Dinolift DINO 260XTD Maintenance Instructions Manual
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Dinolift DINO 260XTD Maintenance Instructions Manual

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MAINTENANCE
INSTRUCTIONS
DINO 260XTD
Manufacturer:
Dealer:
Dinolift Oy
Raikkolantie 145
FI-32210 LOIMAA
Tel. + 358 20 1772 400
info@dinolift.com
www.dinolift.com

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Summary of Contents for Dinolift DINO 260XTD

  • Page 1 MAINTENANCE INSTRUCTIONS DINO 260XTD Manufacturer: Dealer: Dinolift Oy Raikkolantie 145 FI-32210 LOIMAA Tel. + 358 20 1772 400 info@dinolift.com www.dinolift.com...
  • Page 3 ORIGINAL INSTRUCTIONS Valid from serial number 260XTD 26419 -...

  • Page 4: Table Of Contents

    Maintenance instructions • DINO 260XTD CONTENTS TO THE MAINTENANCE PERSONNEL ..............6 1.1. GENERAL WARRANTY TERMS................. 7 1.2. SAFETY AND THE ENVIRONMENT..............8 1.2.1. General safety instructions for maintenance ..............8 1.2.2. Filling quantities of chemical substances ............... 9 1.2.3.
  • Page 5 4.3. INSTRUCTIONS FOR ANNUAL MAINTENANCE OF THE LIFT ...... 29 4.3.1. Inspect thoroughly the support outriggers and the outrigger cylinder joints ....30 4.3.2. Check the frame structures, the boom system, the work platform and the platform carrier 4.3.3. Check thoroughly the tow hitch and the overrun ............31 4.3.4.

  • 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: General Warranty Terms

    1.1. GENERAL WARRANTY TERMS Dinolift Oy warrants newly delivered DINO aerial work platforms to be free from defects in materials, constructional parts, components and workmanship, with terms and limitations set out in the warranty terms. Full warranty terms are provided by the distributor.

  • Page 8: Safety And The Environment

    Maintenance instructions • DINO 260XTD 1.2. SAFETY AND THE ENVIRONMENT 1.2.1. General safety instructions for maintenance Exercise particular caution always when carrying out service- and maintenance operations. A faulty lift, or a lift from which covers, safety devices or other parts have been removed, may operate in an unexpected way.

  • Page 9: Filling Quantities Of Chemical Substances

    1.2.2. Filling quantities of chemical substances Liquid type Volume Fuchs Hydraway Bio SE 22 Hydraulic oil Fuchs Hydraway Bio SE 32-68 30-35 l Mobil EAL 32 Hydraulic oil (winter option) Neste Hydrauli 28 Arctic 30-35 l Mobilux EP2 NLGI 2 Lubricant Mobil Grease XHP 222 Chain lubricant...

  • Page 10: Safety-Related Notifications

    Maintenance instructions • DINO 260XTD 1.3. SAFETY-RELATED NOTIFICATIONS The following safety alert symbols and safety signal words are used in this manual. Observe all the safety instructions that follow these symbols, in order to avoid dangerous situations and personal injuries.

  • Page 11: Safety Devices

    1.4. SAFETY DEVICES 1. Supervision of transport position of the boom 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.
  • Page 12 Maintenance instructions • DINO 260XTD The green light in the control centre on the platform is lit, when the platform is within the allowed operating range. The reach limit switch RK4 will stop the movements, which impair the stability of the lift (extending the telescope and lowering the boom), at a predetermined position.
  • Page 13 5. Supervision of the telescope chain The extension chains for the telescope are doubled. RK15 If the load-bearing chain slackens or breaks, the doubling chain prevents the movements of the telescope, and the safety switch RK7/RK15 breaks the emergency stop circuit. A - A ~32 mm DOUBLING CHAIN...
  • Page 14 Maintenance instructions • DINO 260XTD 7. Safety devices for hose rupture All the load-bearing cylinders are equipped with valves for rupture or leak in the hydraulic system, which prevent the load from falling. Prevent the inching of the Outrigger cylinders Lock valves outriggers in either direction.

