Dino lift 135T Operating Instructions Manual
DINO
®
135
T
OPERATING INSTRUCTIONS
®
Raikkolantie 145
FI-32210 LOIMAA
T. +358 2 762 5900
F. +358 2 762 7160
dino@dinolift.com
www.dinolift.com
DINO 135T
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DINO 135T
3
OPERATING INSTRUCTIONS
Valid from serial number
13021
DINO 135T
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CONTENTS
REACH DIAGRAM..........................................................................................................................6
TECHNICAL SPECIFICATION.....................................................................................................7
GENERAL SAFETY REGULATIONS...........................................................................................8
REGULAR INSPECTION..............................................................................................................10
WORKSITE INSPECTION............................................................................................................11
OPERATION OF THE SAFETY DEVICES................................................................................12
OPERATING CONTROLS............................................................................................................14
OPERATING CONTROLS ON CHASSIS PANEL......................................................................14
OPERATING CONTROLS ON CHASSIS PANEL......................................................................15
OPERATING CONTROLS ON THE PLATFORM......................................................................16
MEASURES TO BE TAKEN IF THE LIFT IS AT RISK OF LOSING ITS STABILITY.....18
START-UP........................................................................................................................................19
OPERATING THE LIFT FROM THE CHASSIS PANEL............................................................22
OPERATING THE LIFT FROM THE PLATFORM PANEL.......................................................23
EMERGENCY DESCENT SYSTEM............................................................................................29
DRIVING DEVICE .........................................................................................................................30
DRIVING DEVICE .........................................................................................................................31
SPECIAL INSTRUCTIONS FOR WINTER USE.......................................................................32
MEASURES TO BE TAKEN AT THE END OF THE WORKING DAY ................................33
PREPARING THE LIFT FOR TRANSPORT.............................................................................34
CONNECTION TO THE TOWING VEHICLE..........................................................................35
SERVICE AND MAINTENANCE.................................................................................................36
GENERAL SERVICE INSTRUCTIONS......................................................................................36
SERVICE AND INSPECTIONS...................................................................................................37
LUBRICATION PLAN .................................................................................................................38
LOAD HOLDING AND LOAD REGULATION VALVES.........................................................40
WHEEL BRAKES AND BEARINGS...........................................................................................42
LEVELLING SYSTEM OF THE PLATFORM ............................................................................44
REGULAR SERVICING...............................................................................................................45
TESTING OF THE LOAD LIMIT SWITCHES..........................................................................52
ADJUSTMENT OF THE OVERLOAD LIMIT SWITCHES.......................................................54
INSPECTION INSTRUCTIONS ...................................................................................................59
FIRST
INSPECTION.....................................................................................................................59
DAILY INSPECTION (START-UP INSPECTION) ....................................................................60
MONTHLY INSPECTION (MAINTENANCE INSPECTION)...................................................61
ANNUAL INSPECTION (REGULAR INSPECTION)................................................................62
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EXTRAORDINARY INSPECTION.............................................................................................65
T
EST LOADING INSTRUCTION FOR REGULAR INSPECTION
................................................................66
FAULT FINDING............................................................................................................................67
GENERAL INFORMATION OF HYDRAULICS.......................................................................74
ELECTRIC COMPONENTS.........................................................................................................76
CHASSIS CONTROL CENTRE (LCB), RELAYS.......................................................................76
CHASSIS CONTROL CENTRE (LCB), SWITCHES..................................................................78
CHASSIS CONTROL CENTRE (LCB), OTHER ITEMS............................................................79
PLATFORM CONTROL CENTRE (LCB), RELAYS..................................................................80
PLATFORM CONTROL CENTRE (UCB), SWITCHES.............................................................81
PLATFORM CONTROL CENTRE (LCB), OTHER ITEMS.......................................................82
LIMIT SWITCHES........................................................................................................................82
OTHER MARKINGS....................................................................................................................83
ADJUSTMENT OF THE MOVEMENT SPEEDS.......................................................................84
ELECTRIC COMPONENTS 135T 13021 →→→→ ...............................................................................86
WIRING DIAGRAM.......................................................................................................................91
ELECTRIC DIAGRAM 135T 13021 →→→→........................................................................................92
HYDRAULIC COMPONENTS ...................................................................................................104
HYDRAULIC DIAGRAM............................................................................................................105
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REACH DIAGRAM
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TECHNICAL SPECIFICATION
Max. working height 13.5 m
Max. platform height 11.5 m
Max. outreach to the side 9.1 m
Boom rotation continuous
Platform rotation 90°
Turn area refer to reach diagram
Support width 3.80 m
Transport width 1.78 m
Transport length 5.91 m
Transport height 2.20 m
Weight (without aggregate) 1560 kg
Max. allowed load on platform 215 kg
Max. number of persons + additional load 2 henkeä + 55 kg
Max. allowed sideways load (caused by persons) 400 N
Max. lateral inclination of chassis ±0,3°
Max. wind speed during operation 12,5 m/s
Min. ambient temperature during operation - 20 °C
Max. support force on outriggers 11300 N
Platform size 0.7 x 1.3 m
Gradeability 25%
Power supply:
- mains current 230V / 50Hz / 16A
- petrol engine aggregate (optional extra) 4.8 kW (6.5 hp) / 3600 rpm
Socket outlets on platform 230V / 50Hz / 16A
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GENERAL SAFETY REGULATIONS
Make yourself familiar with these operating instructions before using the lift!
