STINAR DPT-512 Manuale

sales@stinar.com |P651.454.5112 |F651.454.5143 |www.stinar.com

DISABLED PASSENGER LIFT

OPERATION & MAINTENANCE MANUAL

MODEL: DPT-512

SERIAL NO: 25781

MANUFACTURE DATE: 09/2021

REV.02.2022

Disabled Passenger Lift DPT-512 | 2

Eective Pages SECTION PAGE DATE

Title Page 1October 2021

List of Eective Pages 2October 2021

Contents 3-5 October 2021

Introduction 6October 2021

SECTION 1

Introduction 7-10 October 2021

Section 1-1 11-30 October 2021

Section 1-2 31-44 October 2021

Section 1-3 45-48 October 2021

SECTION 2

Introduction 49 October 2021

Section 2-1 50-56 October 2021

Section 2-2 57-71 October 2021

Section 2-3 72-74 October 2021

SECTION 3

Introduction 75 October 2021

SECTION 4

Introduction 76 October 2021

Section 4-1 77 October 2021

Section 4-2 78 October 2021

Parts Order Form 79 October 2021

FIGURES

Disabled Passenger Transporter, Model DPT-512 80-83 October 2021

Electrical System 84-89 October 2021

Hydraulic System 90-91 October 2021

Scissors Assembly 92-93 October 2021

Platform Assembly 94-95 October 2021

Van body Interior 96-98 October 2021

Rear Stabilizer Assembly 99-100 October 2021

Front Stabilizer Assembly 101-102 October 2021

Emergency Lift Gate Manual Override

Schematic 103-104 October 2021

Electrical Box Interior 105-106 October 2021

Cab Controls and Indicators 107-108 October 2021

Van Body Control Station 109-110 October 2021

Rear Van Control Station 111-112 October 2021

Disabled Passenger Lift DPT-512 | 3

Table of Contents MANUAL OVERVIEW � � � � � � � � � � � � � � � � � � � � � � � � � � 7

SECTION 1 | GENERAL INFORMATION & OPERATING

PROCEDURES � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8

1�1 | Description � � � � � � � � � � � � � � � � � � � � � � � � � � � 11

1.1.1 | Equipment Systems and Components . . . . . . . . . . . . . . . . . . . 11

1.1.1.1 | Truck Chassis-cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Figure 1.1.1 | Disabled Passenger Transporter, Model DPT-512. . . . . . . . .12

Figure 1.1.1 | Disabled Passenger Transporter, Model DPT-512. . . . . . . . .13

1.1.2 | Hydraulic Stabilizers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.1.3 | Body Lift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.1.4 | Van Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.1.5 | Front Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.1.6 | Screen Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.1.7 | Power Lift Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.1.8 | Generator Set and Related Components . . . . . . . . . . . . . . . . . 17

Figure 1.1.9 | Hydraulic System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . .18

1.1.9 | Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.1.10 | Power Lift Gate Electro-Hydraulic System . . . . . . . . . . . . . . . 21

Figure 1.1.10 | Hydraulic Component Group . . . . . . . . . . . . . . . . . . . . . . . . .22

1.1.11 | Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.1.11.1 | Master Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.1.11.2 | Intercom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Figure 1.1.11 | Electrical System Schematic (Page 1 of 4) . . . . . . . . . . . . . .28

Figure 1.1.11 | Electrical System Schematic (Page 2 of 4) . . . . . . . . . . . . . .29

Figure 1.1.11 | Electrical System Schematic (Page 3 of 4) . . . . . . . . . . . . . .30

Figure 1.1.11 | Electrical System Schematic (Page 4 of 4) . . . . . . . . . . . . . .31

1�2 | Operation � � � � � � � � � � � � � � � � � � � � � � � � � � � � 32

1.2.1 | Operating Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . .32

1.2.1.1 | Cab Controls and Indicators (See Figure 1.2.1.1) . . . . . . . . . . . . 32

Figure 1.2.1.1 | Cab Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . .33

1.2.1.3 | Van Body Control Station (See Figure 1.2.1.3) . . . . . . . . . . . . . . . 34

1.2.1.4 | Rear Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Figure 1.2.1.3 | Van Body Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . .36

1.2.1.5 | Generator Set Operating Controls . . . . . . . . . . . . . . . . . . . . . . . 37

1.2.1.6 | Mini Split Unit Operating Controls. . . . . . . . . . . . . . . . . . . . . . . . . 37

1.2.1.7 | Emergency Operating Controls (See Figure 1.2.1.7) . . . . . . . . . . . . . 37

Figure 1.2.1.7 | Emergency Operating Controls . . . . . . . . . . . . . . . . . . . . . .38

1.2.2 | Pre-Operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

1.2.3 | Operating Procedures – Normal Operation . . . . . . . . . . . . . . 40

1.2.3.1 | Starting and Driving Unit – Engine and Transmission . . . . . . . . . 40

1.2.3.2 | Operating the Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Disabled Passenger Lift DPT-512 | 4

