Dinolift DINO 160XT II, Maintenance Instructions Manual

Page 1: ...MAINTENANCE INSTRUCTIONS Manufacturer Dinolift Oy Raikkolantie 145 FI 32210 LOIMAA Tel 358 20 1772 400 info dinolift com www dinolift com DINO XT II 160 180 210...

Page 2: ......

Page 3: ...3 TRANSLATION OF THE ORIGINAL INSTRUCTIONS Valid from serial number 160XT II 17414 180XT II 30268 210XT II 3642...

Page 4: ...y descent the emergency stop and the sound signal 22 3 1 8 Decals stickers and signs 22 3 1 9 Instruction manuals 22 4 PERIODIC SERVICE 23 4 1 INSTRUCTIONS FOR MONTHLY SERVICE AND INSPECTION 23 4 1 1...

Page 5: ...ols 37 4 3 14 Signs labels and machine plates 37 4 3 15 Instruction manuals 37 4 3 16 Check the attachment and condition of the safety devices 37 4 3 17 Check the operation of the safety limit switche...

Page 6: ...intenance operations A faulty machine may cause severe unforeseen risks If you are not sure which parts tools or measures are necessary consult your dealer or the manufacturer s service organisation D...

Page 7: ...m maintenance or storage normal wear of the equipment and damage resulting therefrom nor wearing parts and materials such as rubber tyres seals hoses fittings batteries filters etc damage failure or l...

Page 8: ...sition where the load does not rest on the structure under repair or cause any other danger e g in transport position or use of supporting structures When removing hydraulic cylinders also note that t...

Page 9: ...10W 30 0 6 l Honda 1 1 l Hatz Consult the separate engine manual for more information and specific recommendations for engine oil The hydraulic oil type used in the lift is marked on the label affixe...

Page 10: ...lastic parts are marked with material ID Tyres Battery Lead battery Recyclable Electric components Wires components Partly recyclable Hydraulic hoses Not recyclable Hazardous waste Oils and lubricants...

Page 11: ...rs must be in the support position before the boom is lifted Make sure that the wheels are off the ground The safety limit switches RK11 RK12 RK13 and RK14 are located on the support outriggers RK11 R...

Page 12: ...ed the movement While at the outreach limit the red warning light and the green signal light will flash in turns In this situation the lift can be operated in the direction in which it remains inside...

Page 13: ...ENSION CHAIN DOUBLING CHAIN RETRACTION CHAIN RK7 6 Preventing the inclination of the platform The platform is levelled hydraulically by means of a so called slave cylinder system where the master cyli...

Page 14: ...nts the inclination of the platform 7 Emergency stop buttons Depressing the emergency stop button stops all the movements immediately and turns off the power unit The button can be found at each contr...

Page 15: ...ous situation which if not avoided may result in death or serious injury DANGER WARNING CAUTION NOTICE Orange WARNING message is used in connection with potential risk factors which if not avoided und...

Page 16: ...wheel slide and threads I G 19 Brakes C C 20 Axles and suspension I DANGER WARNING CAUTION NOTICE In addition to the daily maintenance routines according to the maintenance schedule every operator is...

Page 17: ...climate may speed up the deterioration of the structures and induce malfunctions the maintenance intervals must be shortened or the influence of corrosion and malfunctions must be reduced by using ap...

Page 18: ...conditions intervals between the inspections shall be reduced The overall operating condition of the lift as well as the condition of the safety related control devices shall be established in the re...

Page 19: ...19 6 9 7 11 7 8 1 5 5 3 2 12 3 4 10 13 2 2 LUBRICATION PLAN 14...

Page 20: ...n Clean the lift especially carefully before services and inspections Impurities may cause serious problems for example in the hydraulic system Use original spare parts and consumables Consult the spa...

Page 21: ...lights as well as the road traffic lights of the trailer 3 1 4 Check the hydraulic oil level Check the hydraulic oil level with the platform in the transport position If necessary top up hydraulic oi...

Page 22: ...triggers must not operate in any position of the selector switch 3 1 7 Check the operation of the emergency descent the emergency stop and the sound signal Test the operation of the emergency stop the...

