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160XT 180XT 210XT

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4. Make sure that the platform is in the transport position and the outriggers are lifted in the upper position make sure that the mains cable is long enough to cover the whole travel distance power supply from mains switch the driving device to the drive position 44 UP THE JOB 160 180 210XT release the parking brake drive the unit using the pushbuttons forward backward 28A to the left 28A 28L to the right 28A 28R do not drive the jockey wheel into obstacles or potholes If one of the wheels bumps into an obstacle the lift may turn abruptly N after the driving apply the parking brake Switch off the driving device disconnect the driving device from the wheel Remote control for the driving device optional extra plug in the remote control cable to the socket in the control box of the driving device Be careful not to damage the jockey wheel tube by extending it too much 45 UP THE JOB 160 180 210XT When moving the lift using the driving device a suitable length for the jockey wheel s stem can be achieved by adjusting the gap between the lower surface of the tow bar brake rod and the wheel to 1 3 cm Then the wheel may turn freely 15 SPECIAL INSTRUCTIONS FOR WINTER USE the lowest allowed operating temperature of the li
5. nnn nensi nnns rra nsns nnn 15 5 GENERAL SAFETY 16 5 1 INSTRUCTIONS FOR SAFE OPERATION 19 E CE VIS ESSE EPI UE UE UNE RIEF SIN 20 WORKSITE INSPECTION nnnc cuanta tu tiun ira dn nouo d uo aiu i hu a 21 8 OPERATION OF THE SAFETY 0CVICC5 22 9 OPERATING CONTROLS IN THE CHASSIS CONTROL CENTRE 24 9 1 OPERATING CONTROLS OF DRIVE 5 25 9 2 OPERATING CONTROLS OF OUTRIGGERS 25 9 3 OPERATING CONTROLS IN PLATFORM CONTROL CENTRE 26 10 A MEASURES BE TAKEN IN THE CASE OF THE LIFT IS RISK OF LOSING 5 28 11 30 11 11 OPERATING THE LIFT FROM THE CHASSIS CONTROL CENTRE 33 11 2 OPERATING THE LIFT FROM THE PLATFORM CON
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12. UP THE JOB 160 180 210XT The platform movements can be operated with continually adjustable speed from the platform control centre not from the chassis control centre 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 Lowering the platform to transport position Always retract the telescope completely and turn 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 18 Observe when lifting the platform ae LV LIMIT SWITCHES RK4 and RK5 i l PRESSURE SPING ARTICULATED ARM LIFT CYLINDER 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 Working a long time in the same position there are pushbuttons for both stopping and starting in both the platform and the chassis control centres 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
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17. manufacturer s requirements The operator must be given instructions and consent from the manufacturer for all such specific work methods or conditions that the manufacturer has not explicitly defined 18 AN A 160 180 210XT 5 1 Instructions for safe operation Use a safety harness while on the platform Use hearing protectors when operating the power unit Sound pressure level at the lower control unit 92 dB Never add load onto the platform while in the upper position The lift must not be used when the temperature is below 20 C and the wind speed exceeds 12 5 m s Beware of live power lines within the work area The lift MUST NOT be used as a crane Always ensure the load bearing capacity of the standing surface Ensure the unobstructed range of movement before operating the outriggers While in the support position ensure that the wheels are off the ground Always verify the horizontal position of the machine Ensure that the outriggers cannot slide while on a gradient Always ensure that the work area is clear of outsiders Danger of 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 centre on the tu
18. 14 Platform drifts forward Double load regulation valve on the rod side is leaking Measures as above 15 Outriggers do not move although the selector switch is in position 1 Boom does not rest on the transport support Drive the boom onto the support Electric valve for movement of boom outriggers does not operate jams in the centre position For remedy refer to item 4 83 UP THE JOB 160 180 210XT FAULT REMEDY 16 Outrigger does not stay in the support position see illustration Load regulation valve on the bottom side For remedy refer to item 5 lock valve leaking Tightening torque 55 Nm 17 Outrigger does not stay in the transport position see illustration Load regulation valve on the rod side is Measures as above leaking 18 Driving device does not operate although the selector switch is in position 1 Boom does not rest on the transport Drive the boom onto the support support Electric valve for the boom outriggers For remedy refer to item 4 movement does not operate jams in the centre position 84 UP THE JOB 160 180 210XT FAULT 19 Too low braking force REMEDY Too much play in the brake system Adjust the brakes Brake linings not yet run in Pull the parking brake lever slightly and drive 2 3 kilometre
19. 14 Turning device bearings and gear ring 15 Bearing on the rod side of the upper levelling cylinder Lubricant Esso Beacon EP2 or equivalent The overload protection device joint point 1 must absolutely be lubricated regularly and always immediately after the lift has been washed Moving parts of the of the outrigger limit switch mechanism must be lubricated every 50 hours If necessary apply a thin grease film on the moving parts of the ball coupling Always lubricate the lift and apply a protective grease film immediately after the washing Remove the crescent shaped covers from the underside of the lift and lubricate the turning bearing nipples 4 pieces Lubricate the visible parts of the Flyer chains of the boom twice a year Use Master chain lubricant 1 4014 or equivalent 19 4 LONG TERM STORAGE Clean the machine carefully lubricate it and apply protective grease to it before putting it into storage for a longer period of time see point Lubrication plan Repeat the cleaning and lubrication procedures when you resume the operation The periodic inspections must be executed following the steps described in the instructions 53 UP THE JOB 160 180 210XT a DINDIift UP THE JOB 160 180 210XT 5 19 5 LOAD HOLDING AND LOAD REGULATION VALVES Checking the operation 1 To check the load holding va
20. 180 210XT Description of the machine s intended use The intended use of the Aerial Work Platform is exclusively limited to transferring people and tools and acting as a work platform within its permissible load bearing capacity and reach refer to the table Technical Specifications and the Reach Diagram The intended use also covers Following all the instructions in the Operating Instructions Performance of the inspections and maintenance operations Example of the machine s nameplate Raikkolantie 145 Year of manufacture Address of manufacturer 32210 Loimaa FINLAND Weight kg Max load 215 kg Max load of persons 2 Additional load 55 side force 400N Max inclination of chassis 0 3 Voltage 230V Frequency 50Hz Min operating temperature 20 C Max wind force 12 5m s 15 UP THE JOB 160 180 210XT 5 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 Advise new users and strictly follow all instructions given by the manufacturer Make sure you clearly understand all instructions relating to the operational safety of the lift Always use chocks under the wheels when disconnecting the lift from the car Only specially trained perso
21. Main switch turned off turn on the switch 2 None of the platform movements is operational although the electric motor is running and the selector switch is in position 2 or 3 Green signal light for outriggers is not illuminated Green signal light for the outrigger limit switches is illuminated but the boom movements do not operate Check the operation of the outrigger limit switches RK11 RK12 RK13 and RK14 Check the operation of the safety relay SR2 for the outrigger circuit Boom has been overloaded Retract the telescope via buttons 6 or 21 until the platform returns inside its operating range the green light in the platform control centre is illuminated 80 UP THE JOB 160 180 210XT FAULT REMEDY 3 Outriggers do not move Boom is not resting on the transport support Drive the boom onto the transport support The selector switch is in the wrong position Turn the selector switch to position 1 Limit switch on the boom support has not closed Drive the boom onto the transport support and check the operation of the limit switch 4 Platform cannot be turned Automatic fuse F10 has tripped Reset the automatic fuse via its reset button 5 No power supply to the lift although the switch is in position 1 2 or 3 main switch is on and the selector Power supply has not been activated Pr
22. UP THE JOB 160 180 210XT 25 ADJUSTMENT THE MOVEMENT SPEEDS 1 Measuring devices required for the adjustment volt ohm milliammeter with possibility to measure direct current A screwdriver with narrow tip for adjusting the trimmer 2 Disconnect the conductor 523 from the connector K25B 22 on the cover of the LCB centre Connect the volt ohm milliammeter between the connector K25B 22 of the relay and the conductor 523 as shown in 01 3 Connect the measuring leads to the direct current inlets of the volt ohm milliammeter and turn the selector switch of the meter to the position max current Imax 2A Lift the machine off the ground with the outriggers for operating the boom 4 Turn the key switch to position 3 the power unit does not have to be running 5 Check that the adjustable resistors TR9 TR10 TR11 and TR12 on the circuit card of the main centre have been turned counter clockwise to their extreme positions 100 160 180 210XT CONTROL CARD SCREWS Maximum current Imax Minimum current Imin Frequency adjustment Intensity of frequency Ascending ramp Descending ramp 6 Adjustment of the frequency the lift in the boom mode the power unit is running Turn at first the adjustment screw 3 on the control card to its minimum position extreme position counter clockwise After that turn it 1 4 ro
23. attachment of the overrun clearance condition of the towball coupling condition of the locking device check that the overrun brake mechanism moves freely 8 Inspecting the axle and the suspension check the attachment of the axle check the condition of the rubber absorbers and the torsion arms 9 Inspecting the safety devices check the attachment and the condition of the limit switches externally from the tow bar transport position of the platform RK3 safety device RK4 and RK5 support outriggers RK11 RK12 RK13 and RK14 boom RK7 and RK8 63 UP THE JOB 160 180 210 10 Operation of the safety devices from the chassis control centre lift the platform slightly up from the transport position the outriggers must not operate in any position of the selector switch lift the boom and test the following 1 emergency stop 3 2 emergency descent retracting the telescope 6 3 emergency descent lowering the boom 5 and 8 bring the boom to the transport position and lift the outriggers with the driving device connected the boom must not operate in any position of the selector switch disconnect the driving device and lower the outrigger
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26. NOT OPERATIONAL 1 If the emergency descent system does not operate try to warn other personnel present on the site or call for help so that the power supply required for normal operation can be resumed or the emergency descent system can be made operational by changing for example the battery so that the person on the platform can be brought down safely Always check the condition of the emergency descent system battery before putting the lift into operation see point Operating from the chassis control centre 29 160 180 210XT 11 STARTING THE USE 2 Ground stability make sure that the ground is even and hard enough to support the lift in a steady level position pressure kg cm Gravel High density Medium density Loose Sand High density Medium density Loose Fine sand High density Medium density Loose Sand mud High density very hard to work Medium density hard to work Loose easily worked if the ground is soft use sufficiently large and sturdy additional plates under the support outriggers 5 8 II observe the effect of ice possible rain and inclination of the N 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 3 Drive or push the lift to the inspected lifting site engage the parking
