Dino lift Dino 180XT Operation Instructions Manual Download

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DINO 180XT

INSPECTION ON THE WORKSITE

General

Is the lift suited for the job at hand?

Is the performance of the lift sufficient for the job (reach, loadability etc.)?

Is the lift located safely on a site so that no negative influence on work safety is possible?

Is there enough illumination for safe working?

Documents

Are the operating and service instructions for this particular lift present? (Manufacturers
manual)

Have the inspections and service measures mentioned in the instructions been made and
defects that could influence safety been repaired? (Inspection protocols)

Structures and construction (Optical inspection and functional test)

General condition of the lift

Functioning and protection of controls

Emergency stop, signal horn and limit switches

Electrical devices and cables

Oil leaks

Load markings and signs

Operator

Is the lift operator old enough?

Has the operator recieved the necessary training?

Special circumstances on the work site

Are there factors connected with the work site or work task that demand special attention or

additional instructions / directives?

Summary of Contents for Dino 180XT

Page 1: ...Raikkolantie 145 FI 32210 LOIMAA Tel 358 2 762 5900 Fax 358 2 762 7160 dino dinolift com www dinolift com DINO 180XT OPERATION INSTRUCTIONS...

Page 2: ...DINO 180XT 2...

Page 3: ...DINO 180XT 3 OPERATION INSTRUCTIONS Valid from serial number 18154...

Page 4: ...TING UP THE LIFT 21 OPERATING THE UNIT FROM THE CHASSIS CONTROL PANEL 26 OPERATING THE UNIT FROM THE WORK PLATFORM 27 EMERGENCY DESCENT SYSTEM 31 DRIVING DEVICE 32 SPECIAL INSTRUCTIONS FOR WINTER USE...

Page 5: ...OTHER MARKINGS 80 PROPO CONTROL CARD 81 MAINBOARD 82 PROCESSOR CARD 83 ELECTRIC COMPONENTS 84 ELECTRIC SCHEMA 230VAC 85 ELECTRIC SCHEMA 110 230VAC 86 ELECTRIC SCHEMA 110VAC 87 ELECTRIC SCHEMA DRIVE UN...

Page 6: ...DINO 180XT 6 REACH DIAGRAM m kg...

Page 7: ...ad caused by persons 400 N Max sideways inclination chassis 0 3 Max wind force when working 12 5 m s Min ambient temperature when working 20 C Max support force on the outriggers 16800 N Platform size...

Page 8: ...DINO 180XT 8 REACH DIAGRAM ft lbs...

Page 9: ...s load caused by persons 88 lbs Max sideways inclination chassis 0 3 Max wind force when working 41 ft s Min ambient temperature when working 4 F Max support force on the outriggers 3800 lbs Platform...

Page 10: ...dditional load of 55 kg 120 lbs or max total load of 215 kg 474 lbs are allowed on the platform When the chassis is supported by the outriggers the carrying capacity of the ground and any possible inc...

Page 11: ...ad traffic and working safety must always be respected Always be especially careful when working in the vicinity of open wire power lines Do not forget the stipulated minimum safety distances refer to...

Page 12: ...st 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 an...

Page 13: ...service measures mentioned in the instructions been made and defects that could influence safety been repaired Inspection protocols 3 Structures and construction Optical inspection and functional test...

Page 14: ...DINO 180XT 14 LIMIT SWITCHES RK4 AND RK5 PRESSURE SPRING LINK LIFT CYLINDER...

Page 15: ...witch RK4 stops extending or lowering the telescopic boom The overload switch RK5 has a back up function for the case that the overload switch RK4 is not working When the lift is working within the pe...

Page 16: ...DINO 180XT 16...

Page 17: ...shbutton emergency descent 6 7 Turning lever 8 Boom movement lever 9 Telescopic movement lever 10 Voltage meter 11 Fuse 12 Right rear support outrigger 13 Left rear support outrigger 14 Left front sup...

Page 18: ...be locked when using the lift 17 Operating lever 18 Warning lights green inside the reach limits red at the reach limit 20 Start pushbutton emergency descent 21 Fuse 22 Emergency stop stop by pushing...

