Dinolift DINO 160XT II Maintenance Instructions Manual
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Dinolift DINO 160XT II Maintenance Instructions Manual

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MAINTENANCE INSTRUCTIONS
Manufacturer:
Raikkolantie 145
FI-32210 LOIMAA
Tel. +358 20 1772 400
info@dinolift.com
www.dinolift.com
160XT II
180XT II
210XT II
Dealer:

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  • Page 1 MAINTENANCE INSTRUCTIONS 160XT II 180XT II 210XT II Manufacturer: Dealer: Raikkolantie 145 FI-32210 LOIMAA Tel. +358 20 1772 400 info@dinolift.com www.dinolift.com...
  • Page 3 DINO XT II ORIGINAL INSTRUCTIONS Valid from serial number: 160XT II 17156 -> 180XT II 20001, 30002 -> 210XT II 3370 ->...

  • Page 4: Table Of Contents

    DINO XT II TABLE OF CONTENTS TO THE MAINTENANCE PERSONNEL ..............6 1.1. WARRANTY TERMS ................... 7 1.2. SAFETY AND THE ENVIRONMENT..............8 1.2.1. General safety instructions for maintenance .......... 8 1.2.2. Chemicals ....................9 1.2.3. Materials and recyclability ............... 9 1.3.
  • Page 5 DINO XT II 4.2.7. Lubrication of the driving device ............23 4.2.8. Check the adjustment of the outreach limit switch RK4 ......24 4.2.9. Check the load holding and load regulation valves ......24 4.3. INSTRUCTIONS FOR ANNUAL MAINTENANCE AND INSPECTIONS ... 26 4.3.1.

  • Page 6: To The Maintenance Personnel

    Dinolift Oy is constantly developing its products. For this reason, the contents of this manual might not always be in full compliance with the most recent version of the product. Dinolift Oy reserves the right to modify the product without prior notice. Dinolift Oy assumes no liability for any problems caused by changed or missing data or mistakes in this manual.

  • Page 7: Warranty Terms

    DINO XT II 1.1. WARRANTY TERMS 1§ Dinolift Oy, hereinafter called the 5§ No claim will be accepted if non-original Supplier, warrants new aerial work parts or parts not approved by the platforms supplied by the company to Supplier have been used. be free from defects in material and 6§...

  • Page 8: Safety And The Environment

    DINO XT II 1.2. SAFETY AND THE ENVIRONMENT 1.2.1. General safety instructions for maintenance Excercice extreme caution in all service, maintenance, toubleshooting and repair works. A faulty device or a device where covers, safety devices or other parts have been removed or disabled, may function in an unexpected way.

  • Page 9: Chemicals

    DINO XT II 1.2.2. Chemicals Type Volume Mobil EAL 32 Hydraulic oil 20 l Kendall Megaflow AW HVI 22 Hydraulic oil (winter option) Neste Hydrauli 28 Arctic 20 l Mobilux EP2 NLGI 2 Lubricant Mobil Grease XHP 222 Chain lubricant Würth HHS Grease 0,6 l (Honda) Engine oil (in platforms with SAE 10W-30...
  • Page 10 DINO XT II HA-oils (in tread) Tyres can be recycled. Zinc (in tread) Note the national and local regulations and policies. Cadmium (in tread) *Option Other materials Steel, aluminum, cast iron Metals Hydraulic pipes and components Recyclable Power pack, axles Covers, mudguards (ABS, PE) Plastics Recyclable Tyres Battery...

  • Page 11: Safety Messages

    DINO XT II 1.3. SAFETY MESSAGES The following safety alert symbols and safety signal words are used in this manual. Obey all safety instructions that follow these symbols, in order to avoid dangerous situations and personal injuries. This is a general safety alert symbol and it is used to alert you to a potential hazard. Obey all safety messages that follow this symbol.