  • Page 15: Maintenance Schedule

    MAINTENANCE SCHEDULE Service Service interval Service person Instructed operating Daily Operator instructions every month/100 maintenance Competent person who is familiar with the lift hours* instructions DANGER every 6 months/400 maintenance Competent person who is familiar with the lift hours* instructions every 12 Technical specialist, who is well familiar with the maintenance...
  • Page 16 Maintenance instructions • DINO 260XTD Maintenance measures Condition of brakes Axle and suspension Driving device Lights Hydraulic oils Hydraulic hoses, pipe and conections Condition and attachment of battery and wiring Hydraulic pressure Condition and attachment of safety devices Operation of safety devices (limit switches)

  • Page 17: Schedule For Inspections Required By The Authorities

    2.1. SCHEDULE FOR INSPECTIONS REQUIRED BY THE AUTHORITIES The inspections must be performed in accordance with local and national regulations, in accordance with the legislation and standards. The lift must be subjected to a start-up inspection before it is used for the first time and before starting it up the first time after a major repair or modification work. The lift must be subjected to a thorough periodic inspection with related test drive at intervals of year.

  • Page 18: Lubrication Plan

    Maintenance instructions • DINO 260XTD 2.2. LUBRICATION PLAN...

  • Page 19: Routine Maintenance During Operation

    ROUTINE MAINTENANCE DURING OPERATION The maintenance operations, that are the responsibility of the operator, are described in this chapter. The more demanding maintenance operations that require special skills, special tools or specific measurements and adjustment values are instructed in the separate Maintenance Instructions. In such maintenance and repair cases, the operator shall contact an authorized service provider, the distributor or the manufacturer.

  • Page 20: Instructions For Daily Maintenance And Inspections

    Maintenance instructions • DINO 260XTD 3.1. INSTRUCTIONS FOR DAILY MAINTENANCE AND INSPECTIONS 3.1.1. Check the condition of chassis, the boom and the work platform Check visually the condition of the access routes, the work platform, the platform gate and the handrails.

  • Page 21: Check The Operation Of The Safety Limit Switches

    3.1.6. Check the operation of the safety limit switches Test the operation of the safety limit switches that prevent the movements of the boom and the outriggers as follows: 1. The lift is in the transport position with the outriggers in the upper position, and the driving device connected.

  • Page 22: Periodic Service

    Maintenance instructions • DINO 260XTD PERIODIC SERVICE The measures, included in the maintenance schedule, that are the responsibility of a skilled service person, who is thoroughly familiar with the operation and structure of the lift, are described in this chapter.

  • Page 23: Check The Adjustment Of The Tow Hitch And The Overrun Brake

    4.1.3. Check the adjustment of the tow hitch and the overrun brake Check the condition of the tow hitch and the tow ball coupling. Check the brake adjustment. Adjusting the brakes 1. Support the lift by raising its wheels off the ground.

  • Page 24: Check The Driving Device

    Maintenance instructions • DINO 260XTD 4.1.4. Check the driving device Check the condition of the driving device and lubricate the joints. Reference number of the point in the lubrication plan: 12 Check that the driving device is operating correctly. When the lift is transferred by means of the driving device, it must travel straight.

  • Page 25: Instructions For Inspections Every 6 Months

    4.2. INSTRUCTIONS FOR INSPECTIONS EVERY 6 MONTHS These service measures must be carried out between the annual services at every 6 months or 400 hours, whichever comes first. In addition to these service measures, also carry out the measures included in the daily and monthly services. 4.2.1.

  • Page 26: Lubricate The Tow Hitch And The Overrun

    Maintenance instructions • DINO 260XTD 4.2.5. Lubricate the tow hitch and the overrun Reference number of the point in the lubrication plan: 13. If necessary, apply a thin grease film on moving parts of the ball coupling. 4.2.6. Check the condition of the brakes The following service measures must be carried out every six months or after driving 13,000–15,000 km:...

  • Page 27: Checking The Adjustment Of The Overload Protection Device

    4.2.7. Checking the adjustment of the overload protection device Check the adjustments of the overload protection device as follows: 1. Check the test loads and the adjusted values in the table of the chapter “Safety devices”. 2. Put a test load onto the platform 3.
  • Page 28 Maintenance instructions • DINO 260XTD 9VA0867 9VA0938 9VA2103 DANGER WARNING CAUTION NOTICE The valve can only be opened 2–3 times after which it has to be replaced. After this, the valve may start to leak, and it must be replaced by a new one.

  • Page 29: Instructions For Annual Maintenance Of The Lift

    4.3. INSTRUCTIONS FOR ANNUAL MAINTENANCE OF THE LIFT The annual maintenance must be carried out every 12 months or 800 hours of operation, whichever comes first. The measures of the smaller services need not be carried out separately in connection with the annual maintenance as they, to the extent necessary, are included in the instructions for the annual maintenance. DANGER 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...