1.2.3.3 | Operating Stabilizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1.2.3.5 | Operating Over-Cab Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.2.3.6 | Operating Rear Lift Gate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.2.3.7 | Operating Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1.2.3.8 | Operating Van Mini Split Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1.2.3.9 | Operating Intercom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1.2.3.10 | Emergency Lift Gate Manual Override. . . . . . . . . . . . . . . . . . . 42

1.2.4 | Transporting Passengers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1.2.5 | Emergency Operating Procedures . . . . . . . . . . . . . . . . . . . . . . 44

1.2.5.1 | Emergency Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . 44

1.2.5.2 | Emergency Van Body Lowering Procedure . . . . . . . . . . . . . . . . 44

1.2.5.3 | Emergency Hydraulic System Operation . . . . . . . . . . . . . . . . . . 45

1.3 | Specications & Capabilities � � � � � � � � � � � � � � � � � 46

1.3.1 | General Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.3.2 | Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.3.3 | Truck Cab and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.3.4 | Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.3.5 | Power Lift Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

1.3.6 | Mini Split Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

SECTION 2 | SERVICING THE HIGH LIFT TRUCK� � � � � � � � � � � 50

2�1 | Servicing � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 51

2.1.1 | Use of Maintenance Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.1.2 | Truck Chassis-Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.1.2.1 | General Engine/Chassis Servicing . . . . . . . . . . . . . . . . . . . . . . . . 51

2.1.3 | Structural Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.1.3.1 | Sheet, Bar, and Tubular Member (Non-Load Bearing) . . . . . . . 51

2.1.4 | Scissors and Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.1.5 | Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.1.5.1 | Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.1.5.2 | Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.1.5.3 | Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.1.5.4 | Hydraulic Pump and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.1.5.5 | Flow Control Valve, Van Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.1.5.6 | Hydraulic Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.1.6 | Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.1.6.1 | Truck Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.1.6.2 | Control and Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.1.6.3 | Electrical Cables, Wiring, and Lights . . . . . . . . . . . . . . . . . . . . . . 53

2.1.7 | Scheduled Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2.1.8 | Non-Scheduled Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.1.9 | Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.1.9.1 | Truck Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.1.9.2 | Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.1.9.3 | Scissors Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Disabled Passenger Lift DPT-512 | 5

2.1.9.4 | Front Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

2.1.9.5 | Lubrication Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

2.1.9.6 | Special Lubrication Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Figure 2.1.9.3 | Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

2.2 | Troubleshooting � � � � � � � � � � � � � � � � � � � � � � � � 58

2.2.1 | Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Figure 2.2.1 | Hydraulic System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . .63

Figure 2.2.2 | Electrical System Schematic (Page 1 of 4). . . . . . . . . . . . . . .69

Figure 2.2.2 | Electrical System Schematic (Page 2 of 4). . . . . . . . . . . . . . .70

Figure 2.2.2 | Electrical System Schematic (Page 3 of 4). . . . . . . . . . . . . . .71

Figure 2.2.2 | Electrical System Schematic (Page 4 of 4). . . . . . . . . . . . . . .72

2�3 | Adjustments � � � � � � � � � � � � � � � � � � � � � � � � � � 73

2.3.1 | Hydraulic Pressure Relief Valve Adjustment . . . . . . . . . . . . . . 73

2.3.2 | Flow Control Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 73

2.3.2.1 | Increasing the rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

2.3.2.2 | Decreasing the rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

2.3.3 | Bleeding Air from Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . 73

Figure 2.3.1 | Hydraulic Component Group . . . . . . . . . . . . . . . . . . . . . . . . .74

2.3.4 | Hydraulic Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . 75

SECTION 3 | OVERHAUL � � � � � � � � � � � � � � � � � � � � � � � � 76

3.1 | Truck Chassis-cab � � � � � � � � � � � � � � � � � � � � � � � 76

SECTION 4 | PARTS LIST � � � � � � � � � � � � � � � � � � � � � � � � 77

4.1 | Manufacturer Identication � � � � � � � � � � � � � � � � � � 78

4.2 | Detailed Parts List � � � � � � � � � � � � � � � � � � � � � � � 79

4.2.1 | Understanding the Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.2.1.1 | Figure/Item No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.2.1.2 | Manufacturer’s Part No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.2.1.3 | Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.2.1.4 | Vendor Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.2.1.5 | QTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.2.2 | Instructions for Ordering Parts and Assemblies . . . . . . . . . . 79

PARTS ORDER FORM � � � � � � � � � � � � � � � � � � � � � � � � � � 80

Figure 4.2.1 | Disabled Passenger Transporter, Model DPT-512 (1 of 2). .81

Figure 4.2.1 | Disabled Passenger Transporter, Model DPT-512 (2 of 2). .82

Figure 4.2.2 | Electrical System (Page 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . .85

Figure 4.2.2 | Electrical System (Page 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . .86

Figure 4.2.2 | Electrical System (Page 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . .87

Figure 4.2.2 | Electrical System (Page 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . .88

Figure 4.2.3 | Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Figure 4.2.4 | Scissors Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Disabled Passenger Lift DPT-512 | 6