27. Using the selection valve boom chassis is not required for retraction of the telescope O9 74 i S k Valves 3 Main pressure limit 4 Pressure limit for extension of the telescope 6 Pressure limit for turning 7 Adjustment of the platform s levelling speed 8A B Load regulation for levelling of the platform 1A 1B selection boom chassis PR Flow regulation valve Propo SV SP Articulated arms NV NP Lifting of the boom MV MP Levelling of the platform O V Turning of the boom ZV Retraction of the telescope ZP Extension of the telescope To control the valves manually in the case of malfunction press the pins at the end of the electric valves Take into account when you operate valves manually that you can only activate those movements that bring the work platform lower If the movements operate when controlled manually the fault is in the electric system of the operating controls or the valve spools are dirty which causes jamming refer to the fault finding scheme point 6 If none of the movements operate the fault is in the hydraulic system 87 UP THE JOB 160 180 210XT 23 ELECTRIC COMPONENTS 23 1 CHASSIS CONTROL CENTRE LCB RELAYS K1 K2 K3 K4 K5 K6 K7 K9 K10 K11 K12 K13 START CONTACTOR M1 FOR THE ENGINE Control circuit fuse F2 10A AUXILIARY RELAY FOR THE EMERGENCY STOP B
28. however 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 12 VDC in about 1 hour after the electric motor or the combustion engine has been turned off Re activate the power supply by pressing the start button either in the chassis control centre or in the platform control centre 37 UP THE JOB 160 180 210XT 38 160 180 210XT 20 When moving the platform remember the following beware of high voltage power lines donot exceed the max allowed lateral force 400N do not touch open electric wires donot throw objects from the platform donot 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 21 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 30 UP THE JOB 160 180 210XT 22 Adjust
29. 8 Power unit does not start Battery is flat Recharge the battery The mains cable is plugged Disconnect the plug from the mains No direct current supply 12VDC Main switch has been turned off turn on the switch 9 Power unit cranks but does not start Fuel tank is empty Fill the fuel tank Choke is off Throttle lever in idling position Press the choke button cold engine Increase the engine revolutions 10 Boom cannot be lifted The lift turns when the lifting movement is activated Refer to item 4 Electric valve is open Remedy as instructed above in conjunction with the seizure of the electric valve spool Solenoid valve is stuck in the turning position Wash carefully the spool and the housing 82 UP THE JOB 160 180 210XT FAULT REMEDY 11 Telescopic movement does not operate Refer to item 4 Ensure that the solenoid valve for the telescope is not stuck in the centre open position 12 Telescopic movement retracts slowly Load regulation valve is leaking For remedy refer to item 7 lock valve 13 Platform drifts backward Double load regulation valve on the bottom side is leaking For remedy refer to item 7 lock valve Load regulation valve under the platform is leaking For remedy refer to item 7 lock valve
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32. K51 INDUCTIVE LIMIT SWITCH Limits turning of the platform to the right by disconnecting the control voltage circuit for the relay K52 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 ga UP THE JOB 160 180 210XT 23 9 CONTROL CENTRE FOR THE DRIVING DEVICE DCB 524 525 526 DRIVING STRAIGHT FORWARD AND BACKWARD Non locking lever switch TURNING TO THE LEFT Non locking pushbutton TURNING TO THE RIGHT Non locking pushbutton 23 10 OTHER MARKINGS B1 E1 F11 J1 M1 M2 M3 PL SR1 SPV T2 VVK AM1 BATTERY 12VDC 44AH THERMORELAY FOR THE ELECTRIC MOTOR MAIN BATTERY FUSE 125A PLUG ELECTRIC MOTOR 230VAC 1 5kW EMERGENCY DESCENT MOTOR 12VDC Max operating time 10 min MOTOR FOR PLATFORM TURN ROTARY ADAPTOR The electric circuits between the chassis and the turning device go through the electric rotary adaptor Solenoid for the emergency descent unit When energized starts the emergency descent unit M2 Main switch Disconnects the plus terminal of the battery Battery recharger Charging voltage 13 8VDC 10A Charges the battery if the mains supply is connected FAULT CURRENT SWITCH 25A 30 ms SOUND SIGNAL go
33. OF THE 58 198 REGULAR SEBVIGE 59 19 8 1 TESTING THE LOAD LIMIT SWITCHES RK4 AND 5 66 20 INSPECTION INSTRUCTIONS renta ananas uu tu unio rana unda n oa aaa nua suu 72 20 1 72 20 2 DAILY INSPECTION START UP 73 20 3 MONTHLY INSPECTION MAINTENANCE INSPECTION 74 20 4 ANNUAL INSPECTION REGULAR INSPECTION 75 20 5 EXTRAORDINARY 78 20 6 TEST LOADING INSTRUCTIONS FOR REGULAR INSPECTION 79 21 C _ M 80 22 GENERAL INFORMATION OF 87 23 ELECTRIC 88 23 1 CHASSIS CONTROL CENTRE LCB 88 23 2 CHASSIS CONTROL CENTRE LCB SWITCHES 93 23 4 CHASSIS CONTROL CENTRE LCB OTHER ITEMS 9
34. S UP THE JOB 160 180 210XT 2 3 210 9 UP THE JOB 160 180 210XT 3 DIMENSION DRAWING 3 1 10 UP THE JOB 160 180 210XT 3 2 180 11 UP THE JOB 160 180 210XT EA my LI 1490 p IM 12 UP THE JOB 160 180 210XT 4 TECHNICAL SPECIFICATION gt continuous 00000000 Boom rotation Platform rotation Turn area Support width Transport width Transport length Transport height Weight incl Honda power unit Max allowed load on platform Max number of persons additional load Max allowed sideways load c
35. SIXD X SIXD A xonsKof ybu usn xonsKof Sr Y VI ZX 5 CX 12119611 2211 1211 02 11162 82 42 9211 52 22611 1211 02116111 8111 24011 SLEL SELL XVIII UP THE JOB 113 160 180 210XT olol 998927 807001 ynog 7 av 1 012 1 081 1 091 5 0I gt rS rea Pret iUe K 5 Kojas Kojas CI ign i i 25 no umop 1no 12195 S 2 e i mi 1 a oe 5 3IVC C6L 4 56 015 a i mm p EX T E 1 19 T T PL 1 i cef ex E 1 96 5 i i i zx cus E i i Hus Loo E 5 12557 0 i lv E i i i i MI I C N zx Wy I N i i i ec zx dii 1 i i i 5 Wem LC ex 1 1 8 i i H 1 i i H e i 4 8 617 1 9 EYS OG 9 lv _ 32 2 23 lt ___ _3 lt _ _ _ ___ _ _ _ _ _ _ 4 i 4 XC 3 e 2 2 IC 5 82 woog 1 517 e
36. UP TO THE 70
37. and spray with moisture repellent if necessary check the cables and the tightness of the cable clamps test the sound signal the emergency stop and the emergency descent test all the movements test the operation of the overload limit switches before lifting the boom 70 UP THE JOB 160 180 210XT 13 Warning stickers and adhesive tapes make sure that all the warning stickers and adhesive tapes are legible replace if necessary 14 Inspect the brakes and the driving device remove the wheels clean the brake system and check the settings check that the brake shoes can move and that their springs properly return them replace any worn out linings check the condition of the driving device and lubricate the joints Wheel bolts put wheels in place and tighten the wheel bolts 160 90 Nm Remember to re check the tightness of the wheel bolts after a drive of about 100 km check the tyre pressure On the rear axle 270 kPa 2 7 bar On the tow bar jockey wheel 250 kPa 2 5 check the free movement of the overrun brake and the parking brake 180XT and 210XT 325 Nm check the safety wires 15 Traffic lighting check the condition of the lights and the reflectors 16 Anti corrosion treatment repeat the anti corrosion treatment using e g Tectyl 210R anti corrosion agent Test load 17 Test run 160XT 270 kg perform a test run with a load defined in th
38. brake disconnect the lift from the towing vehicle a0 UP THE JOB 160 180 210XT 4 Connecting the power supply to the lift A POWERED BY AC SUPPLY While the mains voltage is plugged in the operating voltage of 12 VDC is supplied by a power source connect the mains cable to the power supply turn on the main switch Fig A with the electric motor at maximum load the voltage must be 230 VAC 10 6 the frequency 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 current the operating voltage of 12 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 the start by depressing the button on the cover of the centre If the battery is flat start the power unit by pulling the starter grip and at the same time keeping the button at the power unit s 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 the operations because the battery will not be recharged unless the combustion engine is running Close the fuel cock when stopping the combustion engine fuel cock must be closed during towing of the lift C POW
39. 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 shall be established to what extent the lessons and practical experience gained since the previous inspection could be utilized to improve the safety even more National legislation must be followed first of all N Regular inspections and service measures are described more thoroughly in the chapter Service and maintenance 20 160 180 210XT 7 WORKSITE INSPECTION 1 General information 15 the lift suited for the intended job 15 the performance of the lift sufficient for the job reach loadability etc ls the position of the lift safe 15 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 applia
40. measuring point in the hydraulic system make the oil flow through the relief valve by driving one of the movements against the end stop read the pressure from the gauge when the oil is warm the pressure should be 21 21 5 MPa 210 215 bar load holding check valves on the outriggers lift the device off the ground with the outriggers and measure the distance to the ground at each outrigger Step on the platform and extend the telescope keeping the boom level Turn the boom round a few times return it to its initial position and check that the distance between the ground and the outriggers has not changed ift the outriggers from the ground and leave them in this position for about 10 minutes Observe that the outriggers do not lower of themselves load holding check valve on the lift cylinder lift the boom to an angle of about 45 from the chassis control centre and extend the telescope Observe about 10 minutes that the boom does not lower of itself load regulation valve of the telescope cylinder Jift the boom and extend the telescope slightly from the chassis control centre leave it in this position for about 5 minutes make sure that the telescope does not retract of itself load regulation valve of the levelling system puta load of about 120 kg on the platform lower the boom 4 5 times make sure that the position of the platform does not change electric directional valves operate all the boom a
41. 0 180 210XT _ 19 6 WHEEL BRAKES AND BEARINGS Adjusting the brakes Support the lift by raising its wheels off the ground Make sure that the wheels can rotate freely The brake rods must be slack with the handbrake released Check the attachment of the brake rods Turn the adjustment wheel behind the hole marked by the arrow until the wheel no longer can be turned by hand Turn the bolt counter clockwise until the wheel can be turned freely 56 160 180 210XT mec Adjust the braking force with the nuts keeping the brake balancer perpendicular to the tow bar so that both wheels will brake If you tighten the brake system too much the brakes will overheat during transportation and the the driving device will require more force We recommend performing a test run after the adjustment in order to ensure flawless operation of the brakes by braking 2 3 times Adjustment of the bearing clearance The wheel bearings are lubricated for life and do not require any service The bearings do not need any 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 lubricate the sliding parts of the overrun brake
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43. 12 H3 H4 HM1 Q1 TC 1 6A FUSE FOR ACTIVATION CIRCUIT OF THE TIMER CARD 10A CONTROL FUSE FOR START CIRCUIT AND MONITORING CIRCUIT OF THE OUTREACH 10A CONTROL FUSE FOR THE DRIVING DEVICE 5A FUSE FOR CONTROL LEVERS AND JOYSTICK IN THE CHASSIS AND PLATFORM CONTROL CENTRES 1 6A CONTROL FUSE FOR THE DRIVING DEVICE 10A CONTROL FUSE FOR THE SOLENOID VALVES 10 A CONTROL FUSE FOR THE EMERGENCY DESCENT CIRCUIT 10A CONTROL FUSE FOR THE COMBUSTION ENGINE TIMER CARD FUSE 16A YELLOW LED SIGNAL LIGHT Indicates the operation of the outrigger limit switches RK11 RK14 RED LED SIGNAL LIGHT Indicates the tripping of the SR3 HOUR METER Measures the running hours of the machine TURN SWITCH WITH KEY Selector switch for choosing the operating location 1 chassis 2 platform 3 chassis centre TIMER CARD Control card for supply voltage Disconnects the supply voltage from the lift after a preset delay normally 1 hour Start buttons S2 and S6 are used for re activation of the control voltage 94 UP THE JOB TR9 TR10 TR11 TR12 U1 160XT 180 210XT ADJUSTABLE RESISTOR Adjustable resistor for the levelling speed of the platform ADJUSTABLE RESISTOR Adjustable resistor for lowering speed of the boom ADJUSTABLE RESISTOR Adjustable resistor for the movement speed when operating from the chassis centre ADJUSTABLE RESISTOR Adjustment of the articulated arms lower