Keep these Operating Instructions in the place reserved for them.
Make sure that all users of the lift are familiar with these instructions.
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 loadbearing 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:
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.
Voltage Min. distance below
(m)
Min. distance at the
side (m)
100 – 400 V hanging 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
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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 "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 worksiite 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 protocol)
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 THE SAFETY DEVICES
1. Support outriggers
The safety limit switch RK3 prevents the operation of
the outriggers and the driving device when the boom is
raised from the parking support. The switch is located on
the parking support of the towbar.
2. Overload protection switches
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.
RK4 & RK5
RK3
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3. Lifting the boom
All support outriggers of the lift
must be in the supporting position
before lifting the boom. Make sure
that the wheels are off the ground.
The safety limit switches RK11,
RK12, RK13 and RK14 are
located on the support outriggers.
4. The emergency stop pushbutton immediately stops the movement and shuts off the power
unit.
The emergency stop pushbutton must be pulled up before the power unit can be restarted
(buttons 3 and 2)
Ensure the operation of the safety devices - do not lock the chassis panel cover with key while
the lift is in operation.
RK11, RK12, RK13, RK14
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OPERATING CONTROLS
OPERATING CONTROLS ON CHASSIS PANEL
1. Selector switch
0 - ignition off
1 - outrigger circuit, hydraulic drive
2 -controlling the boom from the platform
3 -controlling the boom from the chassis
2. Start button
3. Emergency stop button
4. Signal light of the outrigger limit switches
5. Start button of the emergency descent system
6. Pushbutton "Telescope in"
7. Control lever for turning
8. Control lever for boom system
9. Control lever for telescope
10. Voltage meter
29. Stop button
32. Korin kaltevuuden
34. Hour meter
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OPERATING CONTROLS ON
CHASSIS PANEL
12. Rear outrigger, right.
13. Rear outrigger, left
14. Front outrigger, left
15. Front outrigger, right.
16. Level position indicator of the chassis
27. Connetion and disconnection of the
driving device
28. Control levers for driving
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OPERATING CONTROLS ON THE PLATFORM
Close the chassis control panel cover before operating the platform controls.
The cover must not be locked while the lift is in operation.
17. Control lever
BOOM TO
THE RIGHT
BOOM
TO THE LEFT
TELESCOPE
IN
TELESCOPE
OUT
PUOMI
ALAS
BOOM
UP
BOOM
TO THE LEFT
BOOM TO
THE RIGHT
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18. Signal lights
- green = inside the allowed outreach range
- red = at the border of the allowed outreach range
20. Start button of the emergency descent system
21. Telescope in
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. Control lever for turning of the platform (is used simultaneously with pushbutton 35)
31. Fuse for turning of the platform
35. Levelling of the platform / turning (pushbutton). is used simultaneously with the control
levers30 turning of the platform and 36 levelling of the platform
36. Lever for levelling of the platform (is used simultaneously with pushbutton 35)
18
21
23
25
20
24
22
17
26
31
30
35
36
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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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START-UP
1. Ground stability
- make sure that the ground is even and hard enough to support the lift in a steady level
position.
- 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
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
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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. While the mains voltage is not
connected, the12VDC 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
If the battery is empty 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.
4. To access the operating controls open the cover on the chassis.
To ensure the operation of the emergency descent system,
check the condition of the battery.
The state of charge of the battery is indicated by LEDs.
- During charging the red LED is on
- when the battery is about to get fully charged the green
LED comes on
- when the battery is fully charged or recharged, the LEDs
are not illuminated.
5. Turn the selector switch (1) to position 1
6. Start the engine with button 2 (green).
The electric timer of the lift automatically disconnects the
supply voltage (12DVC) 1 hour after the last stopping of
the electric motor or the combustion engine.
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.
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7. Lower the front support outriggers (on the
towbar side)
8. Lower the rear support outriggers (do not
damage the towbar jockey wheel)
9. Level the chassis with the outriggers with the
help of the level gauge(16).
MAKE SURE THAT THE WHEELS ARE CLEARLY OFF THE GROUND
- the (green) signal light 4A on the chassis control panel comes on when all outriggers are in the
lower position and the outrigger limit switches 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 up 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. The movement
should now stop.
2. start the emergency descent power unit
(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 and turn it to the side to enable
its lowering.
5. 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 after that move the lever
carefully in desired movement direction. 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. The
movement should now stop.
- start the emergency descent power unit (pushbutton 20), retract the telescope (lever 9) and lower
the boom (lever 17).
- pull up the emergency stop button.
DO NOT DAMAGE THE TOW BAR JOCKEY WHEEL!
18
21
23
25
20
24
22
17
26
31
30
35
36
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The movement speed of the platform can be continually adjusted with the lever (17).
12. Test the operation of the outreach limit switch RK4
- platform load about 215 kg.
- drive the boom to a horizontal position.
