspections must be kept with the lift or its immediate proximity for at least five years Carry out the inspections regularly basis throughout the service life of the lift The inspection must be carried out within twel...

Page 17: ...d 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...

Page 18: ... boom All the lift s support outriggers must be in the support position before the boom is lifted Make sure that the wheels are off the ground The safety limit switches RK11 RK12 RK13 and RK14 are located on the support outriggers 3 As the emergency stop button is depressed all movements stop and the power unit is turned off The emergency stop pushbutton must be pulled up before starting the power...

Page 19: ...n start Q1 1 OFF power off H3 Signal light for the limit switches for outriggers Q1 2 LCB control centre outriggers S16 Lever for turning the boom system Q1 3 UCB platform control centre S17 Lever for lifting the boom system S1 Emergency stop S18 Lever for telescope movement Vi Power on signal light S20 Lever for platform inclination S2 Low speed selection start ...

Page 20: ...DINO 105TL 20 1 2 3 4 5 9 2 OPERATING CONTROLS OF OUTRIGGERS 1 Rear outrigger right 2 Rear outrigger left 3 Front outrigger left 4 Front outrigger right 5 Position indicator of chassis water level ...

Page 21: ...elector switch Q1 before you start operating the lift from the platform control centre UCB S4 Emergency stop S8 Lever for lifting the boom system S5 Low speed selection start S9 Lever for telescope movement S6 High speed selection start S10 Sound signal S7 Lever for turning the boom system S12 Lever for levelling the platform ...

Page 22: ...t of a fault in the lift repair such a fault immediately Do not use the lift until the fault has been repaired and the condition of the lift has been verified IN CASE OF OVERLOADING 1 If there is time try to find out the reason for the reduced stability and the direction of its effect Warn other people on the worksite using the alarm signal 2 If possible reduce the load from the platform in a safe...

Page 23: ... and inclination of the surface on the support the support outriggers must not slip on the surface the operation is prohibited if the lift is not properly supported and in a level position 0 3 Soil material Density Max ground pressure P kg cm Gravel High density 6 Medium density 4 Loose 2 Sand High density 5 Medium density 3 Loose 1 5 Fine sand High density 4 Medium density 2 Loose 1 Sand mud High...

Page 24: ... Connection of power supply to the lift connect the mains cable to the power supply for maximum out of the electric motor the voltage must 230 VAC 10 6 the frequency must be 50 Hz and rating of the fuse 10A the length of the connecting cable has some effect 4 Turn the selector switch Q1 to position LCB chassis centre 5 Start the engine from the pushbutton S2 or S3 ...

Page 25: ...riggers in accordance with the level gauge DO NOT LOAD THE TOW BAR JOCKEY WHEEL MAKE SURE THAT THE WHEELS ARE CLEARLY OFF THE GROUND the green signal light H3 on the chassis control centre LCB comes on when all the outriggers are in the support position and the outrigger limit switch circuit is connected make sure all outriggers are firmly supported on the ground ...

Page 26: ...nd the telescope 1 2 metres lever 8 keeping the emergency stop button depressed The movement should now stop 2 To retract the telescope turn the selector lever to the left and pump with the hand pump until the telescope is fully retracted The extension arm for the hand pump is under the bottom plate of the turning device see picture below 3 To lower the boom turn the selector lever to the right an...

Page 27: ...rt position you can operate the boom from the control levers S7 S8 S9 and the work platform from the lever S12 To operate the boom movements you need the keep either the button S5 or S6 simultaneously depressed selection of speed low high Only use the button S6 high speed with short boom and at low platform height Whenever possible keep the boom short while lifting and lowering the platform DO NOT...

Page 28: ...ated simultaneously only the movement with the least resistance will operate NOTE Lowering the platform to transport position Always retract the telescope completely before lowering the boom onto the transport support DO NOT TAKE ADDITIONAL LOAD IN THE UPPER POSITION 16 When moving the platform remember the following be careful of the high voltage power lines do not exceed the max allowed lateral ...

Page 29: ... control centre LCB in the following way Turn the selector switch Q1 to the position LCB chassis centre Depress the button S2 S3 and simultaneously select the desired direction for the correction movement using the control lever S20 From the platform control panel UCB The platform may also be levelled from the platform control centre UCB in the following way Turn the selector switch Q1 to the posi...