Figure 4.2.5 | Platform Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Figure 4.2.6 | Van body Interior (Page 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . .97

Figure 4.2.6 | Van body Interior (Page 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . .98

Figure 4.2.7 | Rear Stabilizer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Figure 4.2.8 | Front Stabilizer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .102

Figure 4.2.10 | Electrical Box Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

Figure 4.2.11 | Cab Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . .107

Figure 4.2.12 | Van Body Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Figure 4.2.13 | Rear Van Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . .111

Disabled Passenger Lift DPT-512 | 7

This publication provides operating and maintenance instructions,

including detailed part lists for the Maintenance High Lift Truck, Model

MHL-216. This truck was manufactured by:

Stinar, LLC

500 Stinar Way

Blooming Prairie, MN 55917

Section 1 | General Information & Operating

Instructions

Includes a unit description, recommended procedures for operation, plus

specications and capabilities.

Section 2 | Servicing The High Lift Truck

Provides unit maintenance information, service and lubrication data, a

troubleshooting guide, and adjustment information.

Section 3 | Maintenance

Presents instructions for component maintenance and repair.

Section 4 | Parts List

Contains a manufacturers’ list, and illustrated part lists for the

assemblies, subassemblies, and systems within the unit.

MANUAL OVERVIEW

Disabled Passenger Lift DPT-512 | 8

SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES

SAFETY ALERT SYMBOL – Look for this symbol to point out important

safety precautions.

DANGER: The word “DANGER” denotes a most serious specic potential

hazard. A forbidden practice should denitely be avoided in connection

with a serious hazard.

WARNING: The word “WARNING” is used to denote a specic potential or

hidden hazard which, if not avoided, has the potential for serious injury.

CAUTION: The word “CAUTION” is used to denote a general reminder of

good safety practices or to direct attention to unsafe practices. Following

safe behavioral practices consistent with operating and maintenance

instructions will help the operator and others avoid accident involvement.

NOTE: The word “NOTE” is used to denote something that can cause minor

machine damage or poor performance if ignored.

IMPORTANT: The word “IMPORTANT” informs the reader of something

they need to know to prevent minor machine damage if a certain

procedure is not followed.

General Safety

• Do not rush

• Do not alter your machine

• Read and follow all warning labels. Replace any labels that are

missing or illegible.

• Check all controls and operating functions of the machine in a safe

area before starting work

• Never allow unauthorized persons around machinery when

performing operation functions

• A re extinguisher and rst aid kit should be carried in the truck at

all times

SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES

NOTE:

Example

WARNING!

Example

DANGER!

Example

CAUTION!

Example

Disabled Passenger Lift DPT-512 | 9

SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES

Before Operation

1. Perform a general all-around visual inspection and equipment check

of the entire unit

2. Check all markings and nameplates for legibility.

3. Perform any checks required by airport or airline regulations

4. Always determine hydraulic oil level and ll tank to proper level

with all hydraulic cylinders fully retracted. Overlling may occur if

cylinders are not retracted which may damage the system

5. If operating at night, check compartment lights for proper operation.

6. Check lights, horn, mirrors, wipers, safety belt, and all other safety

equipment for proper operation

During Operation

Engine and Transmission

• To operate the engine, refer to the truck operator’s manual for

recommended engine starting and operating procedures

• Failure to follow towing procedure may result in transmission

damage. Please check the manufacturer’s recommendations before

towing your unit

• These procedures are suggested general operating procedures. For

specic aircraft servicing, follow procedures specied by your airline

After Operation

• Stop engine and allow machine to come to a complete stop before

leaving the cab or allowing anyone near the unit

• Remove ignition key when parked

Service Safety

• Do not clean, adjust or service this unit while it is in motion

• Periodically check tightness of nuts and bolts, and check for loose,

worn or misaligned parts. Use only approved replacement parts.

• Any new components installed during repair must include the

current safety signs specied by Stinar.

• Perform all work in accordance with authorized standard shop

practices.

• Perform no welding, cutting, patching, and such on any load bearing

or supporting structure. If such repairs are necessary, contact the

Engineering department of Stinar before making any alterations.

• Do not mix hydraulic oils of dierent specications. Oils may not

Disabled Passenger Lift DPT-512 | 10

SECTION 1 | GENERAL INFORMATION & OPERATING PROCEDURES

be compatible and could result in damage to hydraulic system

components.

• A thin oil lm should be visible on the hydraulic cylinder shaft. A

steady drip of oil indicates a need for service.

• Should there be a hydraulic system associated with this unit, always

determine hydraulic oil level and ll tank to the proper level with all

hydraulic actuating cylinders fully retracted. Otherwise, damage may

occur to the tank when the system is operated.

Your safety and the safety of those around you depend upon the operator

using care and good judgment in the operation of this unit. Know the

positions and functions of all controls before attempting to operate.

All equipment has limitations. Understand the speed, braking, steering,

stability and load characteristics of the unit before starting operation.

READ YOUR OPERATOR’S MANUAL!

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