Dino 210XT Operating Instructions Manual
DINO
®
210
XT
OPERATING INSTRUCTIONS
®
Raikkolantie 145
FI-32210 LOIMAA
T. +358 2 762 5900
F. +358 2 762 7160
dino@dinolift.com
www.dinolift.com
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DINO 210XT
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OPERATING INSTRUCTIONS
Valid from serial number 2945->
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CONTENTS
REACH DIAGRAM..........................................................................................................................6
TECHNICAL SPECIFICATION.....................................................................................................7
GENERAL SAFETY REGULATIONS ..........................................................................................8
REGULAR INSPECTION..............................................................................................................10
WORKSITE INSPECTION ...........................................................................................................11
OPERATION OF SAFETY DEVICES .........................................................................................13
OPERATING CONTROLS............................................................................................................15
OPERATING CONTROLS ON THE CHASSIS CONTROL PANEL .........................................15
OPERATING CONTROLS OF DRIVE SYSTEM........................................................................16
OPERATING CONTROLS OF OUTRIGGERS...........................................................................16
OPERATING CONTROLS ON THE PLATFORM......................................................................16
OPERATING CONTROLS ON THE PLATFORM......................................................................17
MEASURES TO BE TAKEN IF THE LIFT IS AT RISK OF LOSING ITS STABILITY.....19
START-UP........................................................................................................................................21
OPERATING THE LIFT FROM THE CHASSIS PANEL............................................................26
OPERATING THE LIFT FROM THE PLATFORM PANEL.......................................................28
EMERGENCY DESCENT SYSTEM............................................................................................34
DRIVING DEVICE .........................................................................................................................35
DRIVING DEVICE .........................................................................................................................36
SPECIAL INSTRUCTIONS FOR WINTER USE.......................................................................38
MEASURES TO BE TAKEN AT THE END OF THE WORKING DAY ................................39
PREPARING THE LIFT FOR TRANSPORT.............................................................................40
CONNECTION TO THE TOWING VEHICLE..........................................................................41
INSTRUCTIONS FOR SERVICE AND MAINTENANCE........................................................42
GENERAL SERVICE INSTRUCTIONS......................................................................................42
SERVICE AND INSPECTION INSTRUCTIONS........................................................................43
LUBRICATION PLAN .................................................................................................................44
LOAD HOLDING AND LOAD REGULATION VALVES.........................................................47
WHEEL BRAKES AND BEARINGS...........................................................................................48
LEVELLING
SYSTEM OF THE PLATFORM ............................................................................51
REGULAR
SERVICING...............................................................................................................52
TESTING THE LOAD LIMIT SWITCHES RK4 AND RK 5................................................59
ADJUSTMENT OF THE OVERLOAD LIMIT SWITCHES ................................................61
INSPECTION INSTRUCTIONS ...................................................................................................66
FIRST INSPECTION.....................................................................................................................66
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DAILY INSPECTION (START-UP INSPECTION)....................................................................67
MONTHLY INSPECTION (MAINTENANCE INSPECTION)...................................................68
ANNUAL INSPECTION (REGULAR INSPECTION)................................................................69
EXTRAORDINARY INSPECTION.............................................................................................72
TEST LOADING INSTRUCTIONS FOR REGULAR INSPECTION.........................................73
FAULT FINDING............................................................................................................................74
GENERAL INFORMATION OF HYDRAULICS.......................................................................81
ELECTRIC COMPONENTS.........................................................................................................82
CHASSIS CONTROL CENTRE (LCB), RELAYS.......................................................................82
CHASSIS CONTROL CENTRE (LCB), SWITCHES..................................................................86
CHASSIS CONTROL CENTRE (LCB), OTHER ITEMS............................................................87
PLATFORM CONTROL CENTRE (UCB), RELAYS .................................................................88
PLATFORM CONTROL CENTRE (UCB), SWITCHES.............................................................89
PLATFORM CONTROL CENTRE (UCB), OTHER ITEMS.......................................................90
LIMIT-SWITCHES.......................................................................................................................90
DRIVING DEVICE CONTROL CENTRE (DCB)........................................................................91
OTHER MARKINGS....................................................................................................................91
ADJUSTMENT VALUES OF MOVEMENT SPEEDS...............................................................92
ELECTRIC COMPONENTS 2945 >.........................................................................................94
WIRING DIAGRAM.......................................................................................................................98
ELECTRIC DIAGRAM 2945-->................................................................................................99
HYDRAULIC COMPONENTS 2945 >...................................................................................117
HYDRAULIC DIAGRAM 2945 >............................................................................................118
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REACH DIAGRAM
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TECHNICAL SPECIFICATION
Max. working height 21,0 m
Max. platform height 19,0 m
Max. outreach 11,7 m
Boom rotation continuous
Platform rotation 90°
Turn area refer to reach diagram
Support width 4,30 m
Transport width 1,92 m
Transport length 7,88 m
Transport height 2,18 m
Weight 2 440 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 22800 N
Platform size 0,7 x 1,3 m
Gradeability 25 %
Power supply:
- mains current: 230V / 50Hz / 10A
- 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
Socket outlets on the platform 230V / 50Hz / 16A
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GENERAL SAFETY REGULATIONS
Make yourself familiar with these operation 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.