  • Page 12: Servicing And Maintenance

    DINO XT II SERVICING AND MAINTENANCE Maint. Schedule Person responsible Reference Operating Daily Operator instructions Maintenance 1 month / 100 hours* Competent person who is familiar with the lift instructions 6 months / 500 Maintenance Competent person who is familiar with the lift hours* instructions Annually / 1000...
  • Page 13 DINO XT II Maintenance item Axles and suspension Driving device Lights Hydraulic oil Hydraulic hoses, pipes and fittings Condition and attachment of battery, electrical devices and wiring Hydraulic pressure Condition of safety limit switches Operation of safety limit switches Operation of overload protection device Load holding and load regulation valves Platform levelling system Platform control devices...

  • Page 14: Inspections Required By Authorities

    DINO XT II 2.1. INSPECTIONS REQUIRED BY AUTHORITIES Inspections must be performed in accordance with local, state or federal regulations, legislation, directives, standards. The manufacturer recommends following inspections, as required by local authorities in platforms country of origin. A pre-use inspection must be done before taking the platform to use for the first time and before first start-up after major repairs and alterations. A thorough inspection and a test loading of the lift must be carried out at least once every twelve (12) months.

  • Page 15: Lubrication Plan

    DINO XT II 2.2. LUBRICATION PLAN...

  • Page 16: Routine Maintenance During Operation

    DINO XT II ROUTINE MAINTENANCE DURING OPERATION This chapter describes the service and maintenance operations that the operator of the platform is responsible for. Other maintenance operations require special training, tools and materials or specific measurements and adjustment values. They are separately described in maintenance instructions manual. Please contact your maintenance partner, dealer or manufacturer. Make sure that all service and maintenance prochedures are performed in time and according to instructions.

  • Page 17: Daily Maintenance Tasks

    DINO XT II 3.1. DAILY MAINTENANCE TASKS 3.1.1. Condition of chassis, boom and work platform Inspect visually the condition of access systems, work platform, platform gate and handrails. Check that the chassis and boom have no visible signs of structural damage. 3.1.2.

  • Page 18: Check The Emergency Descent, Emergency Stop And Sound Signal

    DINO XT II 3.1.7. Check the emergency descent, emergency stop and sound signal Test the correct operation of emergency stop, emergency descent system and the sound signal from the lower controls and platform controls. • lift the boom up approximately 1-2 meters and drive the telescope out 1-2 meters. While driving the movement, push down the emergency stop button. The movement should stop.

  • Page 19: Periodic Service

    DINO XT II PERIODIC SERVICE Periodic service shall be done according to these instructions. These maintenance and service prochedures shall be performed by competent maintenance personnel. 4.1. INSTRUCTIONS FOR MONTHLY SERVICE AND INSPECTION Always do all daily inspections in addition to monthly service tasks. If you notice any flaws, defects or damage to the lift, take necessary corrective action.

  • Page 20: Check The Coupling Device And Overrun

    DINO XT II 4.1.3. Check the coupling device and overrun Check the condition of the coupling device and the overrun devise. Check the brakes. Adjusting the brakes 1. Support the lift by raising its wheels off the ground. 2. Make sure that the wheels can rotate freely.

  • Page 21: Check The Levelling System

    DINO XT II 4.1.6. Check the levelling system A so-called Slave Cylinder System is applied for levelling of the platform. The slave cylinder under the platform is controlled by 21,5 Mpa 21,5 Mpa 215 bar a master cylinder. 215 bar 3100 psi 3100 psi The platform keeps its level position only if the valves in the system are tight.

  • Page 22: Instructions For Service And Inspections Every 6 Months

    DINO XT II 4.2. INSTRUCTIONS FOR SERVICE AND INSPECTIONS EVERY 6 MONTHS These service measures must be done between annual service at every 6 months or 500 hours, whichever comes first. Always do all daily inspections and monthly service measures in addition to the service tasks described here.

  • Page 23: Lubrication Of The Coupling Device And Overrun

    DINO XT II 4.2.5. Lubrication of the coupling device and overrun Number 13 in lubrication plan. If necessary, apply a thin grease film on the moving parts of the ball-coupling 4.2.6. Brakes The following procedures must be done every 13,000 - 15,000 km or every six months: • check the brake linings for wear • check the operation of the overrun brake DANGER • lubricate the sliding parts of the overrun brake The wheel bearings are lubricated for life and do not require any service.