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46. 4 23 5 PLATFORM CONTROL CENTRE UCB RELAYS 95 23 6 PLATFORM CONTROL CENTRE UCB SWITCHES 95 23 7 PLATFORM CONTROL CENTRE UCB OTHER ITEMS 97 238 LIMIT SWITCHES c 98 23 9 CONTROL CENTRE FOR THE DRIVING DEVICE 99 23 10 99 25 ADJUSTMENT OF THE MOVEMENT SPEEDS 100 26 ELECTRIC DIAGRAM LUE 103 27 HYDRAULIC Ctm RR re LE KE Od lona 123 27 1 STANDARD MACHINE Mec 123 27 2 AUTOMATIC LEVELLING OPTION 124 27 2 1 Sample of inspection protocol for the access platform 126 5 DINOIift UP TO THE JOB 1 160 180 210XT EU Declaration of Conformity Manufacturer Dinolift Oy Raikkolantie 145 FI 32210 Loimaa FINLAND which has authorised the Chief Engineer Mr Seppo Kopu Dinolift Oy Raikkolantie 145 32210 Loimaa FINLAND to draw up the Technical Construction File declares that DINO 160XT Aerial Work Platform no YGC D160XT X X XXXXX DINO 180XT Aerial Work Platform no YGC D180XT X X XXXXX D
47. B 160 180 210XT 6 Inspect the boom and the frame with the telescope extended inspect the platform its attachment and the boom inspect the joints of the boom and the play of the sliding pads readjust if necessary Lubricate the sliding surfaces check the condition locking and adjustment of the Flyer chains make sure that the unloaded Flyer x chain is properly attached to the 10fl 3000 boom by pulling the chain by hand oW with the boom at its maximum length T 3mm 0 12in inspect the turning device and its attachment lubricate the turning bearing and the gear ring Remove the crescent shaped covers from the underside of the lift and lubricate the turning bearing nipples 4 pieces Excess grease pressure may press out the turning bearing seal check the turning bearing play Max allowed axial play is about 1 mm check the attachment bolts of the turning device for M16 280 Nm tightness M12 150 Nm If you have to turn open or tighten the attachment bolts do not forget to use bonding adhesive tighten crosswise check the chassis and the welded seams on it especially around the turning device and attachment points of the outriggers inspect the outriggers check the tow bar in particular its attachment to the chassis 62 UP THE JOB 160 180 210XT lubricate the bearings of the boom and outrigger joints 7 Check the overrun
48. BUZZER Indicates the operation of the safety limit switch RK5 and the emergency stop switches S1 and S4 97 160 180 210XT 23 8 LIMIT SWITCHES RK3 RK4 RK5 RK7 RK8 RK9 RK10 LIMIT SWITCH ON THE BOOM SUPPORT Prevents the operation of the outriggers and the driving device if the boom is not resting on the support in the transport position Controls the relay K30 SAFETY LIMIT SWITCH FOR THE ADJUSTED OPERATING RANGE The operation of the limit switch stops the boom down movement and the telescope out movement BACKUP LIMIT SWITCH FOR THE SAFETY LIMIT SWITCH Trips after the preset delay 2 4 seconds the safety relay SR3 which controls the sound signal AM2 and switches off the control voltage to the limit switch RK4 SAFETY LIMIT SWITCH FOR THE TELESCOPE CHAIN Operation of the safety limit switch stops the electric motor The limit switch switches off the control voltage to the contactor K1 after which only the emergency descent unit will operate SAFETY LIMIT SWITCH TELESCOPE FULLY RETRACTED The limits switch closes when the telescope is completely retracted If the RK4 or RK5 has failed the boom cannot be lowered until the telescope has been completely retracted and the points of the limit switch RK8 have closed INDUCTIVE LIMIT SWITCH Limits turning of the platform to the left by disconnecting the control voltage circuit for the relay
49. ERED BY DIESEL ENGINE do not connect the mains cable 230 VAC turn on the main switch Fig A Refer to the separate user manual for the diesel engine delivered with the lift for instructions about starting up the engine when the battery is flat Leave the combustion engine running between the operations because the battery will not be recharged unless the combustion engine is running To avoid damaging the electronics of the diesel engine do not disconnect the mains current while the diesel engine is running 5 access the operating controls open the cover on the chassis Check the condition of the battery to ensure the 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 is flashing if both LEDs are lit after the charging the battery is dead 6 Turn the selector switch 1 to position 1 Fig B UP THE JOB 160 180 210XT 7 Start the engine by depressing the button 2 green The electric timer of the lift automatically disconnects the supply voltage 12 VDC in about 1 hour after the electric motor or the combustion engine has been turned off Re activate the power supply by pressing the start button either in the chassis control centre
50. ING EMERGENCY STOP SWITCH Stops all the other functions except the emergency descent and the sound signal which remain operational START SWITCH Controls the contactor of the electric motor and start solenoid of the combustion engine if the combustion engine is used STOP SWITCH Disconnects the control voltage from the control contactor of the electric motor and the stop relay of the combustion engine START SWITCH OF THE EMERGENCY DESCENT SYSTEM Controls the solenoid for the emergency descent unit which starts the unit and supplies the control voltage to the control levers while the the emergency descent system is in operation TURNING OF THE BOOM TO THE RIGHT LEFT Non locking lever switch chassis control centre BOOM UP DOWN Non locking lever switch chassis control centre TELESCOPE IN OUT Non locking lever switch chassis control centre ARTICULATED ARMS DOWN UP Non locking lever switch chassis control centre LEVELLING OF THE PLATFORM FORWARD BACKWARD Non locking lever switch chassis control centre TELESCOPE IN Non locking button switch After the SR3 has tripped the telescope can be retracted by depressing the button COMBUSTION ENGINE CHOKE Non locking button switch Depressing the button keeps the choke of the combustion engine active 93 UP THE JOB 160 180 210XT 23 4 CHASSIS CONTROL CENTRE LCB OTHER ITEMS F1 F2 F3 F4 F5 F6 F7 F8 F
51. INO 210XT Aerial Work Platform no YGC D210XT X X XXXXX complies with the provisions of the Machine Directive 2006 42 EC 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 the 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 Measured sound power level Petrol Diesel Lwa 96 1 5 97 5 98 5 1 5 100 dB Guaranteed sound power level Petrol Diesel Lwa 97 5 0 5 97 5 100 0 5 100 dB Notified body no 0537 VTT P O Box 1300 33101 Tampere FINLAND has granted the certificate no VTT 176 524 09 In designing the machine the following harmonised standards have been applied SFS EN 280 1 2 SFS EN 60204 1 1 LoimaaXX XX XXXX place date signature Seppo Kopu Chief Engineer name in block letters position UP THE JOB 160 180 210XT 2 REACH DIAGRAM 2 1 160XT C CW N 7 UP THE JOB 160 180 210XT 2 2 180 1 mA lun ABEL JS E 1 I 91 0 1 2 3 8
52. PERATING INSTRUCTIONS 160XT DINO 11 DNO gt Manufacturer Dealer TO THE JOB UP 145 FI 32210 LOIMAA Tel 358 20 1772 400 info dinolift com www dinolift com 160 180 210XT 2 UP THE JOB 160 180 210XT TRANSLATION OF THE ORIGINAL OPERATING INSTRUCTIONS Valid from serial number 160XT 16931 17008 gt 180XT 19029 19034 gt 210XT 3265 gt 3 160 180 210XT TABLE OF CONTENTS 1 EU DECLARATION OF CONFORMITY 6 2 REACH NI RS a UE Id UO 2E cR UE ING 7 m 7 8 PA E A VV 7 9 E 9 3 DIMENSION 065 MVVIMC 10 MEC rm 10 3 2 C 11 coc 210 qe HT D T2 4 TECHNICAL SPECIFICATION 13 4 1 GENERAL DESCRIPTION OF THE MACHINE eene eene nennen nennen nnns nns n nnns 14 4 2 DESCRIPTION OF THE MACHINE S INTENDED USE eene nennen nnn nnns nnne 15 4 3 EXAMPLE OF THE MACHINE S
53. TROL CENTRE 35 12 EMERGENCY DESCENT 5 42 13 DRIVING 43 14 C 44 15 SPECIAL INSTRUCTIONS FOR WINTER 5 46 16 MEASURES TO BE TAKEN AT THE END OF THE WORKING DAY 47 17 PREPARING THE LIFT FOR TRANSPORT 2 224 4 0 4 44 48 18 CONNECTING TO THE TOWING VLIIICIL C 49 19 INSTRUCTIONS FOR SERVICE AND 50 19 1 GENERAL SERVICE INSTRUCTIONS eese 50 19 2 SERVICE AND INSPECTION INSTRUCTIONS 51 19 3 LUBRICATION PLAN bcd Fon 52 19 4 LONG TERM STORAGE 53 19 5 LOAD HOLDING AND LOAD REGULATION VALVES 55 4 UP THE JOB 160 180 210XT 19 6 WHEEL BRAKES AND 8 22 56 19 7 LEVELLING SYSTEM
54. TROL CENTRE 12 Turn the selector switch 1 to position 2 and take away the key Do not lock the protective cover of the chassis control centre with the key now you can operate the boom with the lever 17 in the platform control centre Press first the rocker switch at the end of the control lever and after that move the lever carefully in the desired direction of movement If you move the lever before pressing 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 keeping the emergency stop button depressed now the movement shall stop Start the power unit for the emergency descent 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 35 DINnDlift UP TO THE 70 160 180 210XT 13 Test the operation of the overload limit switch RK4 put a load on the platform as shown in the picture below drive the boom to a horizontal position extend the telescope When the movement stops the red overload light 18 shall be illuminated compare the outreach with the outreach diagram in this manual 12A Measures to be taken after an event of overloading The overl
55. The service life of the double row angular contact compact bearings is long and they are maintenance free Therefore the bearings very rarely break under normal operating conditions If a bearing failure due to exceptional operating conditions occurs replace the entire brake drum assembly with the pressed in bearings and locking nut Assign a specialized workshop for the work Turn the wheels at least once every 3 months to keep the lubricating film intact 57 160 180 210XT 19 7 LEVELLING SYSTEM THE PLATFORM The platform is levelled by means of a so called slave cylinder system the slave cylinder under the platform is controlled by a master cylinder the platform stays in level position only if the valves in the system are tight the levelling system comprises the following parts Mastercylinder Slave cylinder Load regulation valve Double load regulation valve 8A 8B in the picture presenting the block Electric directional valve e Ifthe platform viewed by the operator drifts forwards the reason can be aleak in the slave cylinder s double load regulation valve on the piston rod side towards the electric directional valve which is by design not tight aninternal leakage in the cylinder Ifthe platform viewed by the operator drifts backwards the reason can be aleak in the load regulation valve 4 on the piston bottom side o
56. Transport length Lowest temperature 20 C Transport height Weight 2070 kg Basket size Inspection points Y meet standards N do not meet standards YN A STRENGTH 6 Plate for supports 1 Certificate of material 7 Safety colours 2 Certificate of strength SAFETY REQUIREMENTS B STABILITY 1 Indicating device for horizontal 1 Certificate of stability test position 2 Working space diagram 2 Locking device and lockings 3 Stop device for lifting C GENERAL REQUIREMENTS 4 Stop for opening of support 1 User s manual 5 Safety distances 2 Place for safekeeping for users manual 6 Position of working face 3 Machine plate checking plate 7 Structure of working face 4 Load plate 8 Emergency descent system 5 Waming plate 9 Limit devices LI lt z S S OO SIS S ES S ES IST S oO LILILILIL 126 UP THE JOB 160 180 210 E ELECTRIC APPLIANCES G SAFETY DEVICE 1 Electric appliances 1 Safety limit switch 2 Sound signal s F CONTROL DEVICES 1 Protections 2 Symbols directions 3 Placings 4 Emergency stop H LOADING TEST 1 Dynamic 237 kg 2 Static 323 kg 3 Work movements MO MO MO MO FAILINGS AND NOTES Dinolift Oy Raikkolantie 145 FIN 32210 LOIMAA FINLAND Tel 358 20 1772 400 Fax 358 2 7627 160 e mail info dinolift com 127 DINnDlift