Advice the 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 who are well familiar with the device and 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 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 factors will not adversely affect the 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
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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 either by using
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 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 clean of any dirt which may impair the safe operation and impede the inspection of the
structures
The device must be serviced and inspected regularly.
Only skilled persons who are familiar with the service and reparation instructions are allowed to
carry out the service and reparation work.
It is strictly prohibited to use a lift which is out of order.
The device must not be modified without the manufacturer´s consent.
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REGULAR INSPECTION
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 keep it always with the unit stored in the space reserved
for it.
Carry out he inspections on regular basis throughout the service life of the lift.
The inspection must be carried out within twelve (12) months from the first or the 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.
ATTENTION! Primarily the national legislation must be followed!
Regular inspections and service measures are described more thoroughly in the chapter "Serviceand maintenance".
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WORKSITE INSPECTION
1. General
- 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 lighting on the worksite sufficient?
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 work site
- Are there any additional regulations relevant to the worksite or the work?
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OPERATION OF SAFETY DEVICES
1. Support outriggers (Fig. A)
The safety limit switch RK3 prevents the operation of the outriggers and the driving device when
the boom does not rest on the transport support. The switch is located on the tow-bar at the transport
support.
2. Lifting the boom (Fig. B)
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 ja RK14 are located on the support outriggers.
3. Overload protection switches (Figs. A and C)
The safety limit switches prevent overloading of the lift. At a predetermined position the overload
limit switch RK4 stops extension of the telescope and lowering of the boom.
The overload limit switch RK5 backs up if the RK4 for some reason does not work.
The green light in the platform control centre is lit when the platform is inside the allowed operating
range. The red light comes on as the RK4 stops the movement. When the red light is on, the lift can
be operated in the direction where it stays inside the allowed outreach area. The safety limit switch
RK5 backs up the operation of the RK4 by switching on the buzzer on the platform.
4. 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 the power unit can be restarted
(button 3 on page 14 and button 22 on page 18).
Ensure the operation of the safety devices - do not lock the chassis panel cover with key while
the lift is in operation.
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OPERATING CONTROLS
OPERATING CONTROLS ON THE CHASSIS CONTROL PANEL
1. Selector switch
0 - ignition off
1 - outrigger circuit, hydraulic drive
2 -controlling the boom from the platform panel
3 -controlling the boom from the chassis panel
2. Start button
3. Emergency stop button
4A. Green signal light for limit switches of the outriggers
4B. Red signal light for the safety device (RK5)
5. Start button of emergency descent system
6. Telescope in, pushbutton
7. Lever switch for turning
8. Lever switch for boom system
9. Lever switch for telescope movement
10. Voltage meter
12. Rear outrigger, right
13. Rear outrigger, left
14. Front outrigger, left
15. Front outrigger, right
16. Position indicator of chassis
29. Stop button
32. Lever switch for platform
inclination
33. Lever switch for articulated arms
34. Hour meter
40. Choke
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OPERATING CONTROLS OF DRIVE SYSTEM
28A. Forward - backward
28A + 28L drive to the left
28A + 28R drive to the right
OPERATING CONTROLS OF
OUTRIGGERS
12. Rear outrigger, right
13. Rear outrigger, left
14. Front outrigger, left
15. Front outrigger, right
16. Position indicator of chassis
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OPERATING CONTROLS ON THE PLATFORM
Close the cover of the chassis control panel before operating the platform controls.
The cover must not be locked while the lift is in operation.