Page 19: ...e you should try to find out the cause of the instability and ascertain in which direction the destabilizing forces are working Warn persons in the vicinity by using the alarm horn 2 Retract the teles...

Page 20: ...DINO 180XT 20 Notes...

Page 21: ...ecause of ice rain or ground inclination It is prohibited to use the lift if it is not properly supported and completely level 2 The lift should be driven or pushed onto the area where it is to be use...

Page 22: ...DINO 180XT 22...

Page 23: ...n movements too because the battery will only be charged when the aggregate is running Attention The fuel cock must be closed when the lift is towed C Internal combustion engine power diesel aggregate...

Page 24: ...DINO 180XT 24...

Page 25: ...control centre Motor running speed raises by turning switch no 30 fig B 7 Lower the front support outriggers towbar 8 Lower the rear support outriggers 9 Use the outriggers to adjust the chassis so t...

Page 26: ...lever 9 and lower the boom lever 8 3 Lift up the emergency stop push button 4 Lift up the platform from the tow bar and turn it to the side so that it can be lowered 5 Extend the telescope enough to...

Page 27: ...carefully move the lever in the desired direction of movement test the emergency descent function as follows Lift the boom about 1 2 m 4 7 ft with lever 17 and extend the telescope about 1 2 m 4 7 ft...

Page 28: ...e chassis control panel extends it as far as it will go low above the ground When the overload warning light lits no load may be added to the platform The telescope should be retracted If the emergenc...

Page 29: ...reach depend on the platform load refer to technical data The movements are controlled by two safety limit switches RK4 and RK5 mounted beneath a cover The switches must not be adjusted or tampered w...

Page 30: ...king area 20 When the lift is left alone move the unit into a safe steady position preferably into transport position switch off the power unit prevent unauthorized use of the unit by locking the main...

Page 31: ...d valve 700W DC motor The emergency descent system is started from the pushbutton 20 on the platform or 5 on the chassis control panel The system is activated only when the button is pressed Note When...

Page 32: ...e petrol Adjust the running speed by turning switch no 35 diesel The speed of the driving device depends on the aggregate running speed Turn the operating switch 1 into position support outriggers Mak...

Page 33: ...Disconnect the driving device from the wheel Switch on the driving device by turning the switch 27 to position 0 When using the remote control of the driving device extra equipment the cable of the re...

Page 34: ...raulically actuated movements Start by making short warm up movements to force warmed up oil into the cylinders which improves the functioning of the valves Make sure that the limit switches and emerg...

Page 35: ...erating the support outriggers if the platform is not lowered completely 4 Close the cover on the platform operating panel 5 Turn the operating switch into position 0 6 If you want that the battery wi...

Page 36: ...he cover on the platform operating panel 5 Turn the operating switch into position 1 support outriggers 6 Raise the support outriggers start with the rear outriggers do not damage the rear lights afte...

Page 37: ...position Especially when parking and uncoupling the lift on a sloping surface the handbrake should be applied by pulling strongly so that the spring cylinder is drawn With the handbrake correctly app...

Page 38: ...om the manufacturer Faults and wear that might influence the operational safety of the unit must be repaired and corrected immediately Oil must not be let out onto the floor or ground Always keep the...

Page 39: ...65 lbs and turn the boom horizontally Now extend the telescope until the red light lights up and the movement stops Measure the stroke achieved as described on page 53 and compare it with the overload...

Page 40: ...DINO 180XT 40 LUBRICATION PLAN...

Page 41: ...ery six months 11 Telescope cylinder bearing 12 Driving unit 13 Overrun device 14 Turning bearing and gear ring 15 Joint bearing on the upper stabilization cylinder piston rod side Recommended lubrica...

Page 42: ...DINO 180XT 42 1...

Page 43: ...alve Extend the telescope and measure the stroke Wait for a few minutes and check if the telescope has retracted Note The boom should be almost vertical 4 Check the tightness of the platform stabilizi...

Page 44: ...dbrake released Check the attachment of the brake rods Tighten the bolt shown by the arrow by turning it clockwise until the wheel can no longer be turned by hand Open the bolt by turning it countercl...