Page 23: ...bricant Esso Beacon EP2 or equivalent Lubrication point Number in the lubrication plan Bearings of the overload protection device 1 Joints of the outriggers and the outrigger cylinders 2 and 3 Joints...

Page 24: ...an be turned freely S T 6 Once the hand brake has been released and the operating brakes adjusted the springs on the brake rod extension must be pre tightened as shown in the picture 135 mm 160 XT II...

Page 25: ...rectional valve If the platform viewed by the operator drifts forwards the reason can be a leak in the slave cylinder s double load regulation valve on the piston rod side towards the electric directi...

Page 26: ...ate the turning bearing and the gear ring Reference number of the point in the lubrication plan 14 1 Remove the crescent shaped cover plates from the underside of the lift 2 Lubricate the turning bear...

Page 27: ...000 km check the brake linings for wear check the operation of the overrun brake by means of a test run execute a few test brakings lubricate the sliding part of the overrun brake The wheel bearings...

Page 28: ...surface measure the distance from the chassis to the floor separately at each outrigger leave the lift in this position for a few minutes measure the distances again The distances should be the same a...

Page 29: ...ove and clean the valve Check the O rings and if necessary replace them Put the valves carefully in place Do not change the set values of the valves If necessary replace the valve DANGER WARNING CAUTI...

Page 30: ...re and the operation of the lift are allowed to maintain the lift DANGER WARNING CAUTION NOTICE The annual maintenance of the lift with relevant inspections does not replace the annual inspection exec...

Page 31: ...he overrun and its attachment to the chassis check the rims the tightness of the wheel bolts the tyres and the tyre pressures The correct pressures are marked on the wheels and on the jockey wheel bra...

Page 32: ...axle and the suspension check the attachment of the axle check the condition of the rubber absorbers and the torsion arms 4 3 6 Check thoroughly the condition of the brakes 1 remove the wheels 2 clean...

Page 33: ...or check the attachment bolts of the turning device for tightness M16 280 Nm M12 115 Nm DANGER WARNING CAUTION NOTICE If you have to turn open or tighten the attachment bolts secure them with threadlo...

Page 34: ...s the length of the spring see Point 5 4 Check that the extension chain A farther away from the limit switch sags in the middle by about 40 mm Adjust as necessary 5 Check the length of the spring of t...

Page 35: ...ck the condition of the cylinder the piston rod and tightness of the connections 3 lubricate the joints of the lifting cylinder the telescope cylinder and the levelling cylinders 4 check the condition...

Page 36: ...e mains cable plug check the condition of the electric motor Battery for the emergency descent system The system incorporates an automatic battery recharger with short circuit and overheat protection...

Page 37: ...all the plates adhesive tapes and instructional labels on control stations are intact clean and legible If the labels have started to come off or tear apart or if the symbols or texts are illegible t...

Page 38: ...ift the outriggers the boom must not operate in any position of the selector switch 3 lower the outriggers level the lift 4 put a load on the platform as shown in the picture 160XT II w 270 kg 180XT I...

Page 39: ...control centre 2 Lift lower and lift again the rear edge of the work platform using its levelling function 2 Lifting the rear edge of the platform 1 Lowering the rear edge of the platform DANGER WARN...

Page 40: ...er lead between the points X1 and X2 of the relay SR3 9 Retract the telescope and then extend it again 10 Measure the telescope cylinder s projecting part L and compare the measure with the value for...

Page 41: ...ovement 6 Turn the boom round over 360 7 Retract the telescope and lower the boom to a horizontal position 8 Extend the telescope until the safety limit switch RK4 stops the movement 9 Establish the s...

Page 42: ...mful to the skin Changing the hydraulic oil and the filter 1 remove the plug and drain the oil tank with the lift s all cylinders fully retracted 2 clean and rinse the oil tank with suitable agent 3 r...

Page 43: ...he circuit card of the main centre have been turned counter clockwise to their extreme positions CONTROL CARD SCREWS 1 Maximum current Imax 2 Minimum current Imin 3 Adjusting the frequency 4 Intensity...

Page 44: ...n try to increase the maximum current The intensity of the current must not be too high as then the adjustment range of the joystick will decrease The movement speeds are adjusted using the adjustable...