17. Control lever
TELESCOPE
IN
ARTICULATED
ARMS
DOWN
ARTICULATED
ARMS
UP
TELESCOPE
OUT
BOOM
UP
BOOM
TO THE LEFT
BOOM
TO THE RIGHT
BOOM
DOWN
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18. Signal lights
- green inside allowed outreach range
- red at the border of allowed outreach range
20. Emergency descent device start button
21. Retracting the telescope
22. Emergency stop
- push to stop
- pull to reset
23. Sound signal
24. Socket outlet 230VAC/ (2 pcs.)
25. Stopping the engine
26. Starting the engine
30. Turning the platform (is used simultaneously with pushbutton 35)
31. Platform swing fuse
35. Levelling of the platform (pushbutton)
36. Lever for levelling of platform (is used simultaneously with pushbutton 35)
41. Choke
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MEASURES TO BE TAKEN IF THE LIFT IS AT RISK OF LOSING ITS
STABILITY
The reason for the reduced stability can be a fault in the lift, the wind or other lateral force, collapse
of the standing base or negligence in providing sufficient support. In most cases a sign of the
reduced stability is the inclination of the lift.
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 work site using the alarm signal.
2. Reduce the outreach to the side by retracting the telescope. Avoid abrupt movements.
3. Turn the boom away from the danger zone, i.e. to a position where the stability of the lift is
normal.
4. Lower the boom.
If the stability has been lost as a result 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.
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Notes
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START-UP
1. Ground stability
- make sure that the ground is even and hard enough to support the lift in a steady level
position
Soil material Density Max. ground
pressure
P kg/cm²
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 density (very hard to work) 1,00
Medium density (hard to work) 0,50
Loose (easily worked) 0,25
- if the ground is soft, use sufficiently large and sturdy additional plates under the support
outriggers
- observe the effect of ice, possible rain 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
2. Drive or push the lift to the inspected lifting site
- apply the parking brake
- disconnect the lift from the towing vehicle
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3. Connection of power supply to the lift
A. POWERED BY AC-SUPPLY
While the mains voltage is plugged in, the12VDC supplied by a separate unit.
- connect the mains cable to the power supply
- turn on the main switch (Fig. A)
- 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)
B. POWERED BY COMBUSTION ENGINE
In the absence of the mains, the12 VDC is supplied by a battery.
- do not connect the mains cable (230 VAC)
- turn on the main switch (Fig. A)
- open the fuel cock
- switch on the choke for starting by depressing the button on the cover of the centre
If the battery is flat start the aggregate by pulling the starter grip keeping the button
at the aggregate bed depressed. Pull the starter grip lightly until you feel resistance,
then pull briskly.
Do not allow the starter grip to snap back against the engine.
- adjust the engine speed to halfway.
Leave the combustion engine running between operations because the battery only recharges while
the engine is running.
Close the fuel cock when stopping the combustion engine.
Note! The fuel cock must be closed when the lift is towed.
C. OPERATION WITH DIESEL ENGINE
- do not connect the mains cable (230 VAC)
- turn on the main switch (Fig. A)
Please refer to separate user manual for the diesel engine delivered with the lift
for instructions concerning the start-up of the engine, when the battery is empty.
Leave the combustion engine running between operations because the battery only recharges while
the engine is running.
To avoid damaging the electronics of the diesel engine; do not disconnect the mains current
while the diesel engine is running!
4. To access the operating controls open the cover on the chassis
Check the condition of the battery to ensure operation of the emergency descent system.
The charge level of the battery is indicated by LEDs.
During charging the red LED is on and the green LED is off.
- when the battery is almost fully charged, both LEDs are lit
- when the battery is fully charged, the green LED is lit and the red one flashes
- if both LEDs are lit after full charging, the battery is dead
5. Turn the selector switch (1) to position 1 (Fig. B)
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6. Start the engine with button 2 (green)
The electric timer of the lift automatically disconnects the supply voltage (12 VDC) 1 hour after the
last time the electric or combustion engines were in operation.
Re-activate the power supply by pressing the start button either on the chassis control panel or on
the platform control panel.
Petrol engine:
- turn off the choke
- adjust the engine speed
7. Lower the front support outriggers (on the tow-bar side)
8. Lower the rear support outriggers (do not damage the tow-bar jockey wheel)
9. Level the chassis with the outriggers with the help of the level gauge (16) (Fig. C). The air
bubble must be located inside the inner ring.
