Dinolift DINO 260XTD, Maintenance Instructions Manual

Page 1: ...MAINTENANCE INSTRUCTIONS DINO 260XTD Dealer Manufacturer Dinolift Oy Raikkolantie 145 FI 32210 LOIMAA Tel 358 20 1772 400 info dinolift com www dinolift com...

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Page 3: ...3 ORIGINAL INSTRUCTIONS Valid from serial number 260XTD 26419...

Page 4: ...he operation of the emergency descent the emergency stop and the sound signal 21 3 1 9 Decals stickers and signs 21 3 1 10 Instruction manuals 21 4 PERIODIC SERVICE 22 4 1 INSTRUCTIONS FOR MONTHLY SER...

Page 5: ...nctionality of the operating controls 36 4 3 14 Decals stickers and signs 37 4 3 15 Instruction manuals 37 4 3 16 Check the attachment and condition of the safety devices 37 4 3 17 Checking the operat...

Page 6: ...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 Dinolift Oy...

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: ...re 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 the cylinde...

Page 9: ...1 2 3 Materials and recyclability Tyres Type Radial M S Size 225 75R17 5 The tyres meet the requirements of the REACH regulation The tyres can be recycled A recycling fee has been paid for the tyres s...

Page 10: ...or potential hazardous 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...

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: ...g 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 the permitted outreach area The overload limit switch RK5...

Page 13: ...C LIMIT SWITCH RK7 RK15 EXTENSION CHAIN DOUBLING CHAIN RETRACTION CHAIN 6 Preventing the inclination of the platform The platform is levelled hydraulically by means of a so called slave cylinder syste...

Page 14: ...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 control station Once the...

Page 15: ...Jockey wheel slide and threads P V DANGER WARNING CAUTION NOTICE In addition to the daily maintenance routines according to the maintenance schedule every operator is obliged to perform a site specif...

Page 16: ...e structures and induce malfunctions the maintenance intervals must be shortened or the influence of corrosion and malfunctions must be reduced by using appropriate protective means 19 Condition of br...

Page 17: ...f the lift must be carried out at regular intervals as long as it is in use If the lift is used under extreme conditions intervals between the inspections shall be reduced The overall operating condit...

Page 18: ...18 Maintenance instructions DINO 260XTD 6 9 7 11 7 8 1 5 5 3 2 12 3 4 10 13 2 2 LUBRICATION PLAN 14...

Page 19: ...ly before services and inspections Impurities may cause serious problems for example in the hydraulic system Use original spare parts and consumables Consult the spare parts list for more detailed inf...

Page 20: ...ydraulic oil level with the platform in the transport position if necessary top up hydraulic oil to the level with the upper edge of the level eye Kyltin numero 30002A Kyltin koko mm 37 x 63 R5 Pohjan...

Page 21: ...e chassis control centre check the overall condition of the operating controls test all the movements Ensure that all the movements stop when the control lever is released 3 1 8 Check the operation of...

Page 22: ...se if necessary Lubricant 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 cylinde...

Page 23: ...eel can 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 M12 3...

Page 24: ...in the levelling system causes rebound and inaccuracy during levelling of the platform If the platform viewed by the operator drifts forwards the reason can be a leak in the slave cylinder s double lo...

Page 25: ...ace DANGER WARNING CAUTION NOTICE Excess grease pressure may press out the turning bearing seal 4 2 2 Lubricate the telescope cylinder bearings Apply grease until the grease that comes out of the join...

Page 26: ...ding part of the overrun brake The wheel bearings are lubricated for life and do not require any servicing The bearings do not need any additional lubrication and they neither need nor can be re adjus...

Page 27: ...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 as at the beginning 2 Load regulati...

Page 28: ...s for the valves Remove and clean the valve Check the O rings and if necessary replace them Put the valves carefully in place Do not change the pre set values of the valves If necessary replace the va...

Page 29: ...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 executed by an expert or an expe...

Page 30: ...assis general condition check the attachment of the tow bar to the chassis check the condition of the overrun and its attachment to the chassis check the rims the tightness of the wheel bolts the tyre...

Page 31: ...check the condition of the platform floor plate check the platform carrier for notable buckles or deformations Perform visual inspection of all the screw connections 4 3 3 Check thoroughly the tow hi...

Page 32: ...thoroughly the condition of 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 replace...

Page 33: ...ess M16 280 Nm M12 115 Nm DANGER WARNING CAUTION NOTICE If you have to turn open or tighten the attachment bolts secure them with threadlocker Always tighten the bolts crosswise Lubricate the turning...

Page 34: ...of the spring see the 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 the retra...