Page 30: ...pump is under the bottom plate of the turning device see picture below 2 Lowering the boom To lower the boom turn the selector lever to the right and pump with the hand pump until the boom lowers onto the ground 3 The boom can be turned by placing a crank on the worm gear shaft in the opening in the plastic cover of the turning device and by turning it without haste in the desired direction The cr...

Page 31: ... towards the ascent 3 Always chock the wheels before disconnecting the unit from the towing vehicle 4 Always apply the handbrake before disconnecting the unit from the towing vehicle Only use the handbrake as a parking brake or for emergency stopping 5 Never leave the lift on a slope being supported only by the self braking action of the driving device 6 When transferring the lift using the drivin...

Page 32: ...riving device against the wheel on both sides 5 Release the handbrake 6 Drive the unit by turning the levers of the manual directional valve in the desired driving direction Use the right hand lever to drive the right wheel and the left hand lever to drive the left wheel 7 Do not drive the jockey wheel into obstacles or potholes 8 After the driving apply the parking brake 9 Disconnect the driving ...

Page 33: ... Retract the telescope boom completely 2 Check that the platform is perpendicular to the boom 3 Lower the boom platform onto the support on the tow bar 1 if the platform is not in its lowest position the limit switch on the transport support prevents the operation of the support outriggers 4 Close the control centre cover on the work platform 5 Turn the selector switch Q1 to position OFF 6 Disconn...

Page 34: ...release the parking brake and make sure that its locking is in order and that its handle stays in the lower position 5 Lift up the jockey wheel to the transport position No load allowed on the platform during towing of the lift In particular if you are parking or disconnecting the lift from the towing vehicle on a slope apply the parking brake as firmly as possible After having applied the parking...

Page 35: ...DINO 105TL 35 o that the driving device is disconnected from the wheel ...

Page 36: ...re the lift is next used do not let oil spill on the ground keep the lift clean especially the platform clean up the lift before service and inspection use genuine spare parts support the platform boom system and support outriggers in a position in which the load does not rest on the structure under repair or cause any other danger e g transport position or use of supporting structures 18 1 LIFTIN...

Page 37: ...ust the pads if necessary Check the operation of the swing limiters and the condition of the hoses and electric wires routed to the chassis The swing limiters should allow the boom to be turned at maximum 355 in both directions from the boom support 4 Service every six months check the condition of the brakes check the the wheel bolts for tightness 90 Nm grease the gear ring of the turning device ...

Page 38: ...DINO 105TL 38 18 3 LUBRICATION PLAN 1 2 3 4 5 5 6 7 8 10 9 11 12 ...

Page 39: ...turning bearing 2 strokes nipple Lubricant Esso Beacon EP2 or equivalent Moving parts of the mechanism of the outrigger limit switch system must be lubricated every 50 hours If necessary apply a thin grease film on moving parts of the ball coupling Always lubricate the lift and apply a protective grease film immediately after the washing 18 4 LONG TERM STORAGE Clean the machine carefully lubricate...

Page 40: ...easure the stroke and observe in a few minutes time that the stroke does not change Note Drive the boom to an almost vertical position 4 To check the load regulation valve in the levelling system of the platform for tightness put a load of about 100 kg onto the platform and measure the distance from the rear edge of the platform to the floor Observe in a few minutes time that the height position d...

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Page 42: ...The wheel bearings are lubricated for life and do not require any service The bearings need no additional lubrication and they neither need nor can be re adjusted Service intervals 500 km running in 5 000 km adjustment of the brakes lubrication of the moving parts of the overrun 13 000 15 000 km or every six months a check the brake linings for wear b check the operation of the overrun brake c lub...

Page 43: ... which is not tight An internal leakage in the cylinder If the platform viewed by the operator drifts backwards the reason can be A leak in the load regulation valve 4 on the piston bottom side of the slave cylinder in the direction of the electric directional valve 5 which is not tight An internal leakage in the cylinder The leak will cause drifting of the platform until the load regulation valve...

Page 44: ...taff of the dealer 18 9 SCHEDULE FOR REGULAR SERVICING 18 9 1 Clean the lift thoroughly before the service The hydraulic and electric appliances must not be dismantled if they are not clean Any contaminants in the system may cause malfunctions later on Wash the lift externally NOTE Be careful not to direct the high pressure water jet straight to the electric appliances such as the control panels o...

Page 45: ...e the pressure filter install the drain plug refill the tank with fresh oil the volume required for change is about 10 litres factory filling Mobil EAL 32 The viscosity class of the hydraulic oil must be ISO VG32 or ISO VG15 and the oil must meet the requirements according to DIN 51524 HLP Material Safety Data Sheet EXXON MOBIL no 581017 60 never mix different oil sorts as required top up hydrauli...