MAKE SURE THAT THE WHEELS ARE CLEARLY OFF THE GROUND (FIG. D)
- the (green) signal light 4A on the chassis control panel comes on when all outriggers are in the
lower position and the outrigger limit switch circuit is connected
- make sure all outriggers are firmly supported on the ground
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OPERATING THE LIFT FROM THE CHASSIS PANEL
10. Turn the selector switch (1) to position 3
- now you are able to operate the boom with levers 7, 8, 9, 33 and the platform with lever 32 from
the chassis panel
- test the operation of the emergency descent system as follows:
1. start by lifting the boom about 1 - 2 metres (with lever 8) and continue by extending the
telescope 1 - 2 metres (with lever 9) keeping the emergency stop button depressed - thus the
movement shall stop
2. start the power unit of the emergency descent system (pushbutton 5), retract the telescope
(lever 9) and lower the boom (lever 8)
3. pull up the emergency stop button
4. lift the boom from the towbar
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Note! If you have levelled the chassis of the lift ON A GRADIENT turn around the boom
carefully to make sure that the turning device does not bang against the support outriggers.
5. turn the boom to the side to enable its lowering
6. extend the telescope as much as necessary to ensure safe entrance on the platform
DO NOT DAMAGE THE TOW-BAR JOCKEY WHEEL!
The boom movements are noticeably slower when the emergency descent system is used.
The speed of the boom movements cannot be adjusted continually with the control levers when the
lift is operated from the chassis control panel.
Lock the selector switch (1) in position 1 (support outriggers) before working under the boom.
Make sure that neither people nor load are on the platform.
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OPERATING THE LIFT FROM THE PLATFORM PANEL
11. Turn the selector switch (1) to position 2 and take away the key
Do not lock the chassis control panel cover with the key.
- now you can operate the boom with lever 17 on the platform control panel
Start by pushing the rocker switch at the end of the control lever and then move the lever carefully
in the desired direction of motion. If you move the lever before pushing the rocker switch, the
action is deterred.
- test the operation of the emergency descent system as follows:
- start by lifting the boom about 1 - 2 metres (with lever 17) and continue by extending the
telescope 1 - 2 metres (with lever 9) keeping the emergency stop button depressed - thus the
movement shall stop
- start the emergency descent power unit (pushbutton 20), retract the telescope and lower the
boom (lever 17)
- pull up the emergency stop button
DO NOT DAMAGE THE TOW-BAR JOCKEY WHEEL!
The movement speed of the platform can be continually adjusted with the lever (17).
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12. Test the operation of the overload limit switch RK4
- platform load about 80 kg
- drive the boom to a horizontal position
- extend the telescope
As the movement stops the red overload light (18) must light up.
- compare the outreach with the figures in the reach diagram (page 59) in this manual.
12A. Measures to be taken after overloading has occurred
- (The overload limit switch RK5 switches off the electric circuit of the operating controls
and switches on the buzzer on the platform)
- retract the platform to inside the operating range of the RK4 by pushing the ”telescope
in” -button (31 or 36) (the green light lights up)
- after this the lift may be operated normally
WARNING!
Do not add load (e.g. another person) onto the platform while the red overload light (18) is lit.
Example: A person, who is working alone on the platform, extends the telescope, or an empty
platform is driven from the chassis control panel to the maximum reach keeping it close to the
ground. If the overload signal light now lights up, the telescope must be retracted before loading the
platform further.
IF THE SAFETY DEVICES OR THE EMERGENCY DESCENT SYSTEM ARE NOT
WORKING, HAVE THEM REPAIRED BEFORE OPERATING THE LIFT!
13. Refer to the item "Daily inspections" in the task list for servicing
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14. With the boom slightly lifted and the telescope extended, make sure that the platform
does not lower of itself while the operating controls are not being used
15. When working under cold weather conditions, let the engine run for a while without
load to increase the hydraulic oil temperature. Start the operations by driving the
movements carefully without load back and forth from the chassis control panel.
16. Move the platform to the w o rk object
The platform movements can be operated with continually adjustable speed from the platform
control panel (not from the chassis control panel). Only one movement can be operated at a time. If
several control levers are operated simultaneously, only the movement with the least resistance will
operate.
ATTENTION!
Lowering the platform to transport position: Always before lowering the boom onto the transport
support, retract the telescope completely and turn the platform perpendicular to the boom.
DO NOT DAMAGE THE TOW-BAR JOCKEY WHEEL!
DO NOT TAKE ADDITIONAL LOAD IN THE UPPER POSITION!
17. Observe when lifting the platform
- the operating range of the platform depends on the load (see Technical Data) and is
monitored by the safety limit switches RK4 and RK5, which are located under the
protecting cover
The limit switches must not be adjusted or modified. The inspection and adjustment may
only be carried out by an authorized serviceman.
18. Working a long time in the same position
- there are pushbuttons for both stopping and starting on both the platform and the chassis
control panels
When the weather is warm and the platform is kept for a longer period in the same position,
it is not necessary to let the engine run continuously.
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