Dinolift 220XSE Maintenance Instruction
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Dinolift 220XSE Maintenance Instruction

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MAINTENANCE
INSTRUCTIONS
DINO 220XSE
Manufacturer:
Dealer:
Dinolift Oy
Raikkolantie 145
FI-32210 LOIMAA
Tel. + 358 20 1772 400
info@dinolift.com
www.dinolift.com

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  • Page 1 MAINTENANCE INSTRUCTIONS DINO 220XSE 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 220XSE 650008 -...

  • Page 4: Table Of Contents

    Maintenance instructions • DINO 220XSE 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 4.3.3. Inspect the Flyer-chains ....................37 4.3.4. Inspect the turning device .................... 38 4.3.5. Check electro-hydraulic rotary adaptor ................ 38 4.3.6. Inspect the transmission, axles and wheels ..............39 4.3.7. Inspect and service the fuel system of the diesel engine ..........41 4.3.8.

  • 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

    1.1. 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 220XSE 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

    1.2.2. Chemicals Type Volume Mobil EAL 32 Hydraulic oil 90 l Kendall Megaflow AW HVI 22 Hydraulic oil (winter option) Neste Hydrauli 28 Arctic 90 l Mobilux EP2 NLGI 2 Lubricant Mobil Grease XHP 222 Chain lubricant Würth HHS Grease Engine oil SAE 10W-30 5,1 l Reduction gear oil SAE85W90 API GL-5...
  • Page 10 Maintenance instructions • DINO 220XSE Other materials Steel, aluminum, cast iron Hydraulic pipes and Metals Recyclable components Power pack, axles Plastics Covers (ABS, PE) Recyclable Battery Lead battery Recyclable Electrical Wires, components Recyclable components Glass fibre Covers Not recyclable Hydraulic hoses Not recyclable.

  • Page 11: Safety-Related Notifications

    1.3. SAFETY-RELATED NOTIFICATIONS The following safety alert symbols and safety signal words are used in this manual and in safety labels. Observe all the 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 about a potential hazard.

  • Page 12: Safety Devices

    Maintenance instructions • DINO 220XSE 1.4. SAFETY DEVICES 1. Supervision of transport position Transport position of the boom system is monitored with three limit switches: • RK19 = articulated arms down • RK3 = boom down • RK8 = boom extentions in The limit switches prevent driving at maximum speed if the boom or articulated arms are lifted or boom extensions have been extended.
  • Page 13 3. Platform connection control The detachable platfom must always be securely locked and properly connected when in place. The locking of the platform is monitored by limit switches RK99 located above the locking pin and RK100 on the forks. RK99 The electrical connectors must be connected to platform according to instructions.
  • Page 14 Maintenance instructions • DINO 220XSE 4. Load control device (MRV) Overloading the lift is prevented by a load control safety device. It is located under the platform. It prevents overloading with both work platform and pallet fork operation. Alarms for load control device:...
  • Page 15 Signal lights on the device: Fault Alarm Yellow Reset Green Power on User interface Signal ligths Explanation Fault System failure Overload situation or Alarm the load has clashed with an obstacle Is illuminated if the unloaded weight is OK (Empty platform / pallet forks +/-15 kg).
  • Page 16 Maintenance instructions • DINO 220XSE 6. Platform inclination control The platform is levelled hydraulically by means of a so-called slave cylinder system, where the master cylinder controls the slave cylinder that inclines the work platform. The levelling system comprises the following parts: 1.
  • Page 17 9. Crush guard Control column at the platform is equipped with a limit switch mechanism, that stops all movements in case the control column is pushed back. The device helps to protect the user from entrapment and crushing hazards while driving or working near obstructions. STOP LIMIT SWICH RK98...