- extend the telescope.
As the movement stops, the red
overload light (18) must come on.
- compare the outreach with the set
values given on page53) of this
manual.
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12A. Measures to be taken after overloading occurs
- (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 (21 or 6)(the green light comes on)
- after this the lift may be operated normally
The "telescope in" button ( 21 or 6 ) is always operational as the electric motor is running or
the emergency operation button (5 or 20) is depressed.
WARNING
Do not add load (e.g. another person) onto the platform while the red overload light (18) remains 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 comes on, then adding further load onto the platform is not
allowed and the telescope must be retracted.
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
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. To increase the hydraulic oil temperature, let the engine run for a while when working
under cold weather conditions. Carefully start the operation by driving the movements
slowly back and forth from the lower control panel without any load on the platform.
16. Move the platform to the work object
The platform movements can be controlled from the platform controls with continually adjustable
speed (not from the chassis control panel). Only one movement can be operated at a time. If more
than one lever is operated at the same time, only the movement meeting the least resistance will
operate.
NOTE!
Bringing the platform to the transport position: Always start with complete retraction of the
telescope and continue by bringing the platform perpendicular to the boom before lowering the
boom onto the transport support.
DO NOT DAMAGE THE TOW BAR JOCKEY WHEEL!
DO NOT TAKE ADDITIONAL LOAD IN THE UPPER POSITION!
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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 upper and the lower 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.
- When the weather is cold, it is recommended to let the engine run to keep the hydraulic oil
warm.
- It is recommended to also leave the combustion engine running between the operations, to
ensure the battery remains well charged.
- check the stability and condition of the base regularly during the operation, taking into
account the weather and ground conditions.
- The electric timer of the lift automatically disconnects the supply voltage (12DVC) 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.
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19. When moving the platform, remember the
following
- be careful of the high voltage power lines
- do not exceed the max. allowed lateral force
(400N)
- do not touch open electric wires
- do not throw objects from the platform
- do not damage the lift
- do not take additional load in the upper position
- do not damage other devices
- do not load the platform vertically more than
what is allowed
20. When leaving the lift
- drive the lift to a safe position, preferably to the transport position
- switch off the power unit
- prevent unauthorized use of the lift by locking the control
centre cover.
21. Adjustment of the platform position
From the chassis control centre (LCB)
The position of the platform may be adjusted
from the chassis control panel in the following
way:
- Turn the selector switch (1) to position 3
- Select the correction movement direction with the
control lever (32).
Carry out the adjustment while the boom is in the
horizontal position
No persons allowed on the platform
during adjustment
Carry out the levelling of the platform while the lift is in the support
position (the outriggers down)
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From the platform (UCB):
The position of the platform may be adjusted from the platform control panel in the following way:
- Turn the selector switch (1) to position 2
- Press the selector button (35) for platform levelling.
- Select the correction movement direction with the control lever (36).
Carry out the adjustment while the boom is in the horizontal position
Carry out the levelling of the platform while the lift is in the support position (the outriggers down)
18
21
23
25
20
24
22
17
26
31
30
35
36
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EMERGENCY DESCENT SYSTEM
As a precaution against possible power failure, the lift is equipped with a battery operated
emergency descent system.
1. The setup of the system
- 12V 44Ah
- recharger
- hydraulic unit 12VDC
2. Battery service
- the system incorporates an automatic battery recharger with short circuit and overheat
protection.
- maintenance voltage 13.7V
- charging voltage 14,7 V
- nominal current 6A
- if necessary, top up distilled water above the battery elements.
3. The hydraulic unit comprises
- pressure relief valve, set value 16 MPa (160 bar)
- check valve
- direct current motor 800W
Start the emergency descent system with the pushbutton (20 on the platform and 5 on the chassis).
The emergency descent system can only be operated when the pushbutton is depressed.
Note!
Start by retracting the telescope completely, continue by lowering the boom and finally turn the
boom system.
The emergency descent system can also be used for raising the support outriggers to the transport
position
If the emergency descent system does not work, try to warn other personnel present on the site so
that they can make the lift engine or the emergency descent unit operational by, for example,
changing the battery.
Always check the condition of the emergency descent system battery before putting the lift into
operation. (Page 20)
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DRIVING DEVICE
The hydraulic driving device is intended for moving the lift within the work area if the towing
vehicle cannot be used.
1. Do not drive downhill with the driving device at the front if the inclination of the surface is
more than 5 per cent, i.e., more than 1/20 (corresponding to a descent of 0.5 m over a distance
of 10 m). If the surface gradient is greater than this, you may lose control of the device.
2. When driving on a slope, the towbar must always point towards the descent.
Never drive with the driving device with the towbar pointing towards the ascent.
3. Always place chocks under the wheels before disconnecting the device from the towing vehicle.
4. Always apply the handbrake before disconnecting the device 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 driving device:
- take care not to allow the wheel to roll over your foot.
- look out for sudden sideways movements of the towbar
- be careful not to cause danger to other people and the environment.
7. Do not move the device on a slope using only handpower. You may lose control over it and
cause an injury.
8. Never park a vehicle combination on a slope.
maks. 5 %
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