Page 46: ... shall be tightened so firmly that it cannot be easily moved by hand 1 Lift the boom away from the support and turn it sufficiently far to the side 2 Test that the limiter cannot be moved too easily by hand 3 Tighten the bolt as required 4 Drive the boom back onto the support in the position shown in the picture ensuring that there is no twisting of the hoses and wires that are routed through the ...

Page 47: ...ndition and tightness of the cylinder lubricate the joints of the lifting cylinder the telescope cylinder and the levelling cylinders inspect the outrigger cylinders and lubricate their joints NOTE ALWAYS DRIVE THE LIFT INTO A POSITION WHERE IT IS SAFE TO CHECK THE CYLINDER 18 9 7 Inspecting the boom and the frame extend the telescope and inspect the platform its attachment and the boom inspect th...

Page 48: ...dition of the locking device check that the overrun brake mechanism moves freely stop the lift push in the towball coupling with its push rod the push rod and the tow ball coupling must return to their initial outer position of themselves following the action of the gas cushion of the hydraulic absorber 18 9 9 Inspection of the axle and the suspension check the attachment of the axle check conditi...

Page 49: ... support outriggers are in their upper position the boom must not operate in any position of the selector switch lift the boom and test the following 1 emergency stop S1 see point Operating controls in the platform control panel UCB 2 emergency descent see point Emergency descent system 18 9 12 Measuring pressure of the hydraulic system connect the pressure gauge to the measuring nipple max pressu...

Page 50: ...re legible replace if necessary 18 9 15 Inspect the brakes and the driving device remove the wheels clean the brake system and check the settings check the free movement of the brake shoes the operation of their return springs replace any worn out linings check the condition of the driving device and lubricate the joints put the wheels in place and tighten the wheel bolts 90 Nm Check the bolts for...

Page 51: ...st run Perform a test run with a load of 130 kg following the loading instructions Check the structures after the test run 18 9 19 Draw up an inspection protocol Save your own copy and give an other copy to the customer NOTES ...

Page 52: ...rk site shall be subjected to a regular maintenance inspection if possible once a week VNA 205 2009 14 18 Keep a journal of any notable shortcomings and defects observed and advise the foreman of them 19 1 FIRST INSPECTION The initial inspection and test loading of the Dino access platforms is performed by the manufacturer A protocol which accompanies the lift is drawn up of the inspection ...

Page 53: ...DINO 105TL 53 19 1 1 SAMPLE OF INSPECTION PROTOCOL FOR THE ACCESS PLATFORM ...

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Page 55: ...test the alarm signal check the signal light for the outrigger limit switches H3 check the operation and cleanliness of the lights and reflectors 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 limit switches which block the movements of the boom see point Operation...

Page 56: ... been duly executed check that the platform does not drift see point Load holding and load regulation valves check that the outrigger do not drift see point Load holding and load regulation valves check the hydraulic oil level check the hoses and the cables at the turning ring for leaks chafing check the tyres and the tyre pressure check the wheel bolts and the rims check the turning gear play che...

Page 57: ...e max pressure for warm 40 60 C oil is 20 5 21 5 MPa 205 215 bar the turning pressure is 6 MPa 60 bar load holding check valves on the outriggers lift the device off the ground with the outriggers and measure the distance to the chassis at each outrigger step on the platform and extend the telescope keeping the boom level Turn the boom round a few times stop at the initial position and check that ...

Page 58: ...master cylinder in the slave cylinder system lower the boom and check the condition of the piston rod and the wiper ring of the slave cylinder under the platform hoses check the hoses for any leaks or chafing pipes check that there are no dents leaks trace of corrosion or chafing at the clamps check that the pipes are properly fastened connections check the hose and pipe connectors for leaks inspe...

Page 59: ... boom attachment for cracks or breaches check the condition of the platform brackets check the locking of the platform pin check the condition of the cable chain its clamp brackets as well as the tightness of the screw connections check the play and attachment of the gliding surfaces on the boom inspect the platform general condition check that the platform does not show signs of deformations subs...

Page 60: ... operation of the boom movements the limit switches on the tow bar which prevent the use of the outriggers after the test loading and the test run make sure that the loading has not caused any defects such as fractures or permanent deformations of dangerous nature on the steel structures or other loaded parts draw up a protocol of the regular inspection with following articles 1 inspection form 2 ...

