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Dinolift 240RXT 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
205RXT
240RXT
265RXT
Dealer:

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  • Page 1 MAINTENANCE INSTRUCTIONS 205RXT 240RXT 265RXT Manufacturer: Dealer: Raikkolantie 145 FI-32210 LOIMAA Tel. +358 20 1772 400 info@dinolift.com www.dinolift.com...
  • Page 3 DINO RXT ORIGINAL INSTRUCTIONS Valid from serial number: 205RXT 20057-> 240RXT 24055 -> 265RXT 26523 ->...

  • Page 4: Table Of Contents

    DINO RXT 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 RXT 4.3.1. Inspection of chassis structures, boom, platform and platform carrier . 24 4.3.2. Inspection of support outrigger joints ............ 25 4.3.3. Inspection of the cylinders and lubrication of cylinder bearings .... 25 4.3.4. Inspection of the flyer-chains ..............26 4.3.5. Inspection of the turning device ............27 4.3.6.

  • 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 WARNING for any problems caused by changed or missing data or mistakes in this manual.

  • Page 7: Warranty Terms

    DINO RXT 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 RXT 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 RXT 1.2.2. Chemicals Type Volume Mobil EAL 32 Hydraulic oil 50 l Kendall Megaflow AW HVI 22 Hydraulic oil (winter option) Neste Hydrauli 28 Arctic 50 l Mobilux EP2 NLGI 2 Lubricant Mobil Grease XHP 222 Chain lubricant Würth HHS Grease Engine oil SAE 10W-30 5,1 l...
  • Page 10 DINO RXT *Option Other materials Steel, aluminum, cast iron Metals Hydraulic pipes and components Recyclable Power pack, axles Covers, mudguards (ABS, PE) Plastics Recyclable Tyres Battery Lead battery Recyclable Electrical Wires, components Recyclable components Glass fibre Covers Not recyclable Hydraulic hoses Not recyclable. Hazardous waste. Oils and lubricants Used oils, oily filters etc.

  • Page 11: Safety Messages

    DINO RXT 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 RXT SERVICING AND MAINTENANCE Maint. Schedule Person responsible Reference Daily Operator Operating instructions DANGER 1 month / 100 hours* Competent person who is familiar with the lift Maintenance instructions 6 months / 500 hours* Competent person who is familiar with the lift Maintenance instructions Skilled technician who is well familiar with the Annually / 1000 hours*...
  • Page 13 DINO RXT Maintenance item Engine oil 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 Emergency descend, emergency stop and...

  • Page 14: Inspections Required By Authorities

    DINO RXT 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 RXT 2.2. LUBRICATION PLAN...

  • Page 16: Routine Maintenance During Operation

    DINO RXT 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. DANGER Make sure that all service and maintenance prochedures are performed in time and according to instructions.

  • Page 17: Daily Maintenance Tasks

    DINO RXT 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 RXT 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.
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  • Page 20: Periodic Service

    DINO RXT 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 21: Check The Condition And Fastening Of The Battery And Wiring

    DINO RXT 4.1.3. Check the condition and fastening of the battery and wiring Check the condition and correct fastening of the battery. Perform visual inspection of all electric wiring. 4.1.4. 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 a master cylinder.

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

    DINO RXT 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: Check The Adjustment Of The Outreach Limit Switch Rk4

    1. Put a carefully weighed test load on the platform according to the picture. 205RXT: w = 215 kg 240RXT: w = 80 kg 265RXT: w = 80 kg 2. Drive the boom to a horizontal position from the chassis control panel.
  • Page 24 CAUTION DINO RXT Service instructions NOTICE 1. Disconnect and clean the valve 2. Check the O-rings and replace, The valve can only be opened 2-3 times before it if necessary has to be replaced. Otherwise it may start to leak. 3. Put the valves carefully in place DANGER 4. Replace the valve, if necessary 5.

  • Page 25: Instructions For Annual Maintenance And Inspections

    DINO RXT 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 26: Inspection Of Support Outrigger Joints

    DINO RXT • 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 Inspect the platform • general condition • check that the platform does not show signs of deformations, substantial wear or buckles •...

  • Page 27: Inspection Of The Flyer-Chains

    DINO RXT 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. Outrigger cyliners •...

  • Page 28: Inspection Of The Turning Device

    DINO RXT 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. Inspect the turning device DANGER • general condition • check the play and attachment of the angular gear •...

  • Page 29: Inspection Of Hydraulic Hoses, Pipes And Connections

    WARNING DINO RXT 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. clean and rinse the oil tank with suitable agent 3.

  • Page 30: Inspection Of The Battery, Elecrical Devices And Wiring

    DINO RXT 4.3.11. Inspection of the battery, elecrical devices and wiring Thorough inspection of the electric system • check that the control panel boxes are dry, clean and tight. • check the condition of the cable connections and their protection against moisture •...

  • Page 31: Inspection Of The Condition And Fastening Of Safety Devices

    3. Lower the boom to boom support and lift the outriggers • the boom must not operate 4. lower the outriggers (level the lift to operating position) 180XT II = 215 kg 5. put a test load onto the work platform according to the picture: 205RXT II: w = 215 kg 240RXT II: w = 80 kg...

  • Page 32: Testing The Outreach- And Overload Limit Switches (Rk4 And Rk5)

    DINO RXT 265RXT II: w = 80 kg 6. lift 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 4.3.15. Testing the outreach- and overload limit switches (RK4 and RK5) LIMIT SWITCHES RK4 AND RK5 PRESSURE SPRING ADJUSTMENT SCREW ARTICULATED ARM...