57. UTTON Switches off the mains supply 230VAC Control circuit fuse F2 10A TURNING THE BOOM CLOCKWISE Control circuit fuse F9 1 6A Platform control centre and F4 10A Chassis control centre TURNING THE BOOM COUNTER CLOCKWISE Control circuit fuse F9 1 6A Platform control centre and F4 10A Chassis control centre AUXILIARY RELAY FOR THE DOWN MOVEMENT Control circuit fuse F9 1 6A Platform control centre and F4 10A Chassis control centre RETARDATION OF THE DOWN MOVEMENT Decreases the maximum lowering speed of the boom by connecting a resistor to the control circuit of the control card Control circuit fuse F9 1 6A Platform control centre and F4 10A Chassis control centre AUXILIARY RELAY FOR THE UP MOVEMENT Control circuit fuse F9 1 6A Platform control centre and F4 10A Chassis control centre AUXILIARY RELAY FOR THE TELESCOPE IN MOVEMENT Control circuit fuse F9 1 6A Platform control centre and F4 10A Chassis control centre AUXILIARY RELAY FOR THE TELESCOPE OUT MOVEMENT Control circuit fuse F9 1 6A Platform control centre and F4 10A Chassis control centre LOWERING THE ARTICULATED ARMS Control circuit fuse F9 1 6A Platform control centre and F4 10A Chassis control centre RETARDATION OF THE ARTICULATED ARMS DOWN MOVEMENT Decreases the maximum lowering speed of the articulated arms by connecting a resistor to the control circuit of the control card C
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59. aused by persons Max lateral inclination chassis Max wind speed during operation Min ambient temperature when working Max support force on the outriggers Platform size Gradeability Power supply e mains current Sound pressure level e petrol driven power unit option Sound pressure level e diesel driven power unit option Sound pressure level Socket outlets on the platform continuous refer to the reach diagram 215 kg 2 persons 4 55 kg 400 N 12 5 m s 20 16 800 N 16 800 N 22 800 N 0 7x1 3m 230 50 2 10 Under 70 dB 4 8 kW 6 5 hp 3 600 rom 98 dB 4 4 kW 6 hp 2 800 rpm 101 dB 230V 50Hz 16A 13 UP THE JOB 160 180 210XT 4 1 General description of the machine The denominations of the machine s essential parts and concepts which are used later in these instructions are described on this page Turning Left Counter clockwise to the left drive direction Platform Levelling cylinder of 2 the platform slave Boom extension 3 Turning Right Clockwise to the right Boom extension 1 Telescope cylinder Mastercylinder Lifting cylinder Articulated arms Boom support b De 5 Outrigger cylinder NN wr X i 9 E rlovica 22 Al MI 14 4 2 160
60. ay is active the control voltage to the Propo card is supplied via additional resistors As the relay is not active the control voltage is supplied to the joystick by means of which the control voltage is adjusted to desired value with the help of adjustable resistors inside the joystick Control circuit fuse F9 1 6A Platform control centre and F4 10A Chassis control centre FUNCTION RELAY FOR THE OUTREACH LIMIT SWITCH RK4 Switches off the telescope out movement as the RK4 operates Delay about 1 2 sec Control circuit fuse F2 10A AUXILIARY RELAY FOR SWITCHING OFF THE BOOM DOWN MOVEMENT Safety limit switch RK4 controls the relay which switches off the spool control circuit of the relay K5 Control circuit fuse F2 10A AUXILIARY RELAY FOR SWITCHING OFF THE TELESCOPE OUT MOVEMENT Closing tip of the safety limit switch RK4 controls the relay which switches off the spool control voltage of the relay K10 delay 2 5 sec Control circuit fuse F2 10A 111 111114 UP THE JOB 23 24 25 K25B K26 K27 K28 K29 K31 K32 K33 K34 K35 K390 160 180 210XT CHANGE OVER RELAY ON THE CHASSIS Controls the solenoid valve for selecting on the chassis Fuse F2 10A CENTRE POSITION ACTIVATION OF THE JOYSTICK Depressing the dead man switch DMK switches off the control voltage from the spool of the relay K17 which would otherwise disconnect the control voltage o
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62. e loading 2 instructions Check the structures after the test run 18 TEST PROTOCOL draw up a test protocol save your own copy and give the other copy to the customer UP TO THE JOB 160 180 210XT 20 INSPECTION INSTRUCTIONS All lifting equipment and lifting gear must be inspected in accordance with the national regulations before using them at a construction site Keep a journal of any notable shortcomings and defects observed and advise the foreman of them 20 1 FIRST INSPECTION The initial inspection and test loading of the Dino aerial work platforms is performed by the manufacturer A protocol drawn up during the inspection will accompany the lift 72 160 180 210XT 20 2 DAILY INSPECTION START UP INSPECTION To be always performed at a new worksite and in the beginning of every work day The user of the lift shall performed this inspection During inspection attention shall be paid to the following issues establishing the load bearing capacity of the ground at the lifting site see the indicative table Maximum permissible ground pressure for different soil materials verification of the lift s standing stability controlling the due operation of the position indicator testing of the emergency stop system s operation both from the platform and the chassis control centres testing the emergency de
63. ean and tight check the condition of the cable connections and their protection against moisture check the condition and attachment of the limit switches check the limit switch lead throughs for tightness check the connections of the electric valves check the connections of the solenoid valves perform visual inspection of all electric wiring check the condition of the mains cable plug check the condition of the electric motor check the attachment points of the hydraulic cylinders check the condition of the bearings and pins of the outrigger cylinders and the locking of the pins check the condition of the lifting cylinder bearings and pins and the locking of the pins check the condition of the articulated arm cylinder bearings and pins and the locking of the pins check the condition of the telescope cylinder bearings and pins and the locking of the pins 76 UP THE JOB 160 180 210XT Check the condition of the gas springs check the condition of the master and slave cylinder bearings and pins as well as the locking of the pins check the condition of the boom s joint check the bearing and the pin of the boom joint and the locking of the pin check the condition and attachment of the articulated arm joint pins and bearings check the support outriggers and their footplates check the mechanical structure of the outriggers and the welded seams The structures must not show signs of deforma
64. ess the start button to activate the power supply One of the fuses F1 F11 or F12 has blown Change the fuse an press the start button Battery is flat Recharge the battery Check whether the fault is in the electric system or in the hydraulic system 6 Malfunctions of platform movements only one of the movements can be operated 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 particles that cause malfunctions cannot possibly be spotted with the naked eye Also temporary contact failures in the joysticks may cause malfunctions Spray with moisture repellent Lifting and lowering of the boom and the extension of the telescope are not operational the red light is illuminated on the platform and in the chassis control centre and the buzzer is audible The boom has been overloaded retract the telescope and retry the operation automatic reset 81 UP THE JOB 160 180 210XT FAULT 7 Boom drifts slowly downward REMEDY The lock valve i e the pressure activated check valve is leaking Remove and clean the valve Check the condition of the o rings Install the valve carefully the correct tightening torque is 60 Nm If necessary replace the valve
65. f the micro switches on the joystick CONTROL RELAY FOR THE 1B VALVE Switches the voltage of 12VDC to the selector valve of the boom CONTROL RELAY FOR THE PR VALVE When driving the chassis switches the voltage of 12VDC directly to the PR valve When driving the boom the points direct the adjusted current from the control card to the PR valve RPM RELAY Controls the combustion engine revolutions Increases the revolutions when the control movement is active Control circuit fuse F9 1 6A Platform control centre and F4 10A Chassis control centre AUXILIARY RELAY FOR CURRENT SUPPLY TO THE DRIVING DEVICE The relay is controlled by the limit switch RK3 Fuse F3 10A CONTROL RELAY FOR THE SOLENOID OF THE EMERGENCY DESCENT UNIT Switches on the voltage supply to the emergency descent unit solenoid SR1 Fuse F7 10A PREVENTION OF DUAL CONTROL The relay is controlled by the emergency descent buttons 511 and 513 Control circuit fuse F7 10A SWITCH OFF RELAY FOR THE COMBUSTION ENGINE Fuse F2 10A SWITCH OFF RELAY FOR THE COMBUSTION ENGINE Fuse F2 10A AUXILIARY STARTING RELAY FOR THE DIESEL ENGINE RELAY FOR PREVENTING THE ELECTRIC MOTOR FROM RESTARTING Prevents the electric motor from starting after the failure in AC power supply by switching off the control voltage from the control contactor of the motor RELAY FOR PREVENTING THE ELECTRIC MOTOR FROM RESTARTING Connects the voltage supply to the relay K34 if the voltage in t
66. f platform Lever switch for articulated arms 24 UP THE JOB 160 180 210XT 9 1 OPERATING CONTROLS OF DRIVE SYSTEM 28A Forward backward 28A 28L drive to the left 28A 28R drive to the right 9 2 OPERATING CONTROLS OF OUTRIGGERS Rear outrigger right Rear outrigger left Front outrigger left Front outrigger right 6 Position indicator of chassis e Dort 25 UP THE JOB 160 180 210XT 9 3 OPERATING CONTROLS IN PLATFORM CONTROL CENTRE Close the cover of the chassis control centre before operating the controls on the platform The cover must not be locked while the lift is in operation 17 Control lever The functions to be controlled are selected using the dead man buttons at the end of the joystick Always press the button first and only after that turn the handle The safety connection prevents the movements if the handle is turned before depressing the button TELESCOPE IN ARTICULATED ARTICULATED ARMS ARMS DOWN UP TELESCOPE OUT BOOM 4 UP BOOM BOOM TO THE LEFT TO THE RIGHT BOOM DOWN A piece of extra equipment that requires two
67. f the slave cylinder towards the electric directional valve 5 which is by design not tight aninternal leakage in the cylinder The leak will cause drifting of the platform until the load regulation valve 3 under the platform closes The closing is caused by dropping of the pressure on the piston rod side to the opening ratio which is 5 1 If the valves are not tight refer to the point Load holding and load regulation valves in the service instructions Settings of the load regulation valves the opening pressure of the double load regulation valves 4 is 21 5 MPa 215 bar the opening pressure of the load regulation valve 3 under the platform is 21 5 MPa 215 bar Do not adjust the settings of the valves 58 UP THE JOB 160 180 210XT 19 8 REGULAR SERVICE The lift shall be serviced regularly at intervals of 11 12 month Under demanding conditions where moist corrosive substances or corrosive climate may speed up the deterioration of the structure and induce malfunctions the inspection must be performed more often and the influence of corrosion and malfunctions must be reduced by using appropriate protective means Only technical specialists who are familiar with the structure and the operation of the lift are allowed to maintain the lift We recommend turning to the service staff of the dealer SCHEDULE FOR REGULAR SERVICING 1 Clean the lift thoroughly before the service The hydrau
68. ft is 20 C if the temperature is below zero let the power unit run for a few minutes before starting the movements start with a few movements to warm up oil in the cylinders and to ensure proper operation of the valves check that the limit switches and the emergency descent devices are operational and clean from dirt snow ice etc protect the control centre and the platform from snow and ice whenever they are not in use Always keep the lift free from dirt snow etc 46 160 180 210XT 16 MEASURES BE TAKEN THE END OF THE WORKING DAY 1 Retract the telescopic boom fully 2 Check that the platform is perpendicular to the boom 3 Lower the boom platform onto the support on the tow bar the limit switch on the transport support prevents the operation of the support outriggers if the platform is not down 4 Close the cover of the platform control centre 5 Turn the selector switch to position 0 and turn off the main switch 6 If you want to recharge the battery leave the mains cable connected otherwise disconnect the lift from the mains supply 7 Make sure that the covers are locked 47 160 180 210XT 17 PREPARING THE LIFT FOR TRANSPORT 4 B 6 Retract the telescopic boom fully Check that the platform is perpendicular to the boom Lower the boom platform onto the support on