Page 45: ...easure the time The time should be 35 40 seconds As necessary adjust it with adjustment screw A B A 15 Platform turning UCB control mode Adjust the instensity of the current with TR13 to 800 mA Set th...

Page 46: ...or RK5 in the table Adjust with the adjustment screw if needed 4 Tighten the locking screw of the RK5 and check once more the settings Check that the red light is on Adjusting the RK4 1 Set the RK4 to...

Page 47: ...inspection disassembled a separate report with the following information shall be attached to the protocol which structures were disassembled which non destructive inspection methods were applied whic...

Page 48: ...sure the wall thickness of the boom profile 3 0 mm using a thickness gauge Check the operation of the thickness gauge before the measurement using a calibration piece Measurements must be performed bo...

Page 49: ...49 6 Inspect the welded seams highlighted in the picture by applying the magnaflux method 7 Inspect all other welded seams visually...

Page 50: ...es 13 the brackets of the lift cylinder and the telescopic master and slave cylinders and the platform Magnaflux method 14 the bushings and play of the boom joint 15 the bearings and play of the overl...

Page 51: ...of corrosion measure the thickness of the plate if required 7 the play and gasket of the turning bearing 8 the condition wear out grade of the gear ring 9 the play of the swing gear box construction o...

Page 52: ...of corrosion If you observe signs of corrosion measure the thickness of the plate 4 the bushings and play of the pins 5 the attachment bolts of the pin caps 6 the welded seams and plates of the inter...

Page 53: ...hassis 1 remove the protective plates from the turning centre 2 Inspect the welded seams highlighted in the picture by applying the magnaflux method also on the underside 160XT 180XT 190XTE Top Unders...

Page 54: ...ct all other welded seams visually Check 4 that there are no cracks deformations dents buckles or signs of corrosion in the frame plates If you observe signs of corrosion measure the thickness of the...

Page 55: ...d in the picture by applying the magnaflux method 160XT 7 Inspect the outrigger cylinder brackets on the central frame side by applying the magnaflux method Check 8 the bearings and play of the outrig...

Page 56: ...shings Replace parts attachment bolts of the platform to the carrier Mandatory Cylinders 1 Remove the covers of the support outrigger cylinder rod and outreach limit mechanism of the boom Check on all...

Page 57: ...e plate and the load holding valve of the outrigger cylinder Mandatory attachment bolts of the valve plate on the outrigger Mandatory attachment bolts of the platform to the bearer Mandatory Tightenin...

Page 58: ...ration of the selector switch and replace it if necessary Voltage is supplied to the selector switch and is also transmitted further Check the operation of the motor s control contactor and thermo rel...

Page 59: ...t the plug from the mains No supply of direct current 12VDC because the main switch is disengaged Switch on the main switch 4 Power unit cranks but does not start Fuel tank is empty Fill the fuel tank...

Page 60: ...e Boom is not resting on the transport support Drive the boom onto the transport support The selector switch 1 is in the wrong position Turn the selector switch to the correct position The limit switc...

Page 61: ...some other movement Some of the solenoid valves for the boom movements is jammed in the open position Wash carefully the spool and the housing 10 Telescopic movement does not operate Refer to item 8...

Page 62: ...slowly downward Load regulation valve is leaking 9VA0867 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...

Page 63: ...the support position Load regulation valve on the bottom side is leaking For remedy refer to item 13 lock valve Tightening torque 55 Nm 17 18 18 Outrigger does not stay in the transport position Load...

Page 64: ...ake wires rusty or cracked Replace the wires 20 Braking uneven and jerky Too much play in the brake system Adjust the brake system Shock absorber of the overrun device faulty Replace the shock absorbe...

Page 65: ...the diameter of the ball must be max 50 mm and min 49 5 mm If the measure is different or the ball is not perfectly spherical replace the ball Always when changing brake shoes replace all the shoes o...

Page 66: ...justment of the platform s levelling speed 8A B Load regulation for levelling of the platform 1A 1B selection boom chassis PR Flow regulation valve Propo SV SP Articulated arms NV NP Lifting of the bo...