  • Page 33: Inspection Of The Operating Controls On The Platform

    5. Measure the stroke (L) and compare it to the values given below. The length shall be: 205RXT: L = 1350 mm +0 / -50 mm 240RXT: L = 1800 mm +0 / -50 mm 265RXT: L = 1600 mm +0 / -50 mm 6. If the stroke is too long, adjust the limit switch and secure its position with a seal.

  • Page 34: Test Loading

    DINO RXT DANGER 4.3.17. Test loading WARNING The correct operation of outreach- and overload limit switches RK4 and RK5 must be CAUTION done before test loading! ( I ) 1. Place the lift on an even surface with good carrying capacity. Drive the outriggers to their NOTICE lowest position (the minimum support width).

  • Page 35: Adjustment Of Outreach- And Overload Limit Switches

    205RXT: w = 215 kg of the platform´s rear edge 100 mm 240RXT: w = 80 kg 265RXT: w = 80 kg To adjust overload limit switch RK5 1. Remove the cover 2.

  • Page 36: Special Inspection

    DINO RXT 4.5. SPECIAL INSPECTION (INSPECTION AFTER AN EXCEPTIONAL SITUATION) The inspection is required if the lift has been damaged in a manner which may affect its load-bearing capacity or safe operation. • in this case the lift shall be inspected according to the instructions for the annual inspection •...

  • Page 37: Fault Finding

    DINO RXT FAULT FINDING 5.1. PROBLEMS WITH POWER SOURCE FAULT REMEDY 1. The engine does not start Switch on the main switch and activate the current feed by depressing the pedal switch The main current is not connected. (OK1) or by executing some movement (OK2). Emergency stop button is stuck.

  • Page 38: Problems With Platform Movements

    DINO RXT 5.2. PROBLEMS WITH PLATFORM MOVEMENTS FAULT REMEDY 3. None of the platform movements is operational though the outriggers are down, the driving is operational Make sure that the outriggers are steady The outrigger signal light between the supported on the ground. Check operation of outrigger control levers is not illuminated.

  • Page 39: Drifting Of Boom Or Outriggers

    DINO RXT FAULT REMEDY 7. Boom cannot be lifted Refer to item 6. The solenoid valve is in the neutral or in the lowering position. Remedy as instructed above in conjunction with the seizure of the electric valve spool. 8. Telescope movement does not operate Refer to item 6.

  • Page 40: Driving Device Does Not Operate

    DINO RXT FAULT REMEDY 11. Platform drifts backward Double load regulation valve on the bottom See item 10. side is leaking. Load regulation valve under the platform is See item 10. leaking. 12. Platform drifts forward Double load regulation valve on the rod side See item 10.

  • Page 41: Hydraulic System

    DINO RXT HYDRAULIC SYSTEM 6.1. GENERAL INFORMATION ON HYDRAULIC SYSTEM All main components and pipes, hoses and fittings are described in detail in a separate spare parts list accompanying the platform. Detailed drawings and part numbers for all components are included in the spare parts list. Block valve connections are marked with identifying letters or letter and number combinations that can be found in the valve block and spare part drawings and hydraulic diagram.
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  • Page 44: Electric System

    DINO RXT 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. MAIN CONTROL CENTRE Start contactor of electric motor M1(optional extra) Contactor of EMERGENCY STOP button.
  • Page 45 DINO RXT By-pass relay for the boom raising Passes by the outrigger limit-switches as the by-pass button S26 and the button 1 on the joystick are depressed. Enables lifting of the boom to the horizontal plane as the drive function is operational. Auxiliary relay for chassis Switches over the control voltage to the changeover valve 5A as one of the movements on chassis is activated.
  • Page 46 DINO RXT Socket outlet on platform 10A autom. (PK). Module XS2-A0 3A (PK). Module XA2-A0 10A (PK). Module XA2-A0 10A (PK). Module XS2-A0 10A (PK). Basket rotation 10A (PK). XA2-A0 Power supply unit Bus module used for controlling the propo valves and relays and as a connection terminal for the sensors. XS2-A0 Signal unit Bus module used for controlling the relays and as a connection terminal for the sensors. CONTROL CENTRE 2 Locking EMERGENCY STOP button.
  • Page 47 DINO RXT CONTROL CENTRE 1 Signal light The alarm display, the reason can be checked on the MDM display on the platform control panel. Signal light for the outrigger limit switches. Lights up if all outrigger limit-switches have closed. Signal light for glowing The light is illuminated as the key switch is turned to position Glowing. The light only indicates that the key is in the glowing position, not e.g.

  • Page 48: Limit Switches

    DINO RXT Non-locking lever switch. Control switch for outrigger 4 Non-locking lever switch for platform levelling The levelling operates as the lever switch is turned to the desired direction. The levelling can be operated with the emergency descent system. Button for driving with raised boom As the button is depressed, the boom can be raised during the driving to the level position or the machine can be driven with the boom in the horizontal position.
  • Page 49 DINO RXT This limit switch switches off the combustion engine. After this only the emergency descent system can be operated. Limit switch for controlling emergency descent As the emergency descent is operated, and the telescope is fully retracted, the limit-switch will automatically direct the emergency descent system to serve the lowering of the boom and the articulated arms.
  • Page 50 DINO RXT Control relay Release of the brakes on the drive motors, operates during the execution of the driving or turning movements. Control relay Control of the outrigger selector valve, is active during the operation of the outriggers. Emergency descent button Starts the emergency descent unit for operation of support outriggers (the mains current of the lift must be switched on).

  • Page 51: Electric Diagram

    DINO RXT Angle sensor on the rear axle. Angle sensor on the front axle. Fuel sensor. Fault current switch 25A 30 ms. ÄM1 Sound signal. 7.2. ELECTRIC DIAGRAM...
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This manual is also suitable for:

2005726523205rxt24055265rxt

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