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70. he control circuit of the contactor is switched off CHANGE OVER RELAY FOR OPTIONAL FUNCTIONS When the relay is active the lifting lowering movements of the articulated arms 90 K391 K40 K41 K42 K60 SR2 SR3 SR4 160 180 210XT are switched over to the joystick movements in the X direction When the relay is not active the joystick movements in the X direction control turning of the boom to the left and right CHANGE OVER RELAY FOR OPTIONAL FUNCTIONS When the relay is active the in out movements of the telescope are switched over to the joystick movements in the Y direction As the relay is not active lifting lowering movements of the boom are switched over to the joystick movements in the Y direction CONTROL OF THE COMBUSTION ENGINE CHOKE Switches on the combustion engine choke Fuse F2 10A SENSOR RELAY FOR THE AC SUPPLY When the lift is connected to an AC supply the relay switches off the start circuit and switches on the stop circuit of the combustion engine The relay spool is controlled by the AC voltage START RELAY FOR THE COMBUSTION ENGINE Fuse F2 10A SWITCH OFF RELAY FOR THE FUNCTIONS CONTROLLED FROM THE CHASSIS CONTROL CENTRE Switches off the voltage supply to all the other boom movements during levelling of the platform Safety relay monitoring the operation of the outriggers The safety relay resets as soon as all the outrigger safety
71. he target is about 50 cm If this cannot be achieved you can try to increase the maximum current The intensity of the current must not be too high as then the adjustment range of the joystick will decrease 101 UP THE JOB 160 180 210XT 12 The movement speeds adjusted using the adjustable resistors the circuit card in the main control centre The speed of the following movements can be adjusted TRO levelling the platform 9 10 n TR10 the speed of the movements QOL 901 I MI II when controlled from the chassis control centre affects the speed of all movements when controlled from the chassis centre TR11 lowering the boom TR12 lowering the articulated arms T 13 Adjustment of the movement speed from the chassis control centre the lift in the boom mode the power unit is not running Drive the boom up movement and simultaneously adjust the intensity of current via the adjustable resistor TR10 to liower 1500 mA 14 Adjusting the lowering speed of the boom 14 1 Drive the boom down movement and simultaneously adjust the intensity of current via the adjustable resistor TR11 1 250 mA 14 2 Check the lowering speed of the boom gt start the power unit and retract the telescope Lift the boom until the floor of the platform reaches the height of 2 8 metres 14 3 Lower the boom to its lowermost position over a dista
72. ing speed VOLTAGE METER As the control voltage is connected the voltage meter indicates the alternating voltage reading 23 5 PLATFORM CONTROL CENTRE UCB RELAYS K50 K51 K52 CONTROL RELAY FOR SIGNAL LIGHTS INDICATING THE STATE OF LOADING OF THE PLATFORM The relay is controlled by the opening point of the limit switch RK4 TURNING THE PLATFORM TO THE LEFT Controlled by the non locking lever switch S36 The control movement is stopped by the inductive end limit switch RK9 of the linear motor TURNING THE PLATFORM TO THE RIGHT Controlled by the non locking lever switch S36 The control movement is stopped by the inductive end limit switch RK10 of the linear motor 23 6 PLATFORM CONTROL CENTRE UCB SWITCHES DMK JST S4 S5 DEAD MAN SWITCH JOYSTICK As the right side of the rocker switch is depressed the movements are boom up down and turn right left As the left side of the rocker switch is depressed the movements are telescope in out and articulated arms up down LOCKING EMERGENCY STOP SWITCH Stops all the other functions except the emergency descent and the sound signal which remain operational STOP SWITCH 95 UP THE JOB S6 S10 S11 512 529 531 536 541 160 180 210XT Disconnects the control voltage from the control contactor of the electric motor and the stop relay of the combustion engine START SWITCH Contr
73. ing the position of the platform From the chassis control centre LCB The position of the platform may be adjusted from the chassis control centre in the following way turn the selector switch 1 to position 3 select the direction for the correction movement using the control lever 32 40 160 180 210XT From the platform UCB The position of the platform may be adjusted from the platform control centre in the following way turn the selector switch 1 to position 2 press the selector button 35 for levelling of the platform select the direction for the correction movement using the control lever 36 41 UP THE JOB 160 180 210XT 12 EMERGENCY DESCENT SYSTEM As aprecaution against possible power failure the lift is equipped with a battery operated emergency descent system 1 The system comprises 12V 44 Ah recharger hydraulic unit 12 VDC 2 Servicing the battery the system incorporates an automatic battery recharger with short circuit and overheat protection output 125 W charging voltage 13 7 14 7 V rated current 10A 3 The hydraulic unit comprises pressure relief valve set
74. it switches on the outriggers which prevent the operation of the boom movements the limit switches on the tow bar which prevent the use of the outriggers after the test loading and test drive make sure that the steel structures or other loaded parts do not show signs of structural defects such as fractures or dangerous permanent deformations draw up a protocol of the regular inspection with following articles 1 inspection form 2 data of repair welds a date of repair b repaired by whom c what was repaired when the machine is ready for operation after the annual inspection mark the inspection date on the inspection plate affixed to the lift 20 5 EXTRAORDINARY INSPECTION INSPECTION AFTER AN EXCEPTIONAL SITUATION The inspection is required if the lift has been damaged in a manner which may affect its strength or safe operation 78 UP THE JOB 160 180 210XT inthis case the lift shall be inspected according to the instructions for the annual inspection the lift shall be subjected to a test loading and stability test aprotocol shall be drawn up for the inspection 20 6 TEST LOADING INSTRUCTIONS FOR REGULAR INSPECTION 1 Place the lift on an even surface with good carrying capacity Drive the outriggers to their lowest position the minimum support width 2 Turn the boom to the side from the tow bar and lower it on the ground Test load 1 3 Put a weighed load 1 onto the pla
75. joysticks operates like this 4CB6631 4CB6630 26 UP THE JOB 160 180 210XT Fig 2 Operating controls on the platform 18 Signal lights green inside the allowed outreach range red at the border of the allowed outreach range 20 Starting the emergency descent system 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 used simultaneously with pushbutton 35 31 Fuse for turning the platform 35 Levelling the platform pushbutton 36 Lever for levelling the platform used simultaneously with pushbutton 35 41 Choke 27 160 180 210XT 10 MEASURES BE TAKEN IN THE CASE OF THE LIFT IS AT RISK OF LOSING ITS STABILITY Reduced stability can be caused by a fault in the lift the wind other lateral force collapse of the standing N base or negligence in providing sufficient support In most cases one sign of reduced stability is the inclination of the lift WHEN AT RISK OF LOSING THE STABILITY 1 Ifthere 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 manner 3 Reduce the outreach
76. lic 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 electric appliances such as the control centres on the chassis and on Be careful not to direct the high pressure water jet straight to the the platform relays solenoid valves and limit switches use pressure air to dry the electric devices hydraulic connectors etc before opening them apply appropriate moisture repellent to the electric appliances after the drying always protect the piston rods with e g CRC3 36 anti corrosive agent after washing with a solvent Remember cleanliness N 59 UP THE JOB 160 180 210XT 2 Change the hydraulic oil and replace the filter protect your skin against the hydraulic oil remove the plug and drain the oil tank with the lift s all cylinders fully retracted clean and rinse the oil tank with suitable agent replace the pressure filter install the drain plug refill the tank with fresh oil the volume required for change is about 20 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 if necessary top up hydraulic oil to the level with the upper edge of the level eye
77. limit switches RK11 RK12 RK13 and RK14 have closed After that it is possible to operate the boom SAFETY RELAY FOR MONITORING THE OVERLOADING OF THE BOOM Safety limit switch RK5 controls the operation of the safety relay Overloading of the SR3 is disconnected The safety relay is automatically boom reset upon return to the normal outreach range The delay adjusted with the capacitors affects the tripping moment of the SR3 If the RK5 fails SR3 is disconnected The safety relay is not automatically reset but the due operation of the electric equipment must be checked The delay adjusted with the capacitors affects the tripping moment of the SR3 SAFETY RELAY FOR THE EMERGENCY STOP CIRCUIT SR4 switches off control voltage from the engine control contactors The safety relay operates provided that the emergency stop buttons on the upper and lower control centres are in their upper positions and the chain limit switch RK7 is not active In addition the contactors K1 and K2 must be inactive 160 180 210XT The safety relay will trip if one of the emergency stop buttons either on the upper or on the lower control centre is depressed or the chain limit switch is activated 160 180 210XT 23 2 CHASSIS CONTROL CENTRE LCB SWITCHES 51 52 53 513 516 517 518 519 520 532 540 LOCK
78. lves of the outrigger cylinders for tightness measure the height of the chassis from the floor separately at each outrigger and observe the height in a few minute s time 2 To check the load regulation valves of the boom cylinder and the cylinders of the articulated arms for tightness drive the boom to a position in which its position can be reliably measured Observe the possible movement of the boom in a few minute s time 3 check the load regulation valve of the telescope cylinder for tightness extend the telescope and stop the movement at any position measure 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 of the platform s levelling system for tightness put a load of 100 200 kg on 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 does not change Service instructions 1 Remove and clean the valve 2 Check the O rings and if necessary replace them 3 Putthe valves carefully in place 4 f necessary replace the valve 5 Do not change the set values of the valves Support the platform the boom system and the outriggers in a position where the load does not rest on the structure to be repaired Ensure that there is no residual pressure left in the cylinders 55 16
79. nce of 2 m The lowering should take about 13 seconds As necessary adjust it via the trimmer TR11 15 Lowering the articulated arms Drive the articulated arms down movement and simultaneously adjust the intensity of current using the adjustable resistor TR12 to liower 1400 mA Lift the articulated arms to their highest position lower them all the way down and measure the elapsed time The time shall be 20 seconds As necessary set the time as specified via the trimmer TR12 16 Finally disconnect the meter and reconnect the lead S23 102 UP THE JOB 160 180 210XT 26 ELECTRIC DIAGRAM lt G97C 1 012 lt 72061 62061 1 081 5799807 ou 0 1 012 1 081 1 091 uonisod 0212132 3 lt 800 11 69 1X091 491108 114 UO O O1 wJ0 0 d 014 gon nsKor 64 DPUOH Z OH 8 4 3 SeA DA 94 lt 4 891 5 74 807 85594364 821 14015 424 891 uo 14 Soils XM 019 WNINYSL 8000 821 ZX 42018 WNINYSL SISSVHO XX SSJNMVH 3415 530010 xMvdS I X 42018 TVNINM3L 827 STVNINM3I GON ZX STVNINS3LI 1I I 827 IX 532018 IVNIWS3L vH Qavolinoslo 891 318vO 419 5 LAA
80. nces and wiring leaks Load markings and signs 4 Operator ls the operator old enough Has the operator received the required training 5 Special issues on the worksite Are there any additional regulations relevant to the worksite or the work 21 160 180 210XT 8 OPERATION OF THE 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 is not resting on the transport support The switch is located on the tow bar at the transport support 2 Lifting the boom Fig B The lift s all 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 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 the extension of the telescope and the 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 control centre on the platform is lit when the platform is within the allowed operating range The red light will illuminate as soon as the RK4 stops the movement When the red light is illuminated the lift can be operated in the direction where i