  • Page 18: Maintenance Schedule

    Maintenance instructions • DINO 220XSE MAINTENANCE SCHEDULE Maint. Schedule Person responsible Reference Operating Daily Operator instructions 1 month / 100 Maintenance Competent person who is familiar with the lift hours* instructions 6 months / 400 Maintenance Competent person who is familiar with the lift...
  • Page 19 Maintenance measures 19 Articulation bearings of pivot joint of wheel 20 Cardan shaft joints 21 Diesel engine and fuel system 22 Hydraulic oils 23 Hydraulic hoses, pipes and connections 24 Condition and attachment of battery and wiring 25 Hydraulic pressure 26 Operation of load regulation valves 27 Operation and condition of platform's levelling system 28 Operating controls and signal lights...

  • Page 20: Schedule For Inspections Required By The Authorities

    Maintenance instructions • DINO 220XSE 2.1. SCHEDULE FOR INSPECTIONS REQUIRED BY THE 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.

  • Page 21: Lubrication Plan

    2.2. LUBRICATION PLAN Grease nipples are marked in the machine with this label unless they are in a clearly visible place.

  • Page 22: Routine Maintenance During Operation

    Maintenance instructions • DINO 220XSE 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 23: First Service

    3.1. FIRST SERVICE After the first 20 working hours: Change the pressure and return filters. • • Check the transmission oil levels. Visually check that the hoses or connectors do not show leaks or chafing. • • Check the tightening torque of the attachment bolts: • wheel bolt – 360 Nm (M18, 32 pcs.). • attachment bolts of the steering axle – 520 Nm (M20, 2 pcs.). U-bolts of the fixed axle – 230 Nm (M20, 2 pcs.).

  • Page 24: Instructions For Daily Maintenance And Inspections

    Maintenance instructions • DINO 220XSE 3.2. INSTRUCTIONS FOR DAILY MAINTENANCE AND INSPECTIONS 3.2.1. 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 25: Check The Safety Devices

    3.2.6. Check the safety devices Check that the inclination sensor works properly. • Tilt the sensor to one side. • The alarm should sound a warning • Driving and boom functions should be disabled. Only telescope in should be operational. Check that the load sensing system is in operation.

  • Page 26: Decals, Signs And Manuals

    Maintenance instructions • DINO 220XSE 3.2.9. Decals, signs and manuals 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 27: Periodic Service

    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. 4.1. INSTRUCTIONS FOR MONTHLY SERVICE AND INSPECTION In addition to the measures given in this chapters, you should also carry out the daily inspections according to the maintenance schedule.

  • Page 28: Inspect And Service The Axles And Wheels

    Maintenance instructions • DINO 220XSE 4.1.3. Inspect and service the axles and wheels Check: 1. cleanliness of transmission and axles. 2. the wear of the tread and overall condition of the tyres (cracks, cuts). 3. the tightness of the attachment bolts: Wheel bolts 360 Nm (M18, 32 pcs.)

  • Page 29: Check The Condition And Attachment Of The Battery And The Wiring

    4.1.4. Check the condition and attachment of the battery and the wiring. Check visually the condition and attachment of the battery and the visible wiring. 4.1.5. Check the operation and condition of the platform's levelling system The platform keeps its level position only if the valves in the system are tight.

  • Page 30: Instructions For Inspections Every 6 Months

    Maintenance instructions • DINO 220XSE 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.

  • Page 31: Adjust The Brakes

    4.2.4. Adjust the brakes Adjust the brakes every 6 months or at least every 500 working hours as specified by axle manufacturer. For instructions, see the separate operating and service manual for the axles. 4.2.5. Check and lubricate the transport position control devices Grease the limit switch mechanisms for boom transport position control devices • for articulated arms (RK19) •...

  • Page 32: Check The Operation Of The Load Regulation Valves

    Maintenance instructions • DINO 220XSE 4.2.6. Check the operation of the load regulation valves Check the operation of the valves in accordance with the instructions below. If the valve leaks, carry out the measures according to the Service instructions for load regulation valves.
  • Page 33 4. Lock regulation valves of the oscillating axle lock • Drive the boom of the lift to the transport position on a level surface, and ensure that the boom is exactly parallel to the chassis. (0° or 180°). • Driving from the platform, drive one of the wheels of the oscillating axle onto an elevation of about 150 mm.

  • Page 34: Instructions For Annual Maintenance Of The Lift

    Maintenance instructions • DINO 220XSE 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.