  • Page 24: Check The Adjustment Of The Outreach Limit Switch Rk4

    DINO XT II 4.2.8. Check the adjustment of the outreach limit switch RK4 To check the correct adjustment of the outreach limit switch RK4: 1. Put a carefully weighed test load on the platform according to the picture: 160XT II: w = 270 kg 180XT II: w = 215 kg 210XT II: w = 80 kg 2.
  • Page 25 DINO XT II DANGER WARNING CAUTION Service instructions 1. Disconnect and clean the valve NOTICE 2. Check the O-rings and replace, if necessary The valve can only be opened 2-3 times before 3. Put the valves carefully in place it has to be replaced. Otherwise it may start to 4. Replace the valve, if necessary DANGER leak.

  • Page 26: Instructions For Annual Maintenance And Inspections

    DINO XT II 4.3. INSTRUCTIONS FOR ANNUAL MAINTENANCE AND INSPECTIONS Annual servicing must be done every 12 months or 1000 hours of operation, whichever comes first. This list contains all annual maintenance tasks and inspections. Daily, monthly or 6 month services are not needed in addition. DANGER Under demanding conditions where moisture, 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 WARNING...

  • Page 27: Inspection Of Support Outrigger Joints

    DINO XT II • check the boom attachment for cracks or breaches • check the play and attachment of the gliding surfaces on the boom and adjust the pads if necessary. Lubricate the sliding surfaces. • check the condition of the cable chain, its clamp brackets as well as the tightness of the screw connections •...

  • Page 28: Inspection Of The Flyer-Chains

    DINO XT II 3. Lubricate the joints of the lifting, telescope and levelling cylinders 4. Check the condition of the slave cylinder guard 5. Articulated arm cylinders • extend the articulated arm cylinders from the lower control panel • check the condition of the cylinder, piston rod and the wiper ring of the cylinder and inspect the connections for tightness 6.

  • Page 29: Inspection Of The Turning Device

    DINO XT II 4.3.5. Inspection of the turning device Perform overall visual inspection of the turning device and its weldings. Check especially the attachment of joints and angular gear. DANGER Inspect the turning device • general condition • check the play and attachment of the angular gear WARNING •...

  • Page 30: Jockey Wheel Slide And Threads

    DINO XT II 4.3.8. Jockey wheel slide and threads Lubricate the jockey wheel slide and threads. Number 10 in lubrication plan. 4.3.9. Inspect the brakes 1. remove the wheels 2. clean the brake system and check the settings 3. check that the brake shoes can move, and that their springs properly return them 4.

  • Page 31: Change Hydraulic Oil And Filters

    DANGER DINO XT II WARNING 4.3.13. Change hydraulic oil and filters CAUTION Protect your skin against the hydraulic oil. Used oils can be harmful to the skin. NOTICE To change oil and filters: 1. drain the oil tank through the draining plug opening, with all cylinders in retracted position 2.

  • Page 32: Measure Hydraulic Pressures

    DINO XT II • check the condition of the mains cable plug • check the condition of the electric motor 4.3.16. Measure hydraulic pressures 1. connect the pressure gauge to the measuring point (MP) 2. make the oil flow through the relief valve by driving one of the movements against the end stop 3. read the peressure from the gauge max. pressure with warm oil (40–60 °C): 20–21,5 MPa (200–215 bar) turning pressure 5,5-7,0 MPa (55-70 bar) if you have to readjust the pressure setting, secure the new setting with a seal.

  • Page 33: Inspection Of Correct Operation Of Safety Devices

    DINO XT II 4.3.18. Inspection of correct operation of safety devices Check the operation of the safety devices operated from the chassis control panel: 1. Lift the platform up from the boom support • support outriggers must not work 2. Lower the boom to boom support and lift the outriggers •...
  • Page 34 DINO XT II 3. Extend the telescope until it stops. Do not correct the position of the platform. 4. Make sure that a red signal light on the platform is burning. 5. Measure the stroke (L) and compare it to the values given below. The length shall be: 160XT II: L = 1925 mm + 0 mm / - 50 mm 180XT II: L = 2300 mm + 0 mm / - 50 mm 210XT II: L = 3025 mm + 0 mm / - 50 mm 6. If the stroke is too long, adjust the limit switch and secure its position with a seal. The overload limit-switch RK5 will back up if the outreach limit switch RK4 for some reason would not work.