Page 45: ...of the return springs to 90 mm Apply the parking brake and check that the return springs do not prevent the brakes from functioning Tightening the brake system too much will cause overheating of the...

Page 46: ...es Brake adjustment lubricate the moving parts in the overrun device 13 000 15 000 km 8 000 9 000 miles or every 6 month a Check brake linings for wear and renew if necessary b Check the overrun devic...

Page 47: ...which valve is not conceived to be tight 2 an internal leakage in the cylinder If the platform lowers itself at the rear edge the reasons can be 1 a leaking double load regulating valve 4 on the pist...

Page 48: ...sonnel Regular servicing 1 Always clean the lift thoroughly before starting service and maintenance work Never disassemble hydraulic or electrical equipment without cleaning it first Dirt and moisture...

Page 49: ...nk with a suitable solvent and then rinse it Renew the pressure side filter Reassemble the draining plug Refill tank with fresh oil Capacity about 20 l Factory filling Neste Hydrauli 28 Super or Esso...

Page 50: ...cate the joint bearings refer to lubrication plan Operating from the lower chassis control panel raise the lift cylinder and inspect the piston rod and joints Operating from the lower panel move the l...

Page 51: ...below the chassis to lubricate turning bearing nipples 4 pieces Warning Using too high pressure when lubricating might press the turning bearing seal out of its position Measure play in the turning b...

Page 52: ...all coupling and towbar the ball coupling towbar should automatically return to the original extended position powered by the gas filled hydraulic shock absorber 8 Inspect the axle system Attachment C...

Page 53: ...raction 3 Emergency descent lowering the boom Lower the boom into transport position raise the support outriggers and switch on driving the boom must not function in any position of the operating swit...

Page 54: ...In case the first switch RK4 should fail overload is also monitored by 2 nd limit switch RK5 Disable RK4 by disconnecting lead 40 and using a jumper lead to connect leads 13 and 39 together lower ope...

Page 55: ...DINO 180XT 55...

Page 56: ...DINO 180XT 56 SETTING THE OVERLOAD DEVICES When servicing always test both overload limit switches Load the platform with for example 120 kg 265 lbs Move the boom into horizontal position...

Page 57: ...e RK4 should be set to actuate before RK5 Extend the boom and measure the stroke The length should be 2450 50 mm 96 2 in Tighten the adjusting screw and test the actual values once more Attach a secur...

Page 58: ...are demanded do not forget apply a seal after adjustment 12 Testing the platform operating controls Check the general condition of the electrical devices on the platform If necessary spray with moist...

Page 59: ...hten the wheel bolts Do not forged to check the tightness 325 Nm of the bolts after driving of 100 km 60 miles Check the tire pressures 450 kPa 4 5 bar 65 psi rear axle 250 kPa 2 5 bar 35 psi jockey w...

Page 60: ...lift should be inspected periodically at least once a week during the work period If defects are discovered they should be noted in a logbook and reported to the foreman FIRST INSPECTION The Dino lift...

Page 61: ...ing panels Test alarm horn Inspect warning and signal lights Cleanliness and function of lights and reflectors The condition of the operating controls and execution of the platform movements Check con...

Page 62: ...and condition of repairs and welds that might have been made Make sure that the platform retains its position refer to service manual Check that the outriggers keep their position refer to service ma...

Page 63: ...ch outrigger Step onto the platform and extend the telescope keeping the boom horizontal Make some turning movements and check if the height has changed Raise the outriggers off the ground Leave them...

Page 64: ...aks corrosion Inspect the connections and fixing points Connections Check that the hose and tube connections are tight Thoroughly inspect the electric system The control panels should be clean dry and...

Page 65: ...nd screw connections verify tightness of attachments and spring tightness Check the condition tightness of the cable chain fastening eyes and screw connections Establish the play and correct fastening...

Page 66: ...m movements Limit switches in the tow bar boom preventing use of the outriggers After having made the trial run inspect that the load tests and other movements have not caused any cracks or damages to...