  • Page 35: Inspect The Chassis, Boom System, Work Platform And Platform Carrier

    4.3.1. Inspect the chassis, boom system, work platform and platform carrier 1. Inspect the chassis • General condition. Pay particular attention to the load-bearing structures. The structures must not show signs of deformations or cracks. • Welded seams for cracks, corrosion or breaches 1.

  • Page 36: Inspect The Cylinders, And Lubricate The Joint Bearings

    Maintenance instructions • DINO 220XSE 4.3.2. Inspect the cylinders, and lubricate the joint bearings 1. Boom cylinder: • drive the lift cylinder to its upper position • inspect the condition of the piston rod, wiper rings and tightness of the connections •...

  • Page 37: Inspect The Flyer-Chains

    4.3.3. Inspect the Flyer-chains 1. Drive the boom to a horizontal position. 2. Drive the boom to its maximum length and inspect the condition and attachment of the Flyer-chains and locking of the pins 3. Retract the boom ~30 mm. 4.

  • Page 38: Inspect The Turning Device

    Maintenance instructions • DINO 220XSE 4.3.4. Inspect 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. 1. Check the turning device • general condition •...

  • Page 39: Inspect The Transmission, Axles And Wheels

    4.3.6. Inspect the transmission, axles and wheels 1. Check the general condition 2. Check the attachment bolts for tightness Tightening torque Wheel bolts 360 Nm (M18, 32 pcs.) Steering axle’s attachment bolts 520 Nm (M20, 2 pcs.) Fixed axle’s attachment bolts 300 Nm (M20, 4 pcs.) Oscillating axle’s locking cylinder bolts 62Nm (M12, 8 pcs.)
  • Page 40 Maintenance instructions • DINO 220XSE 9. Check the levels / change the transmission oil • in the reduction gear. • in the differential. • in the planetary gear. 1) Fill 1 + 3 1 + 2 + 3 2) Drain...

  • Page 41: Inspect And Service The Fuel System Of The Diesel Engine

    4.3.7. Inspect and service the fuel system of the diesel engine Refer to the service manual for the engine for more detailed service and inspection instructions. 1. Change the engine oil. • Mobil Delvac MX extra 10W-40 (API CI-4/CH-4/CG-4/CF/SL/SJ) or equivalent filling capacity with/without air filter: 5.5/6 l •...

  • Page 42: Change The Hydraulic Oil And The Filter

    Maintenance instructions • DINO 220XSE 4.3.8. Change the hydraulic oil and the filter CAUTION Protect your skin against exposure to hydraulic oil. Used oil can be harmful to the skin. Changing the hydraulic oil and the filter: 1. Drive the boom in transport position 2. Drain off the hydraulic oil tank via the drain plug.

  • Page 43: Inspect The Hydraulic System

    5. Put the drain plug back in place. 6. Refill the tank with fresh oil, the volume required for change is about 80 litres see the decal affixed to the oil tank for data about the oil filled at • the factory Do not mix different oils types. • The viscosity class of the hydraulic oil must be ISO VG22-32, and the oil must meet the requirements according to DIN 51524- HLP. 7.

  • Page 44: Measure Hydraulic Pressures

    Maintenance instructions • DINO 220XSE 4.3.10. Measure hydraulic pressures 1. Connect the pressure gauge to the measuring points marked in the pictures. The oil must be at operating temperature (40-60 °C) during the measurement. Measuring point for main pressure Measuring point for pressure relief valves 2.

  • Page 45: Check The Battery, The Electrical Appliances And The Wiring

    4.3.11. Check the battery, the electrical appliances and the wiring Check the electric system thoroughly • check that the control centre boxes are dry, clean and tight. • check the condition of the cable connections and their protection against moisture •...

  • Page 46: Check The Operation Of The Inclination Sensor

    Maintenance instructions • DINO 220XSE If the machine has outriggers: 5. Drive the boom and articulated arms down and the telesope in. Make sure that all the outriggers are up. Drive the boom up from the ground controls. Boom functions should be enabled.