  • Page 30: Inspect Thoroughly The Support Outriggers And The Outrigger Cylinder Joints

    Maintenance instructions • DINO 260XTD 4.3.1. Inspect thoroughly the support outriggers and the outrigger cylinder joints check the mechanical structure of the outriggers and the welded seams The structures must not show signs of deformations or cracks No fractures or cracks are allowed in the welded seams.

  • Page 31: Check Thoroughly The Tow Hitch And The Overrun

    • check the condition of the platform brackets • check the locking of the platform pin Inspect the work 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 •...

  • Page 32: Inspect Thoroughly The Hydraulic Hoses, Pipes And Connections

    Maintenance instructions • DINO 260XTD 4.3.4. Inspect thoroughly the hydraulic hoses, pipes and connections • 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 all the pipes are properly fastened • check the hose and pipe connections for leaks, and that the connections are properly tightened Replace any externally damages hoses or buckled pipes.

  • Page 33: Inspect Thoroughly The Turning Device

    4.3.8. Inspect thoroughly the turning device Check visually the turning device and its welded seams. In particular, check the attachment points of the joints and the turning bearing. Check the turning device: • general condition DANGER • play and attachment of the angular gear •...

  • Page 34: Inspect Thoroughly The Flyer-Chains

    Maintenance instructions • DINO 260XTD 4.3.9. Inspect thoroughly the Flyer-chains Inspect the condition and attachment of the Flyer-chains, the locking of the pins and the tightness of the spring. 1. Drive the boom to a horizontal position. 2. Drive the boom extensions completely out and retract them by about 30 mm.

  • Page 35: Inspect The Cylinders, And Lubricate The Joint Bearings

    4.3.10. Inspect the cylinders, and lubricate the joint bearings 1. Lifting cylinder: • drive the lift cylinder to its upper position from the chassis control panel • inspect the condition of the piston rod and tightness of the connections • check the condition of the articulation bearings and their pins as well as the attachment of the pins •...

  • Page 36: Measure Hydraulic Pressures

    Maintenance instructions • DINO 260XTD Battery for the emergency descent system 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 10 A as necessary, top up battery fluid above the elements 4.3.12. Measure hydraulic pressures 1.

  • Page 37: Decals, Stickers And Signs

    4.3.14. Decals, stickers and signs Check that all the signs, warning decals and pictorials on the control centres are in place, intact and clean. If the labels have started to come off or tear apart, or if the symbols or texts are illegible, then the decals must be replaced.

  • Page 38: Checking The Operation Of The Overload Limit Switches Rk4 And Rk5

    Maintenance instructions • DINO 260XTD 4.3.18. Checking the operation of the overload limit switches RK4 and RK5 LIMIT SWITCHES RK4 and RK5 PRESSURE SPRING ADJUSTMENT SCREW ARTICULATED ARM LIFTING CYLINDER Check the operation of the overload limit switches from the chassis control panel LCB.
  • Page 39 In case the outreach limit switch (RK4) fails, overloading of the boom is prevented by a second safety limit switch (RK5). Checking the adjustment of RK5 7. Disable the RK4 for measuring by connecting the terminals 9 and 30 inside the chassis control panel with a jumper lead.

  • Page 40: Test Loading

    Maintenance instructions • DINO 260XTD DANGER 4.3.19. Test loading WARNING The operation of the limit switches RK4 and RK5 must always be checked before the CAUTION test loading! As required, refer to the point “Checking the operation of the overload limit switches RK4 and RK5”...

  • Page 41: Check The Lights

    4.3.20. Check the lights Check the condition of the lights and the reflectors. Replace any burned-out bulbs or lights, and damaged reflectors. 4.3.21. Inspect thoroughly the driving device Check the condition of the driving device, the attachment of its parts and the condition of the covers for the electric components. Check that the valves of the driving device operate properly and no movement occurs when the spool in the neutral position.

  • Page 42: Adjusting The Overload Limit Switches

    Maintenance instructions • DINO 260XTD 4.4. ADJUSTING THE OVERLOAD LIMIT SWITCHES For adjusting the overload limit switches shall be used the same test load as for checking the operation of the overload limit switches. Check the test loads and the adjusted values in the table of the chapter “Safety devices”.

  • Page 43: Instructions For Fault-Finding

    INSTRUCTIONS FOR FAULT-FINDING 5.1. PROBLEMS RELATED TO POWER SUPPLY AND START-UP FAULT REMEDY 1. No voltage supply to the control centre Main battery fuse F1 has blown. Replace the fuse. No voltage supply to the timer card. Main switch is switched off. Switch on the main switch.
  • Page 44 Maintenance instructions • DINO 260XTD 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. Main battery fuse has blown. Replace the fuse. 4. Power unit cranks but does not start Fuel tank is empty.