  • Page 35: Inspection Of The Operating Controls On The Platform

    DINO XT II 4.3.20. Inspection of the operating controls on the platform Check the operating controls on the platform • check the overall condition of the electric appliances inside the box and spray with moisture repellent, if necessary • check the cables and the tightness of the cable clamps •...

  • Page 36: Adjustment Of The Movement Speeds

    DINO XT II 4.4. ADJUSTMENT OF THE MOVEMENT SPEEDS Measuring devices required for the adjustment: • volt-ohm-milliammeter with possibility to measure direct current (A) • screwdriver with narrow tip for adjusting the trimmer 1. 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 pic01.
  • Page 37 DINO XT II 8. 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. 9. Adjustment of min. current of the control card (the lift in the boom-mode, the power unit is not running) 9.1 The intensity of current increases as the screw is turned clockwise.
  • Page 38 DINO XT II 13. Adjusting the lowering speed of the boom 13.1 Drive the ”boom down” movement and simultaneously adjust the intensity of current via the adjustable resistor TR11 to I =1,250 mA. lower 13.2 Check the lowering speed of the boom -> start the power unit, and retract the telescope. Lift the boom until the floor of the platform reaches the height of 2,8 metres. 13.3 Lower the boom to its lowermost position (over a distance of 2 m). The lowering should take about 13 seconds. As necessary, adjust it via the trimmer TR11. 14. Lowering the articulated arms Drive the “articulated arms down” movement and simultaneously adjust the intensity of current using the adjustable resistor TR12 to I =1400 mA.

  • Page 39: Adjustment Of Outreach- And Overload Limit Switches

    DINO XT II 4.5. ADJUSTMENT OF OUTREACH- AND OVERLOAD LIMIT SWITCHES While adjusting the limit switches, use the same test loads as in testing the limit switches. The adjustment of the limit switches may only be carried out after the raising of the platform´s rear edge To adjust overload limit switch RK5 1.

  • Page 40: Fault Finding

    DINO XT II FAULT FINDING 5.1. PROBLEMS WITH POWER SUPPLY FAULT REMEDY 1. Electric motor cannot be started by depressing the start button, although the selector switch 1 is in position LCB or UCB The emergency stop button has jammed in Pull up the button and re-start the motor from the lower position.
  • Page 41 DINO XT II Check, whether the fault is in the electric system or in the hydraulic system. FAULT REMEDY 3. 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).

  • Page 42: Problems With Movements

    DINO XT II 5.2. PROBLEMS WITH MOVEMENTS FAULT REMEDY 5. 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 Check the operation of the outrigger limit illuminated.
  • Page 43 DINO XT II Lifting and lowering of the boom and the extension of the telescope are not The boom has been overloaded; retract the operational, the red light is illuminated on the telescope and retry the operation (automatic platform and in the chassis control centre, reset).

  • Page 44: Drifting Of Boom Or Outriggers

    DINO XT II 5.3. DRIFTING OF BOOM OR OUTRIGGERS FAULT REMEDY 12. Boom drifts slowly downwards 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. The load regulation valve leaks. 13. Telescope retracts slowly See item 12.
  • Page 45 DINO XT II FAULT REMEDY 14. Platform drifts backward Double load regulation valve on the bottom See item 12. side is leaking. Load regulation valve under the platform is See item 12. leaking. 15. Platform drifts forward Double load regulation valve on the rod side See item 12.

  • Page 46: Problems With Towing

    DINO XT II 5.4. PROBLEMS WITH TOWING FAULT REMEDY 19. Too low braking force 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 kilometres. Brake-shoes "glazed", dirty or oil on the Replace the brake-shoe sets. friction surfaces. Clean the friction surfaces of the brake drum.
  • Page 47 DINO XT II 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 Dismantle, clean and lubricate the overrun jams. transmission rod. Parking brake not completely released. Release the parking brake completely. 25.