Page 67: ...dure with a platform load of 120 kg 265 lbs Case II 10 Compare the sideways reach with the data in the reach diagram If necessary adjust as described on page 56 Setting the overload switches When the...

Page 68: ...tart and stop buttons Check if the STOP button sticks or the START button contacts are weak Also check the corresponding buttonsin the platform control panel Replace the buttons if necessary The teles...

Page 69: ...red signal light is lit on the platform s and on the chassis controlpanel and audible signal switched on The boom has been overloaded Retract the telescope and try again automatic resetting 5 The boom...

Page 70: ...k in position turning clean spindle and housing thoroughly 9 Telescope does not work Refer to item 4 Check that telescope solenoid valve is not in central open position 10 Telescope retracts slowly lo...

Page 71: ...ion sticks in mid position ref to 4 above 14 Support outrigger does not hold supporting position fig Lower hold valve leaks as in item 5 hold valve tightening torque 55 Nm 15 Support outrigger does no...

Page 72: ...ective replace shock absorber The automatic reversing relieving brake shoe sticks in its support replace the brake shoe 19 One sided braking only one wheel brake actuates Brakes wrongly adjusted readj...

Page 73: ...e When assembling the brakes make sure that all springs brake shoes and the shoe expander mechanism are mounted correctly When adjusting the brakes always turn the wheels in the FORWARD driving direct...

Page 74: ...alve and turning actuator valve and lifting arms Push the pin on the end of the solenoid valves If the movements can be run the fault will be found in the electrical system or alternatively the cause...

Page 75: ...9 AUXILIARY RELAY TELESCOPE RETRACTION FUNCTION POWER SUPPLY FUSE F1 10A RIGHT JOYSTICK BUTTON RL10 AUXILIARY RELAY TELESCOPE EXTENSION FUNCTION POWER SUPPLY FUSE F7 10A RIGHT JOYSTICK BUTTON RL11 AUX...

Page 76: ...Y IS CONTROLLED BY THE LIMIT SWITCH RK3 RL33 ASSISTANT RELAY FOR LIFTING ARM ADDITIONAL SLOW DOWN RESISTOR MOVEMENT SPEED ADJUSTABLE WITH THE MOTHERBOARD POTENTIOMETER TR3 RL42 JA RL44 ASSISTANT RELAY...

Page 77: ...LOCKING START EMERGENCY DESCENT SWITCH S16 LOWER CONTROL PANEL NON LOCKING BOOM LEFT RIGHT FUNCTION SWITCH S17 LOWER CONTROL PANEL NON LOCKING BOOM UP DOWN FUNCTION SWITCH S18 LOWER CONTROL PANEL NON...

Page 78: ...TE AND BACK UP THE JOYSTICK GATE PATTERN FUNCTION RL23 STOPS THE CONTROL CURRENT FROM THE JOYSTICK TO THE PROPO CONTROL BOARD WHEN USING THE PLATFORM TURNING ELECTRICAL CYLINDER RL31 AND RL32 ASSISTAN...

Page 79: ...EN ACTUATED THE POWER UNIT IS STOPPED BREAKS THE MINUS POLE OF THE SPOOL K1 AND BOOM MOVEMENTS ARE PREVENTED EMERGENCY DESCENT AND TELESCOPE RETRACTION STAY FUNCTIONAL AFTER RETRACTION BOOM LOWERING I...

Page 80: ...H3 YELLOW LED SIGNAL LIGHT SHOWS THAT OUTRIGGER LIMIT SWITCHES RK11 RK12 RK13 AND RK14 HAS ACTIVATED H4 RED LED SIGNAL LIGHT SHOWS THAT THE RELAY RL25 HAS RELEASED H5 RED LED SIGNAL LIGHT SHOWS THAT U...

Page 81: ...ts to increase after this back to counter clockwise about 30 1 Maximum movement speed turn the potentiometer fully to the clockwise operate the boom upwards from the upper control panel and turn the p...

Page 82: ...IT HAS ALSO AN EFFECT ON LIFTING ARMS DOWN MOVEMENT TR2 MOVEMENT SPEEDS FOR LIFTING ARMS TR3 MOVEMENT SPEEDS FOR CHASSIS CONTROL PANEL Setting instructions TR1 10 rotations to the right from minimum...