  • Page 47: Check The Operation Of The Load Control Device

    4.3.16. Check the operation of the load control device Check, that the alarms and boom control limitation works according to the table in chapter “Safety devices”. 1. Drive the lift to a firm, level and even surface. 2. Drive the boom to a position where you can add the test load on the platform. Placing the load onto the platform must not make the bottom of the platform to come in contact with any external structures.

  • Page 48: Inspect The Operating Controls On Lcb And Ucb Control Panels

    Maintenance instructions • DINO 220XSE 4.3.17. Inspect the operating controls on LCB and UCB control panels Check the operating controls on the platform and on the turning device control stations: • Check the overall condition of the electric appliances inside the box and spray with moisture repellent, if necessary •...

  • Page 49: Operational Tests

    4.4.1. Operational tests 1. Test the drive functions from the platform. The drive movement of the lift should stop immediately once the operating controls are returned to their neutral position. 2. Test the sound signal, the emergency stop and the emergency descent 3.

  • Page 50: Service Instructions For Load Regulation Valves

    Maintenance instructions • DINO 220XSE 4.5. SERVICE INSTRUCTIONS FOR LOAD REGULATION VALVES 1. Support the platform, boom system or jib arms in a position, where the load does not rest on the structure to be repaired. CAUTION Protect your skin against exposure to hydraulic oil. Used oil can be harmful to the skin.

  • Page 51: Calibration Of Overload Safety Device

    4.6. CALIBRATION OF OVERLOAD SAFETY DEVICE Needed equipment: • TEACH IN -calibration tool, Dino id:48.19044 • 540 kg weight 1. Remove the platform. There must be no additional load on the lifting forks. Make sure that the forks are not supported by other structures. 2.
  • Page 52 Maintenance instructions • DINO 220XSE 7. The alarm function is now active. (If the alarm function has not yet been activated, push the forks downward lightly with your hand.) 8. Lift the weight off from the forks for at least 4 seconds (lags of the sensor). Put the weight back and check that the light will be turned on.

  • Page 53: Fault Finding

    FAULT FINDING 5.1. ERROR CODES OF THE ELECTRIC CONTROL SYSTEM The signal light H12 in the platform control centre UCB, and in the lower control centre LCB H11 indicate the faults in the electric control system by flashing an error code. When the engine is not running, the light is illuminated continuously. The error codes shall be read as follows: Pause Pause...
  • Page 54 Maintenance instructions • DINO 220XSE Error codes of the control system for the transmission • The error codes of the control system for the transmission will not be reset until the fault has been eliminated. • The error codes of the control system for the transmission will be shown when the operating controls are in the position 0, and the engine is running.

  • Page 55: Fault Finding Table

    5.2. FAULT FINDING TABLE FAULT REMEDY 1. The engine does not start, none of the signal light are illuminated The key switch Q1 or mains switch is Turn on the main switch and ensure that the switched off. key switch is in the correct position. Battery is flat.
  • Page 56 Maintenance instructions • DINO 220XSE FAULT REMEDY 3. Diesel engine cranks but does not start Fuel tank is empty. Refuel and bleed the fuel supply system. Replace the fuse. Fuse is located in LCB control Fuse F2 has blown centre.
  • Page 57 FAULT REMEDY 6. Disturbance of platform movements - only some of the movements are operational Driving prevents movements: • Boom up / down Stop driving and try again • Telescope in / out • Lifting and lowering of articulated arms Chassis inclination is over 5 degrees - inclination signal light is illuminated.
  • Page 58 Maintenance instructions • DINO 220XSE FAULT REMEDY 7. Boom drifts slowly downwards Remove and clean the valve. Check the condition of the o-rings. The load regulation valve leaks. Carefully install the valve in place. If necessary, replace the valve (see point “Load regulation valves”).
  • Page 59 FAULT REMEDY 13. Driving does not work Key switch Q1 in LCB centre is in wrong Select the correct operating location using the position switch Q1. Re-activate the pedal, and check UCB centre: Pedal (DMS) is not active that the signal light is illuminated. Driving is prevented, if the lift is inclined more than 5 degrees, and the boom and Lower the boom onto the support/retract the...
  • Page 60 Maintenance instructions • DINO 220XSE NOTES...