  • Page 48: Hydraulic System

    DINO XT II HYDRAULIC SYSTEM 6.1. 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. Using the selection valve boom/chassis is not required for retraction of the telescope. 4.
  • Page 49 DINO XT II Vakiokone / Standard machine / Standardmaschine / Standardmaskin / Standard maskine...
  • Page 50 DINO XT II Automaattitasauksella / Automatic levelling / Automatische Nivellierung / Automatik nivellering / Automatisk avbalansering / Automatisk nivellering...

  • Page 51: Electric System

    DINO XT II ELECTRIC SYSTEM 7.1. ELECTRIC COMPONENTS Device ID’s used in the electric diagam and component functions are described in this chapter. Spare part numbers of main components are included in a separate spare part list. CHASSIS CONTROL CENTRE (LCB), RELAYS START CONTACTOR (M1) FOR THE ENGINE Control circuit fuse F2 10A.
  • Page 52 DINO XT II K16: LEVELLING THE PLATFORM Levelling the platform forward Control circuit fuse F9 1,6A (Platform control centre) and F4 10A (Chassis control centre). K17: 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 K18: SPEED The relay switches over the control voltage from the propo-card to the adjustable resistor for the boom/levelling of platform.
  • Page 53 DINO XT II K27: AUXILIARY RELAY FOR CURRENT SUPPLY TO THE DRIVING DEVICE The relay is controlled by the limit switch RK3. Fuse F3 10A. K28: 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.
  • Page 54 DINO XT II SWITCH-OFF-RELAY FOR THE FUNCTIONS CONTROLLED FROM THE CHASSIS CONTROL K60: CENTRE Switches off the voltage supply to all the other boom movements during levelling of the platform. SR2: Safety relay monitoring the operation of the outriggers The safety relay resets as soon as all the outrigger safety limit switches (RK11, RK12, RK13 and RK14) have closed. After that it is possible to operate the boom. SR3: SAFETY RELAY FOR MONITORING THE OVERLOADING OF THE BOOM Safety limit-switch RK5 controls the operation of the safety relay.
  • Page 55 DINO XT II S20: LEVELLING OF THE PLATFORM FORWARD-BACKWARD Non-locking lever switch (chassis control centre). S32: TELESCOPE IN Non-locking button switch. After the SR3 has tripped, the telescope can be retracted by depressing the button. S40: COMBUSTION ENGINE CHOKE Non-locking button switch. Depressing the button keeps the choke of the combustion engine active. CHASSIS CONTROL CENTRE (LCB), OTHER ITEMS 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...
  • Page 56 DINO XT II TR11: ADJUSTABLE RESISTOR Adjustable resistor for the movement speed when operating from the chassis centre. TR12: ADJUSTABLE RESISTOR Adjustment of the articulated arms’ lowering speed. VOLTAGE METER As the control voltage is connected the voltage meter indicates the alternating voltage reading. PLATFORM CONTROL CENTRE (UCB), RELAYS K41b: SENSOR RELAY FOR THE AC SUPPLY...
  • Page 57 DINO XT II S11: 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. S12: 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 S12.
  • Page 58 DINO XT II LIMIT SWITCHES RK3: 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. RK4: SAFETY LIMIT SWITCH FOR THE ADJUSTED OPERATING RANGE The operation of the limit switch stops the “boom down” movement and the “telescope out”...

  • Page 59: Electric Diagram

    DINO XT II OTHER MARKINGS BATTERY 12VDC 44AH THERMORELAY FOR THE ELECTRIC MOTOR F11: MAIN BATTERY FUSE 125A PLUG ELECTRIC MOTOR 230VAC 1.5kW EMERGENCY DESCENT MOTOR 12VDC Max. operating time 10 min. ROTARY ADAPTOR The electric circuits between the chassis and the turning device go through the electric rotary adaptor.
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