Page 83: ...DINO 180XT 83 PROCESSOR CARD TR1 RL19 0 5 s 1 2 s TR2 RL2 0 5 s 0 6 s TR3 RL22 0 5 s 2 5 s TR4 RL4 0 5 s 1 2 s TR5 RL25 0 25 s standard 5 s...

Page 84: ...47 815 USA 47 812 ELECTRIC MOTOR POWER UNIT M2 47 2318 ELECTRIC MOTOR AUX POWER UNIT M3 48 2167 LINEAR ACTUATOR PL1 48 3385 ROTATING ADAPTER Q1 48 2316 TURN SWITCH RK3 RK8 48 1936 48 2142 LIMIT SWITCH...

Page 85: ...DINO 180XT 85 RK11 RK12 RK13 RK14 Colours B Black Y Yellow L Blue G Green R Red W White Br Brown O Orange Lb Light blue Lg Light green P Pink Gr Grey ELECTRIC SCHEMA 230VAC 18004...

Page 86: ...DINO 180XT 86 ELECTRIC SCHEMA 110 230VAC 18094...

Page 87: ...ed W White Br Brown O Orange Lb Light blue Lg Light green P Pink Gr Grey RK11 RK12 RK13 RK14 Colours B Black Y Yellow L Blue G Green R Red W White Br Brown O Orange Lb Light blue Lg Light green P Pink...

Page 88: ...RIC SCHEMA DRIVE UNIT OPERATING PANEL Colours B Black Y Yellow L Blue G Green R Red W White Br Brown O Orange Lb Light blue Lg Light green P Pink Gr Grey Py riv liitin Roterande adapter Drehdurchf hru...

Page 89: ...CONTROL V rit Colours B musta Black Y keltainen Yellow L sininen Blue G vihre Green R punainen Red W valkoinen White Br ruskea Brown O oranssi Orange Lb vaalean sininen Light blue Lg vaalean vihre Lig...

Page 90: ...DINO 180XT 90 ELECTRIC SCHEMA 12VDC 230VAC PETROL GASOLINE AGGREG 18154 18222 18226 18228 PRC 26A...

Page 91: ...DINO 180XT 91 ELECTRIC SCHEMA 12VDC 110 230VAC PETROL GASOLINE AGGR 18154 18222 18226 18228 PRC 26A...

Page 92: ...DINO 180XT 92 ELECTRIC SCHEMA 12VDC 230VAC DIESEL AGGREGATE 18154 18222 18226 18228 PRC 26A...

Page 93: ...DINO 180XT 93 ELECTRIC SCHEMA 12VDC 110 230VAC DIESEL AGGREGATE 18154 18222 18226 18228 PRC 26A...

Page 94: ...DINO 180XT 94 Notes...

Page 95: ...DINO 180XT 95 ELECTRIC SCHEMA PETROL GASOLINE AGGREGATE 18069...

Page 96: ...DINO 180XT 96 ELECTRIC SCHEMA DIESEL AGGREGATE...

Page 97: ...DINO 180XT 97 ELECTRIC SCHEMA DIESEL AGGREGATE...

Page 98: ...Double load regulating valve 2 17 47 2660 Switching load valve 1 18 DL6 026 Cylinder articulating arms 2 19 DL6 018 Cylinder lift 1 20 3CA7331 Cylinder telescope 1 21 DL10 005 Cylinder slave 1 22 DL1...

Page 99: ...DINO 180XT 99 HYDRAULIC SCHEME 230VAC 18001...

Page 100: ...alve 1 47 2768 Double load regulating valve 2 17 47 2660 Switching load valve 1 18 DL6 026 Cylinder articulating arms 2 19 DL6 018 Cylinder lift 1 20 3CA7331 Cylinder telescope 1 21 DL10 005 Cylinder...

Page 101: ...DINO 180XT 101 HYDRAULIC SCHEME 110VAC 18001...

Page 102: ...DINO 180XT 102 Notes...

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