Page 67: ...67 T2 PH T P2 P P3 P1 MP ZV ZP S1V S2V S1P S2P V O NP NV MP MV P T A B Vakiokone Standard machine Standardmaschine Standardmaskin Standard maskine...

Page 68: ...XT II 180XT II 210XT II T2 PH T P2 P P3 P1 MP ZV ZP S1V S2V S1P S2P V O NP NV MP MV P T A B P2 P1 Automaattitasauksella Automatic levelling Automatische Nivellierung Automatik nivellering Automatisk a...

Page 69: ...rol circuit fuse F9 1 6A Platform control centre and F4 10A Chassis control centre K9 AUXILIARY RELAY FOR THE TELESCOPE IN MOVEMENT Control circuit fuse F9 1 6A Platform control centre and F4 10A Chas...

Page 70: ...OF THE PROPO CARD As the relay is active the control voltage to the Propo card is supplied via additional resistors As the relay is not active the control voltage is supplied to the joystick by means...

Page 71: ...9 PREVENTION OF DUAL CONTROL The relay is controlled by the emergency descent buttons S11 and S13 Control circuit fuse F7 10A K31 SWITCH OFF RELAY FOR THE COMBUSTION ENGINE Fuse F2 10A K32 SWITCH OFF...

Page 72: ...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 li...

Page 73: ...the unit and supplies the control voltage to the control levers while the the emergency descent system is in operation S16 TURNING OF THE BOOM TO THE RIGHT LEFT Non locking lever switch chassis contr...

Page 74: ...W LED SIGNAL LIGHT Indicates the operation of the outrigger limit switches RK11 RK14 H4 RED LED SIGNAL LIGHT Indicates the tripping of the SR3 HM1 HOUR METER Measures the running hours of the machine...

Page 75: ...relay for start of turning movement T13 ADJUSTABLE RESISTOR Turning speed of the platform PLATFORM CONTROL CENTRE UCB SWITCHES DMK DEAD MAN SWITCH JST JOYSTICK As the right side of the rocker switch...

Page 76: ...ge to button switch S12 as the switch is depressed S31 TELESCOPE IN Non locking pushbutton for retraction of the telescope S36 TURNING THE PLATFORM TO THE LEFT RIGHT Non locking lever switch The turni...

Page 77: ...elay SR3 which controls the sound signal AM2 and switches off the control voltage to the limit switch RK4 RK7 SAFETY LIMIT SWITCH FOR THE TELESCOPE CHAIN Operation of the safety limit switch stops the...

Page 78: ...in PL ROTARY ADAPTOR The electric circuits between the chassis and the turning device go through the electric rotary adaptor SR1 SOLENOID FOR THE EMERGENCY DESCENT UNIT When energized starts the emerg...

Page 79: ...79...

Page 80: ...80 Maintenance instructions DINO 160XT II 180XT II 210XT II...

Page 81: ...81...

Page 82: ...82 Maintenance instructions DINO 160XT II 180XT II 210XT II...

Page 83: ...83...

Page 84: ...84 Maintenance instructions DINO 160XT II 180XT II 210XT II...

Page 85: ...85...

Page 86: ...86 Maintenance instructions DINO 160XT II 180XT II 210XT II...

Page 87: ...87...

Page 88: ...88 Maintenance instructions DINO 160XT II 180XT II 210XT II...

Page 89: ...89...

Page 90: ...90 Maintenance instructions DINO 160XT II 180XT II 210XT II...

Page 91: ...91...

Page 92: ...92 Maintenance instructions DINO 160XT II 180XT II 210XT II...

Page 93: ...93...

Page 94: ...94 Maintenance instructions DINO 160XT II 180XT II 210XT II...

Page 95: ...95...

Page 96: ...96 Maintenance instructions DINO 160XT II 180XT II 210XT II...

Page 97: ...97...

Page 98: ...98 Maintenance instructions DINO 160XT II 180XT II 210XT II...

Page 99: ...99...

Page 100: ...100 Maintenance instructions DINO 160XT II 180XT II 210XT II...

Page 101: ...101...

Page 102: ...102 Maintenance instructions DINO 160XT II 180XT II 210XT II...

Page 103: ...103...