81. nd turning movements and check that they all operate properly and that the movements stop as soon as the levers are released 75 UP THE JOB 160 180 210XT manually operated directional valves check that the valves of the support outriggers and the driving device operate properly and no movement occurs when the spools are in the neutral position electro hydraulic rotary adaptor check the adaptor for tightness check that the lever arm neither seizes nor is loose cylinders hoses pipes lower the outriggers to the support position and check the condition of the piston rods and the wiper rings lift the boom to its upper position and check the condition of the piston rod and the wiper ring of the lifting cylinder lift the articulated arms to their upper position and check the condition of the piston rods and the wiper rings of the cylinders check the condition of the piston rod and wiper ring of the master cylinder in the slave cylinder system Lower the boom and check the condition of the piston rod and wiper ring of the slave cylinder under the platform check the hoses for any leaks or chafing check that the pipes do not show any 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 inspect thoroughly the electric system check that the control centre boxes are dry cl
82. ng brake completely 25 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 replace the ball Always when changing brake shoes replace all the shoes on the axle Always when assembling the brakes make sure to install the springs the brake shoes and the expander in the right way When adjusting the brakes turn the wheels forward in the driving direction Naturally there are many possible reasons for malfunctions but the following are the most common low supply voltage long and thin supply cable the battery is flat low voltage contaminants in the hydraulic system loose electric connection or a contact failure caused by moisture Keep the lift clean and protect it against moisture 86 UP THE JOB 160 180 210XT 22 GENERAL INFORMATION OF HYDRAULICS Activation of any of the movements requires that three electric valves be in operation simultaneously The retraction of the telescope is an exception as it requires simultaneous operation of two valves only The valves are the flow regulation valve PR the selection valve boom chassis 1B and the control valve for the movement in question
83. nnel with authorisation in writing who are well familiarised with the device and at least 18 years old are allowed to operate the unit 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 will not adversely affect 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 Protect your hearing while using the power unit option 92 dB 16 160 180 210XT Use the safety harness N N Connecting points for the safety harness 1 person lug Do not use ladders steps or other similar equipment on the platform Never
84. nt method II Setting the RK5 undo the RK4 as much as necessary to ensure that the RK5 certainly trips first extend the boom and measure the length of one projecting part of the telescope extension L The measure must be 160XT L 2 250 mm 50 mm 180XT L 2 900 mm 50 mm 210XT L 3 600 mm 50 mm tighten the locking of the adjustment screw and check once more the settings Setting the RK4 set the RK4 to trip before the RK5 extend the boom and measure the stroke The measure must be 160XT L 2 000 mm 50 mm 180XT L 2 450 mm 50 mm 210XT L 3 100 mm 50 mm tighten the locking of the adjustment screw and check once more the settings apply a safety wire to the adjustment screws in such a manner that it will not be possible to unscrew the screws away from the limit switches apply a seal on the wire put cover place UP TO THE JOB 160 180 210XT 11 Measuring the pressure connect the pressure gauge to the measuring point inlet MP max pressure of oil at the operating temperature 40 60 C is 20 21 5 MPa 205 215 bar the turning pressure is 5 5 7 0 MPa 55 70 bar if you have to readjust the pressure secure the new setting with a seal 69 UP THE JOB 160 180 210XT 12 Check the operating controls on the platform check the overall condition of the electric appliances inside the box
85. nt towards the descent Never drive with the driving device with the tow bar 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 lift 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 tow bar be careful not to cause danger to other people and the environment 7 Do not move the device on a slope using only hand power You may lose control over it and cause an injury 8 Never park a vehicle combination on a slope 43 UP THE JOB 160 180 210XT 14 DRIVING DEVICE The hydraulic driving device is intended for moving the lift within the work area if the towing vehicle cannot be used start the power unit and adjust its running speed to 34 of the maximum combustion engine The running speed of the power unit affects the driving speed turn the selector switch to the position 1 outriggers
86. oad limit switch RK5 switches off the electricity supply to the operating controls and switches on the buzzer on the platform retract the platform to inside the operating range of the RK4 by pressing the telescope in button 31 or 36 the green light will be illuminated 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 illuminated Example A person who is working alone on the platform extends the telescope or an empty platform is driven from the chassis control centre to the maximum reach keeping it close to the ground If the overload signal light will light up after this it is not allowed to take any additional load onto the platform before the telescope has been retracted IF THE SAFETY DEVICES OR THE EMERGENCY DESCENT SYSTEM ARE NOT WORKING HAVE THEM REPAIRED BEFORE OPERATING THE LIFT 14 Refer to the item Daily inspections in the task list for servicing 15 With the boom slightly lifted and the telescope extended make sure that the platform does not lower by itself while the operating controls are not being used 16 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 centre 17 Move the platform to the work object 36
87. oading with maximum permissible load and a thorough inspection of the supporting structures the first inspection shall be recorded in the start up inspection protocol and the test run shall be recorded in the protocols for the annual and regular inspection 79 UP THE JOB 160 180 210XT 21 FAULT FINDING FAULT REMEDY 1 Electric motor does not start from the start button although the selector switch is in position 1 2 or 3 The emergency stop button has jammed in the lower position Pull up the button and re start the motor from the start button Fuse F1 has blown Replace the fuse 10A No mains supply 230 VAC to the selector switch Check the extension cords possible distribution boards and fuses Fault current safety switch has tripped Reset the fault current safety switch Voltage is supplied to the selector switch but is not transmitted further Check the operation of the selector switch and replace it if necessary Voltage is supplied to the selector switch and is also transmitted further Check the operation of the motor s control contactor and thermo relay as well as the operation of the relays that control the operation of the contactor Limit switch RK7 for the telescope chain has disconnected the contactor circuit Check the operation of the RK7 and readjust according to the instructions No direct current supply 12VDC
88. ols the contactor of the electric motor and start solenoid of the combustion engine if the combustion engine is used SOUND SIGNAL SWITCH EMERGENCY DESCENT SWITCH Controls the solenoid for the emergency descent unit which starts the unit and supplies the control voltage to the control levers while the the emergency descent system is in operation LEVELLING OF THE PLATFORM FORWARD BACKWARD Control switch non locking lever switch The levelling is operated by pressing the button S29 and turning the lever switch 12 SELECTOR SWITCH FOR LEVELLING OF THE PLATFORM Non locking button switch Switches on the control voltage to button switch S12 as the switch is depressed TELESCOPE IN Non locking pushbutton for retraction of the telescope TURNING THE PLATFORM TO THE LEFT RIGHT Non locking lever switch Controls the relays K14 and K15 The turning is operated by pressing the button S29 and turning the lever switch 536 COMBUSTION ENGINE CHOKE Non locking button switch Depressing the button keeps the choke of the combustion engine active a6 160 180 210XT 23 7 PLATFORM CONTROL CENTRE UCB OTHER ITEMS H1 GREEN LED SIGNAL LIGHT The platform inside the operating range H2 RED LED SIGNAL LIGHT The platform at the border of the operating range F10 AUTOMATIC FUSE FOR TURNING OF THE PLATFORM 4A F9 JOYSTICK FUSE 1 6A PR SOCKET OUTLET ON THE PLATFORM 230VAC 16A AM2
89. ontrol circuit fuse F9 1 6A Platform control centre and F4 10A Chassis control centre RAISING THE ARTICULATED ARMS Control circuit fuse F9 1 6A Platform control centre and F4 10A Chassis 88 UP THE JOB 15 K16 K17 K18 K19 K20 K21 K22 160 180 210XT control centre LEVELLING THE PLATFORM Levelling the platform backward Control circuit fuse F9 1 6A Platform control centre and F4 10A Chassis control centre LEVELLING THE PLATFORM Levelling the platform forward Control circuit fuse F9 1 6A Platform control centre and F4 10A Chassis control centre CENTRE POSITION ACTIVATION OF THE JOYSTICK Switches off the voltage from micro switches of the joystick if the dead man switch DMK has not been pressed while the joystick is in the centre position CONTROL RELAY FOR THE ADDITIONAL RESISTORS CONTROLLING THE MOVEMENT SPEED The relay switches over the control voltage from the propo card to the adjustable resistor for the boom levelling of platform When the relay is active the control voltage is routed via the resistor TR10 movement speed of the boom from the chassis control centre As the relay is not active the control voltage is supplied through the TR9 resistor levelling of platform Control circuit fuse F9 1 6A Platform control centre and F4 10A Chassis control centre CHANGE OVER RELAY FOR THE CONTROL VOLTAGE OF THE PROPO CARD As the rel
90. or in the platform control centre Petrol engine turn off the choke adjust the engine speed 8 Lower the front support outriggers on the tow bar side 9 Lower the rear support outriggers do not damage the tow bar jockey wheel 10 Level the chassis with the outriggers with the help of the level gauge 16 The air bubble must be located inside the inner ring Make sure that the wheels are clearly off the ground the green signal light 4A in the main control centre is illuminated when all the outriggers are in the support position and the limit switch circuit of the outriggers is closed make sure all outriggers are firmly supported on the ground 160 180 210XT 11 1 OPERATING THE LIFT FROM THE CHASSIS CONTROL CENTRE 11 turn the selector switch 1 to position 3 now you can operate the boom with the levers 7 8 9 33 and the platform with the lever 32 from the chassis control centre 32 1 10 i 0 34 9 1234h 8 5 Qr 33 1 29 7 LA 3 Test the operation of the emergency descent system as N follows 1 lift the boom about 1 2 metres using le
91. raulics top up if necessary check the hydraulic connections check the structures visually check the operation of the emergency descent and emergency stop functions check the operation of the safety devices 3 Weekly service check the tyre pressure 450 kPa jockey wheel 250 kPa lubricate the joint pins see point Lubrication plan checkthe sliding surfaces of the telescope and lubricate them with silicon if necessary check the clearance between the slide pads and surfaces and adjust the pads if necessary puta load 160XT 270 kg 180XT 120 kg 210XT 80 kg onto the platform and drive the boom to a horizontal position After this extend the telescope until the red signal light lights up and the movement stops Measure the stroke in accordance with the instructions and compare it with the setting of the RK4 see point Adjusting the overload limit switches If the stroke is longer contact the service technician 4 Service every six months change the hydraulic oil and the filter cartridge check the condition of the brakes check the the wheel bolts for tightness 160XT 90 Nm 180XT and 210XT 325 Nm grease the gear ring of the turning device 5 Periodic service every 12 months in accordance with the instructions for regular servicing below in this manual If the lift is operated under demanding conditions in exceptionally humid or dusty environment corrosive climate etc the inte