Page 61: ...nspection have been completed without finding any defects in the structure or stability of the lift the lift may be used provided that the reach and platform load restrictions presented in the reach platform load chart of this manual are observed The max allowed load on the platform is 130 kg In conjunction with the first i e start up inspection the lift shall be subjected to an overload test with...

Page 62: ...ontactor and thermo relay as well as the operation of the relays which control the operation of the contactors 2 None of the platform movements is operational though the electric motor is running and the selector switch is in position LCB or UCB Green signal light for outriggers is not lit Check operation of the safety limit switches RK11 RK12 RK13 and RK14 The green signal light for the outrigger...

Page 63: ...movements is operational Irregular and indefinite malfunctions Make sure that the hydraulic oil and the filter have been changed Thoroughly clean the solenoid valve spools and housings requires utmost cleanliness not all contaminants can be spotted with the naked eye Also temporary contact failures in the joysticks may cause malfunctions Spray with moisture repellent 6 Boom drifts slowly downwards...

Page 64: ...with the seizure of the electric valve spool The lift turns as the lifting movement is activated Solenoid valve is stuck in turning position Clean the valve thoroughly or replace the valve 8 Telescope movement does not operate Refer to item 5 Check that the solenoid valve of the telescope is not stuck in the centre open position ...

Page 65: ...ulation valve under the platform is leaking For remedy refer to item 6 lock valve 11 Platform drifts forward Double load regulation valve on the rod side is leaking Measures as above 12 Support outriggers do not operate though the selector switch is in position 1b Boom does not rest on the transport support Drive the boom onto the support Electric valve for movement of boom outriggers does not ope...

Page 66: ...tion For remedy refer to item 5 16 Too low braking force Too much play in the brake system Adjust the brake system see point Wheel brakes and bearings Brake linings not yet run in Pull the parking brake lever slightly and drive 2 3 kilometres Brake shoes glazed dirty or oil on the friction surfaces Replace the brake shoe sets Clean the friction surfaces of the brake drum Overrun brake jams Lubrica...

Page 67: ... released Release the parking brake completely 22 Ball coupling is not locked Inner parts of the ball coupling dirty Clean and lubricate Tow ball of the towing vehicle too large Measure the tow ball According to DIN74058 the diameter of the ball must be max 50 mm and min 49 5 mm If the measure is different or the ball is nor perfectly spherical it must be replaced Always when you change brake shoe...

Page 68: ...ange over valve and levelling of the platform Manual test run Press the pin at the end of the electric valves If the movement operates the fault is in the operating controls of the electric system or the valve spools are dirty which causes jamming refer to fault finding scheme item 4 If none of the movements operate the fault is in the hydraulic system Change over valve Telescope cylinder Turning ...

Page 69: ...DINO 105TL 69 21 1 NOTES ...

Page 70: ...p has been depressed K35 AUXILIARY RELAY FOR THE ELECTRIC MOTOR Circuit that keeps the engine running SR2 Safety relay monitoring the operation of the outriggers The safety relay resets as soon as all outrigger safety limit switches RK11 RK12 RK13 and RK14 have closed After that it is possible to operate the boom 22 2 CHASSIS CONTROL CENTRE LCB SWITCHES S1 LOCKING EMERGENCY STOP SWITCH Stops all t...

Page 71: ...Off 1b chassis control panel 1c platform control panel VM1 SIGNAL LIGHT FOR VOLTAGE SUPPLY When the control voltage is switched on the light indicates the supply of alternating voltage 22 4 PLATFORM CONTROL CENTRE UCB SWITCHES S4 LOCKING EMERGENCY STOP SWITCH Stops all the other functions except the emergency descent and the sound signal S5 START SWITCH LOW SPEED Controls the contactor of the elec...

Page 72: ... does not rest on the support in the transport position RK11 RK14 LIMIT SWITCHES ON THE OUTRIGGERS The limit switch closes as soon as sufficent force is exerted on the outrigger Prevents the operation of the boom unless the outriggers are not firmly supported on the ground and all limit switches are not closed 22 7 OTHER MARKINGS J1 PLUG M1 ELECTRIC MOTOR 230VAC 1 1kW T1 POWER SUPPLY Feeds the sys...

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Page 81: ...DINO 105TL 81 HYDRAULIC DIAGRAM 10189 ...

Page 82: ...DINO 105TL 82 23 1 NOTES ...