  • Page 45: Operational Problems Related To Movements

    5.2. OPERATIONAL PROBLEMS RELATED TO MOVEMENTS FAULT REMEDY 6. None of the boom movements is operational, although the electric motor is running and the selector switch is in the correct position (operation from the chassis control centre or the platform control centre) Green signal light for outriggers is not Check the operation of the outrigger limit switches illuminated.
  • Page 46 Maintenance instructions • DINO 260XTD FAULT REMEDY 9. Some of the boom movements is operational Refer to item 8. Electric valve is open. Remedy as instructed above in conjunction with the seizure of the electric valve spool. Some of the solenoid valves for the boom Activation of, for example, lifting of the boom, movements is jammed in the open-position.

  • Page 47: Drifting Of Boom Or Outriggers

    5.3. DRIFTING OF BOOM OR OUTRIGGERS FAULT REMEDY 13. Boom drifts slowly downward The “load regulation 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.
  • Page 48 Maintenance instructions • DINO 260XTD FAULT REMEDY 15. Platform drifts backward Double load regulation valve on the bottom side For remedy, refer to item 13 (lock valve). is leaking. Load regulation valve under the platform is For remedy, refer to item 13 (lock valve).

  • Page 49: Problems Related To Towing

    5.4. PROBLEMS RELATED TO TOWING FAULT REMEDY 19. Too low braking force Too much play in the brake system. Adjust the brake system. Pull the parking brake lever slightly and drive 2-3 Brake linings not yet run-in. kilometres. Replace the brake-shoe sets. Brake-shoes "glazed", dirty or oil on the friction surfaces.
  • Page 50 Maintenance instructions • DINO 260XTD 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 transmission overrun jams.

  • Page 51: Hydraulic System

    HYDRAULIC SYSTEM 6.1. HYDRAULIC COMPONENTS 26209 ja 26229 -> Ref. Component Electric motor Hydraulic pump Combustion engine (power pack) Power unit (emergency operation) Check valve Pressure filter Solenoid valve Breather plug Oil level eye Load regulation valve Load regulation valve Load regulation valve Load regulation valve Load regulation valve Load regulation valve...
  • Page 52 Maintenance instructions • DINO 260XTD 26312 ->...

  • Page 53: Electric System

    ELECTRIC SYSTEM 7.1. ELECTRIC COMPONENTS The appliance ID's used in the electric diagrams and the descriptions of the appliances' operation are presented in this chapter. The product codes for ordering spare parts are presented in the separate spare parts list. MAIN ELECTRIC CABINET (PK), RELAYS Control contactor for the motor (M1) Auxiliary contactor for the emergency stop switch...
  • Page 54 Maintenance instructions • DINO 260XTD Change-over relay on the timer card, switches the voltage supply over from either the power supply unit or from the battery, depending on whether the power supply unit is feeding power to the system or not.
  • Page 55 Lifting and lowering the articulated arms, lever switch (also emergency descent). Levelling the platform to the front and to the rear, lever switch Blue control button for the “telescope in” valve. To be used in case the outreach limit RK5 has been exceeded. Requires also that the speed selector switch S8 has been turned.
  • Page 56 Maintenance instructions • DINO 260XTD Control centre (UCB), relays Turning the platform to the left. The linear motor is controlled by means of a relay; the inductive limit switch RK9 limits the maximum turning angle by disconnecting the control voltage from the relay.
  • Page 57 Control centre (UCB), other items Display; shows the alarm messages, the inclination sensor view and helps adjust the parameters (see separate instructions). Power supply to the turning motor of the platform (5A, automatic). The red LED will flash, if the maximum outreach has been reached or exceeded, or if an alarm message is shown on the display. Turning motor of the platform, 12V.
  • Page 58 Maintenance instructions • DINO 260XTD LED signal light. Signal light for the outrigger; lights up if the support outrigger 4 is properly supported on the ground. MC50- Bus module, control unit for the outriggers and the driving device as well as inlet unit 10CCB for the outrigger limit switches.

  • Page 59: Electric Diagram

    RK16 Inductive sensor. Retards the lifting and lowering movements of the boom and the turning movement, if the length of the boom is about 16m. RK17 Inductive sensor. Retards the lifting and lowering movements of the boom and the turning movement, if the length of the boom is about 20m.
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