  • Page 61: Dpf Diesel Particle Filter (Option)

    DPF DIESEL PARTICLE FILTER (OPTION) 5.3. The machine may be fitted with BPdiesel particle filter, type 250-1.22. The Diesel particle filter is fitted with a manually operated bypass valve. DPF is bypassed when the handle is turned down CAUTION The use of the filter may be mandatory in some countries or specific regions or work areas. Use the filter / bypass system according to local legislation! The change interval of the Diesel particle filter cartridge is about 250 hours. The red “DPF” LED in the LCB centre indicates that the cartridge needs to be replaced. DPF signal light...

  • Page 62: Hydraulic System

    Maintenance instructions • DINO 220XSE HYDRAULIC SYSTEM 6.1. COMPONENTS 3CC1824 Drive system FILLING FILTER HYDRAULIC MOTOR HYDRAULIC PUMP HOSE HOSE HOSE HOSE HOSE HOSE 3CC1507 Chassis VALVE BLOCK HYDRAULIC GENERATOR (OPTION) VALVE SHUTTLE VALVE LOAD REGULATION VALVE PRESSURE MEASURING POINT...

  • Page 63: Hydraulic Diagrams

    3CB9614 A-E Boom system POWER UNIT XSE PRESSURE RELIEF VALVE VALVE HOUSING PRESSURE FILTER CHECK VALVE CHECK VALVE PRESSURE FILTER FMP065 VALVE HOUSING CHECK VALVE VALVE BLOCK LOAD REGULATION VALVE LOAD REGULATION VALVE SHUTTLE VALVE LOAD REGULATION VALVE LOAD REGULATION VALVE ROTARY ACTUATOR SOLENOID VALVE VALVE BLOCK...
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  • Page 67: Sähköjärjestelmä

    SÄHKÖJÄRJESTELMÄ 7.1. SÄHKÖKOMPONENTIT Tässä luvussa kuvataan sähkökaavioissa komponenteista käytetyt tunnisteet sekä komponenttien toiminnot. Pääkomponenttien varaosanumerot on esitetty erillisessä varaosaluettelossa. LCB PÄÄOHJAUSKESKUS Ohjausmoduuli Propo-ohjaukset - puomisto Sulake 30A Toimintojen etusulake Sulake 3A Optiot Sulake 50A Hehkutulpat Sulake 30A Moottorin ohjaus Sulake 10A Varalasku Sulake 10A Hätäseis- ja starttipiiri...
  • Page 68 Maintenance instructions • DINO 220XSE Rele Ajon joystickin toiminnan kääntö kun puomi on käännetty Rele Teleskooppi sisällä - kallistuskytkimen ohitus Rele Tukijalkaoptio - puomi ei tuella Rele Virran säästö - herätys Rele Virran säästö Rele Diesel start - can virratomaksi...
  • Page 69 UCB KORIN OHJAUSKESKUS Rele Virran säästö - herätys Rele Virran säästö - virta pois Ohjausmoduuli Ohjaukset - puomisto Merkkivalo Puomiston käyttö sallittu Merkkivalo Diesel - hehku Merkkivalo Plus1 järjestelmä vika, Sauer ajopumppu vika Merkkivalo Diesel - polttoaine vähissä Merkkivalo Dead-man poljin aktivoitu Merkkivalo Kallistushälytys Summeri...

  • Page 70: Sähkökaavio

    Maintenance instructions • DINO 220XSE RAJAKYTKIMET Rajakytkin Puomi käännetty sivulle Rajakytkin Puomi alhaalla Rajakytkin Teleskooppi sisällä RK11-14 Rajakytkin Tukijalkaoptio - tukijalat maassa RK16 Rajakytkin Teleskooppi induktiivirajalla RK18 Rajakytkin Puomin nosto päätyhidastus RK19 Rajakytkin Varsisto alhaalla RK31 Pintakytkin Polttoaine vähissä hälytys...
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