92. reaches have the possible repair welds been properly executed check that the platform does not drift refer to the service instructions check that the outriggers do not drift refer to the service instructions check the hydraulic oil level check the electro hydraulic rotary adaptor for oil leaks or seizures check the tyres and the tyre pressure check the wheel bolts and the rims check the turning gear for play check the operation of the driving device check the condition and attachment of the electric wires check the condition and attachment of the battery check the condition of the overrun make sure that all the signs warnings and pictorials for the operating controls and the control equipment are in place in good condition and clean check that the lift is clean all over 74 UP THE JOB 160 180 210XT 20 4 ANNUAL INSPECTION REGULAR INSPECTION The inspection shall be performed by a skilled technician or an expert inspection body with documented evidence of competence see point Periodic inspection During inspection special attention shall be paid to the the steel structures the safety devices and the operating system Clean the lift before the inspection The inspection includes the following measures and checks measures of the daily and monthly inspections thorough inspection of the hydraulic system inspection of the power unit connect the pressure gauge to the
93. rning device beware of getting pressed against the outriggers or other structures that do not turn with the boom When the 15 in its lowest positions make sure it cannot clash during rotation with structures that do not turn with the boom Before operating always ensure that the safety devices and the emergency descent system are in working order Do not take tools material of large surface area onto the platform The increase in wind load may jeopardize the stability of the device Always keep the lift free from dirt snow and ice Ensure that the lift is inspected and serviced before use Never use a defective lift Never use a lift alone Make sure that there is always someone on the ground who can call for help in case of an emergency 19 UP THE JOB 160 180 210XT 6 INSPECTIONS A thorough inspection of the lift must be carried out at least once every twelve 12 months The inspection shall be carried out by a technically trained person who is familiar with the operation and structure of the lift Draw up a protocol of the inspections and always keep it with the unit stored in the space reserved for it Carry out the inspections regularly throughout the service life of the lift The inspection must be carried out within twelve 12 months of the first inspection or previous regular inspection If the lift is used under extreme conditions intervals between the
94. rvals between the oil changes and the other inspections shall be shortened to meet the prevailing conditions in order to maintain the operational safety and reliability of the lift The performance of the periodic servicing and the inspections is absolutely mandatory because their negligence may impair the operational safety of the lift The guarantee will not remain valid if the servicing and the periodic inspections are not performed 5 UP THE JOB 160 180 210 je 19 3 LUBRICATION PLAN 52 UP THE JOB 160 180 210XT EVERY 50 HOURS Bearings of the overload protection device safety device Bearings of the outrigger cylinders Bearings of the outriggers Bearings of the outriggers foot plates Bearings of the boom and the articulated arms Bearings of the platform Bearings of the levelling cylinders except the bearing on the rod side of the upper levelling cylinder 8 Bearings of the lifting cylinder 9 Sliding surfaces rolls of the telescope 10 Jockey wheel slide and threads DELE TWICE A YEAR 11 Bearing of the telescope cylinder 12 Driving device 13 Overrun brake overrun
95. s 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 Brake rod jammed or bent Lubricate Repair Brake wires rusty or cracked Replace the wires 20 Braking uneven and jerky Too much play in the brake system Adjust the brake system Shock absorber of the overrun device faulty Replace the shock absorber Brake shoe of the reverse automatics jams in its carrier Replace the brake shoe in the carrier 21 The brakes drag only one of the wheels brakes Brake units wrongly adjusted Readjust the brake units according to the instructions Also refer to point 17 for possible cause 22 Lift brakes as soon as the engine speed is decreased Shock absorber of the overrun device faulty Replace the shock absorber 23 Reversing forced or impossible Brakes have been adjusted too tight Adjust the brakes 85 UP THE JOB 160 180 210XT FAULT REMEDY 24 Wheel brakes overheat Brake system wrongly adjusted Adjust the brake system Wheel brake dirty Clean the wheel brake Overrun brake the transmission rod of the overrun jams Dismantle clean and lubricate the transmission rod Parking brake not completely released Release the parki
96. s bring the lift to a level position 64 160 180 210XT puta load onto the platform as shown in the picture 160XT 270 kg 180XT 120 kg 210XT 80 Jift the boom and extend the telescope The movement stops as soon as the red outreach limit signal light lights up at max outreach Now the lifting of the boom should be operational the lowering of the boom must NOT be operational the retraction of the telescope should be operational the extension of the telescope must NOT be operational 65 160 180 210XT 19 8 1 TESTING THE LOAD LIMIT SWITCHES RK4 AND RK5 Put a carefully weighed load onto the platform as shown in the picture Place it at a distance of 100 mm from the rear edge of the platform 160XT 270 kg 180XT 120 kg 210XT 80 Drive the boom to a horizontal position from the chassis control centre Lift and lower the rear edge of the platform using the levelling function 1 Lowering the rear edge of the platform 2 Lifting the rear edge of the platform opa Using the levelling function drive the platform to a horizontal position ending the procedure by lifting the rear edge 66 UP THE JOB 160 180 210XT Adjustment method I Extend the telescope
97. s control centre cover safety device cover platform control centre cover and the rear light cover perform visual inspection of all the screw connections 77 UP THE JOB 160 180 210XT inspect the turning device general condition check the play and attachment of the angular gear check the condition of the gear ring check the play of the turning gear check the tightening torque of the turning bearing s attachment screws M16 280 Nm M12 150 Nm check the attachment of the turning motor check the condition of the chassis general condition check the attachment of the tow bar to the chassis check the condition of the overrun and its attachment to the chassis check the axle and its attachment to the chassis check the attachment and condition of the brake wires and rods check the rims the tightness of the wheel bolts the tyres and the tyre pressure check the condition of the driving device attachment of the parts and condition of the covers for electric components check the condition of the transport support of the boom perform a test run test all the operating controls control the outreach in accordance with the instructions See point Inspection and adjustment of the overload limit switches also check the operation of the limit switches during the test run refer to the service instructions the load sensing limit switches on the safety devices the lim
98. scent system s operation both from the platform and the chassis control centres testing the alarm signal checking the warning and signal lights checking the operation and cleanliness of the lights and reflectors checking the condition of the operating controls and testing of all work movements checking the condition of the access routes the platform gate and the handrails checking the operation of the load limit switches refer to the service instructions checking the limit switches preventing the operation of the boom movements refer to the service instructions checking the limit switches preventing the operation of the boom movements refer to the service instructions checking the hydraulic system for tightness testing of the brakes checking the structures visually observe the location of nearby power lines for safe distance see General safety regulations 73 UP THE JOB 160 180 210XT 20 3 MONTHLY INSPECTION MAINTENANCE INSPECTION This inspection shall be performed by a person who is well familiar with the lift Task list for the inspection perform the daily inspection measures check the attachment points of the boom and the platform check the operation and condition of the platform s levelling system inspect visually the load bearing structures e chassis turning device telescope fully extended support outriggers and their joints welded seams for any cracks corrosion or b
99. t 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 brake push the lift backward to make the reverse automatics release the brake shoes The spring cylinder pulls the parking brake tighter and the brakes of the vehicle will again be properly engaged Adjust the brakes according to the service instructions Place chocks under the wheels as an additional precaution If you leave the lift standing for a longer period of time for example over the winter we recommend propping it up to release any load from the wheels Always ensure before towing 1 transport position of the outriggers locking of the ball coupling operation of the lights parking brake condition and pressure of the tyres rear axle450 kPa 4 5 bar jockey wheel250 kPa 2 5 bar safety wires locking of the brakes after the transportation attachment of the jockey wheel that the driving device is disconnected from the wheel 49 UP THE JOB 160 180 210XT 19 INSTRUCTIONS FOR SERVICE AND MAINTENANCE 19 1 GENERAL SERVICE INSTRUCTIONS carry out the servicing and inspection of the lift in accordance with the instructions incase of more demanding repair works turn to a specialist or contact the distributor or the manufac
100. t stays inside the permitted outreach area The safety limit switch RK5 backs up the operation of the RK4 and at the same time switches on the buzzer on the platform 4 Depressing the emergency stop button stops all the movements immediately and turns off the power unit The emergency stop button must be pulled up before starting the power unit 1 Ensure the operation of the safety devices do not lock the cover of the chassis control centre with key while the lift is in operation PRESSURE SPING pets d LIMIT SWITCHES RK4 and RK5 ARTICULATED ARM LIFT CYLINDER 22 160 180 210XT 3 RKS d RK11 RK12 RK13 RK14 23 M O Oi Hour meter Choke 160 180 210XT OPERATING CONTROLS IN THE CHASSIS CONTROL CENTRE Selector switch 0 switched off 1 outrigger circuit and hydraulic drive 2 controlling the boom from the platform centre 3 controlling the boom from the chassis centre Start button Emergency stop button Green signal light for outrigger limit switches Red signal light for safety device RK5 Start button for emergency descent system Pushbutton for retracting the telescope Lever switch for turning Lever switch for boom system Lever switch for telescope Voltage meter Stop button Lever switch for levelling o
101. tform 160XT 270 kg 180XT and 210 XT 215 kg 4 Lift the boom to as high as it goes and extend the telescope to its full length maximum lifting height 5 Lower the boom until the safety device stops the movement 6 Turn the boom round over 360 7 Retract the telescope and lower the boom to a horizontal position 8 Extend the telescope until the safety limit switch RK4 stops the movement Establish the standing stability in this situation by turning the lift round over 360 9 Carry out the same procedure with load Il on Test load II the platform 160XT and 180XT 270 kg 210 XT 80 kg 10 Compare the outreach with the reach diagram and as necessary readjust according to the instructions for Adjustment of the overload limit switches After the above mentioned test loadings case and case II and the subsequent inspection have been completed without finding any defects in the structure or stability of the lift the lift may be used inside the permitted operating range presented in the reach platform load diagram of this manual The max allowed load on the platform is 215 kg in conjunction with the first i e start up inspection the lift shall be subjected to an overload test with an excess load of 50 and after that the supporting structures shall be thoroughly inspected in conjunction with the annual inspection the lift shall be subjected to a regular inspection a test run and a test l
102. the tow bar the limit switch on the transport support prevents operation of the support outriggers if the platform is not down Close the control centre cover on the work platform Turn the selector switch 1 to position outriggers Lift the support outriggers atfirst the rear support outriggers do not damage the rear lights then the front support outriggers do not damage the jockey wheel Apply the parking brake Make sure that the driving device is disconnected Turn the selector switch to position 0 and disconnect the lift from the power supply 10 Make sure that the covers are locked 48 160 180 210XT 18 CONNECTING TO THE TOWING VEHICLE 1 Lift up and push forward in the driving direction the handle of the ball coupling Now the ball coupling is released 2 Press the ball coupling onto the towball using only a little force The connection and locking take place automatically Always make sure after the connection that the ball coupling is properly locked Clean and lubricate the ball coupling regularly 3 Connect the emergency stop wires and light plug to the vehicle Check the cable for chafing and proper operation of the wires 4 Check the operation of the lights 5 Carefully release the parking brake and make sure that its locking is in order and that its handle stays in the lower position 6 Lift up the jockey wheel to the transpor
103. throw any objects from the platform The lift must not be used for transferring goods or persons between different floors or working levels Never disable the operation of any safety device Always make sure before lowering the platform that the area on the underside is clear of any obstructions Avoid damaging the platform by lowering it on the ground or bringing it in contact with any structures When working in busy areas the operating range of the lift must be clearly marked by using either warning lights or fencing Also observe the regulations of the Road Traffic Act 17 UP THE JOB 160 180 210XT Beware of the live aerial power lines in the area observe the minimum safety distances AA Voltage Min distance below Min distance at the side 100 400 V hanging spiral 0 5 0 5 cable 100 400 V open wire cable 2 2 6 45kV 2 9 110 kV 5 220 kV 4 5 400 kV 5 5 Keep the lift free of any dirt which may impair safe operation and impede the inspection of the structures The device must be serviced and inspected regularly Only skilled persons familiar with the service and repair instructions are allowed to carry out servicing and repair work It is strictly prohibited to use a lift which is out of order The device must neither be altered without the manufacturer s consent nor be used under conditions which do not meet the
104. tions or cracks No fractures or cracks are allowed in the welded seams check the footplates for deformations cracks or breaches Also check that the footplate can turn freely on its joint inspect the boom extend the telescope and check that there are no permanent deformations dents or traces of substantial wear in the boom also check the welded seams for wear cracks or breaches check the boom attachment for cracks or breaches check the condition of the platform brackets check the locking of the platform pin check the condition and attachment of the flyer chain the locking of the pins and the tightness of the spring 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 substantial wear or buckles check that the handrails the steps the gate and the attachment of the gate are in order check that the lock of the gate and the gas spring are in order check the condition of the platform floor plate check the platform carrier for notable buckles or deformations check all the protective covers check the condition of the support outrigger cylinder guards check the condition of the slave cylinder guard check the condition of the boom end cover turning device covers chassi
105. to the side by retracting the telescopic boom using the emergency descent system Avoid abrupt movements 4 Turn the boom away from the danger zone i e to a position where the stability of the lift is normal 5 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 IN THE EVENT 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 a safe manner 3 Reduce the outreach to the side by retracting the telescopic boom using the emergency descent system 4 The green light will illuminate as soon as the overloading situation is reset After this the machine may be operated normally IN CASE THE POWER SUPPLY IS INTERRUPTED diesel mains 1 Lower the boom using the emergency descent system see point Emergency descent system 2 In case of emergency the outriggers can also be operated using the emergency descent system Note The movements are notably slower when operated by the emergency descent system B DIN lift UP TO THE JOB 160 180 210XT 3 Find out the reason why the energy supply was interrupted IN CASE OF MALFUNCTION WHEN EVEN THE EMERGENCY DESCENT SYSTEM IS
106. turer of the lift do not modify the lift without written consent from the manufacturer any such faults which may affect the operational safety of the unit must be repaired before 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 articulated arms 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 the device may be lifted with two slings each with a load carrying capacity of at least 2 500 kg by slinging it at the four lugs see picture Be careful not to damage the device during the lifting operation 50 UP THE JOB 160 180 210XT E 19 2 SERVICE AND INSPECTION INSTRUCTIONS 1 The first service after 20 hours of operation change the pressure filter element adjust the brakes according to the instructions see point Wheel brakes and bearings check the wheel bolts for tightness 160XT 90 Nm 180XT and 210XT 325 Nm after about 100 km of driving 2 Daily service check the oil level in the hyd
107. und clockwise 7 Intensity adjustment of frequency the lift in boom mode the power unit is not running Turn at first the adjustment screw 4 on the control card to its minimum position extreme position counter clockwise After that turn it 1 4 round clockwise 8 Adjustment of the ascending ramp the lift in the boom mode the power unit is not running Turn at first the adjustment screw 5 on the control card to its minimum position extreme position counter clockwise After that turn it 1 5 round clockwise 9 Adjustment of the descending ramp the lift in the boom mode the power unit is not running Turn at first the adjustment screw 6 on the control card to its minimum position extreme position counter clockwise The descending ramp is not used 10 Adjustment of min current of the control card the lift in the boom mode the power unit is not running 10 1 The intensity of current increases as the screw is turned clockwise 10 2 Adjust the minimum current to Imin 300 mA 11 Adjustment of min current of the control card the lift in the boom mode the power unit is not running 11 1 the max current is adjusted via the screw 1 on the control card 11 2 drive the boom up movement 11 3 carry out the adjustment during the lifting the current increases as the screw is turned clockwise adjust the max current to Imax 1 500 mA start the power unit and extend the telescope for 10 seconds Measure the stroke of the cylinder T
108. until it stops Do not correct the position of the platform Measure the length of the projecting part of the telescope extension L 160XT L 2 000 mm 50 mm 180 L 2 450 mm 50 mm 210XT L 3 100 mm 50 mm Make sure that a red signal light on the platform is illuminated the second safety limit switch RK5 backs up if the outreach limit switch RK4 fails disable the RK4 for testing by disconnecting the conductor from the terminal X1 43 and connecting the terminals X3 25 and X1 41 inside the chassis control centre with a jumper lead In addition connect the points X1 and X2 of the relay SR3 using another jumper lead Remember to restore the operation of the RK4 by connecting the conductor to the terminal block X1 43 and removing the jumper leads retract and extend the boom and measure the length of the telescope extension s projecting part 160XT L 2 250 mm 50 mm The measure must 480 L 2 900 mm 50 mm 210XT L 3 600 mm 50 mm if the projecting part is too long adjust the limit switches and secure them again with a seal 00111 UP TO THE JOB 160 180 210XT ADJUSTING THE OVERLOAD LIMIT SWITCHES PRESSURE SPING LIMIT SWITCHES RK4 and RK5 _ gt o ARTICULATED ARM LIFT CYLINDER Always check the operation of both limit switches in connection with the service Adjustme
109. value 16 MPa 160 bar check valve direct current motor of 800 W Start the emergency descent system by depressing the pushbutton 20 on the platform and 5 on the chassis The emergency descent system is operational only when the pushbutton is being depressed Using the emergency descent retract first the telescope completely then lower the boom and finally turn the boom The emergency descent system can also be used for raising the support outriggers to the transport position If the emergency descent system does not operate try to attract the attention of other personnel present on the site so that they can restore the power supply to the lift or make its emergency system operational by for example changing the battery Always check the condition of the battery for the emergency descent system before putting the lift into operation See point Operation of the safety devices 42 UP THE JOB 160 180 210XT 13 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 if the inclination of the surface is more than 5 cent i e more than 1 20 corresponding to a descent of 0 5 m over a distance of 10 m If the gradient of the surface is greater than this you may lose control of the device 2 When driving on a slope the tow bar must always poi
110. ver 8 and extend the telescope 1 2 metres using lever 9 keeping the emergency stop button depressed the movement shall now 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 platform from the tow bar and turn it to the side so that you can lower it 5 extend the telescope as much as is necessary to ensure that stepping onto the platform is safe 33 160 180 210XT _ boom around carefully in the lower position to make sure that the 6 If you have levelled the chassis of the lift ON A GRADIENT turn the boom does not bang against the support outriggers 7 turn the boom to the side so that you can lower it 8 extend the telescope as much as is necessary to ensure that stepping onto the platform is safe 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 centre 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 160 180 210XT 11 2 OPERATING THE LIFT FROM THE PLATFORM CON
111. while the lift is in the transport position 3 Check the hydraulic hoses and pipes Replace any hoses with external damage or clashed pipes Check the connections 60 UP THE JOB 4 160 180 210XT p Inspect the joints of the support outrigger lower the outriggers slightly Swing the outriggers back and forth in the horizontal plane and check the joints for play 160XT and 180XT check the operation and condition of the limit switch mechanisms on the outriggers replace any worn out parts lubricate the joints see point Lubrication plan Lower the outriggers to the support position 5 Inspect the cylinders and lubricate the joint bearings see Lubrication plan drive the lifting cylinder into its upper position from the chassis control centre and check the connections for tightness and the condition of the piston rod drive the lifting cylinder into its lowest position from the chassis control centre and check the connections for tightness retract and extend the telescope cylinder from the chassis control centre and check the condition and tightness of the cylinder lubricate the joints of the lifting cylinder the telescope cylinder and the levelling cylinders extend the articulated arm cylinders from the control centre on the chassis and inspect their condition and tightness inspect the outrigger cylinders and lubricate their joints UP THE JO

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