Page 35: ...ated arms extend the articulated arm cylinders from the chassis control panel check the condition of the cylinders the piston rods the wiper rings and tightness of the connections check the condition...

Page 36: ...he operating controls of the platform control centre and the chassis control centre check the overall condition of the electric appliances inside the box and spray with moisture repellent if necessary...

Page 37: ...d RK15 Telescopic movement fully retracted RK8 Sensor for the boom length RK16 RK17 Sensor for the boom s lifting angle RK18 4 3 17 Checking the operation of the safety limit switches Check the operat...

Page 38: ...ift 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 WARNING CAUTION NOTICE...

Page 39: ...scope cylinder s projecting part L and compare the measure with the value for RK5 in the table in the chapter Safety devices 11 If the projecting part is too long readjust the RK5 and secure it again...

Page 40: ...escope until the safety limit switch RK4 stops the movement 9 Establish the standing stability in this situation by turning the lift round over 360 10 Change the load on the platform to a weighed test...

Page 41: ...raulic oil Used oil can be harmful 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 oi...

Page 42: ...5 in the table Adjust as necessary 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 trip before the RK5 2 exten...

Page 43: ...tion Emergency stop button has jammed in the lower position Pull up the button and re start the engine by actuating any of the control movements Fuse F3 has blown Replace the fuse 10A No mains supply...

Page 44: ...m the mains Main battery fuse has blown Replace the fuse 4 Power unit cranks but does not start Fuel tank is empty Fill the fuel tank Choke is off Press the choke button cold engine 1 2 3 4 Throttle l...

Page 45: ...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 Limit switch on the boom support has not cl...

Page 46: ...l and the housing 10 Telescopic movement does not operate Refer to item 8 Ensure that the solenoid valve for the telescope is not stuck in the centre open position 11 Outriggers are not operational al...

Page 47: ...essure 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 If necessary replace the valve...

Page 48: ...17 Outrigger does not stay in 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 i...

Page 49: ...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 absorber Reverse automatics brake shoe jam...

Page 50: ...58 the diameter of the ball must be max 50 mm and min 49 5 mm If the measure is different or the ball is nor perfectly spherical replace the ball Always when changing brake shoes replace all the shoes...

Page 51: ...valve 14 Load regulation valve 15 Load regulation valve 16 Cylinder telescope 17 Cylinder lift 18 Cylinder articulated arms 19 Cylinder slave 20 Cylinder master 21 Hydraulic motor turn 22 Rotary adapt...

Page 52: ...52 Maintenance instructions DINO 260XTD 26312...

Page 53: ...o the desired motor K7 Switches the valve control over from turning of the boom to the selector valve for the outriggers K8 Emergency descent relay switches on the lowering of the articulated arms onc...

Page 54: ...c appliance must be checked SR4 Safety relay for the emergency stop stops the motors and switches off the control voltage from the boom chassis selector valve The relay will trip if the emergency stop...

Page 55: ...t 1 6A F10 Control fuse for turning of the platform 5A automatic F7 Power supply to the emergency descent circuit 10A F11 Automatic lead protection 10A c curve for the socket outlet on the platform H8...

Page 56: ...g the left hand rocker switch S5 Start and stop switch for the combustion engine Operates only if the mains current is not connected S4 Locking emergency stop switch Stops all other functions except t...

Page 57: ...S40 Emergency descent button for the outriggers starts the emergency descent motor provided that the main current is connected S41 Emergency descent button for the outriggers lifting the outrigger 1 S...

Page 58: ...he boom movements by means of the safety relay SR3 RK7 Prevents the operation of the outriggers and the driving device if the boom is not resting on the transport support Controls the emergency stop s...

Page 59: ...y a green signal light will be flashing on it if the inclination exceeds 10 a red signal light will light up K4 Blocking relay for dual starting of the combustion engine the relay disconnects current...

Page 60: ...MODULE MC050 010 LCB MODULE MC050 10CCB CCB MODULE CCB UCB RK9 RK10 RK7 RK15 RK4 RK5 RK17 RK16 RK8 RK18 RK3 RK11 RK14 RK13 LCB Keyswitch contact diagram 1 2 3 4 5 6 7 8 9 10 11 12 2 1 0 Q1 OFF CHASSIS...

Page 61: ...m Blue 4mm RU Black 16mm Black 16mm Black 16mm 083 222 022 203 189 250 021 021 275 Negative Ground EMC CCB 5A VVK PE RCD Chassis 14 11 9 13 C 2 1 011 004 015 003 010 246 002 005 016 016 Red Red Blu 01...

Page 62: ...S44 11 12 C8 8 C8 6 DCB UCB DCB 226 224 008 005 232 006 007 045 276 034 X2 20 X2 1 403 X1 6 X2 2 A 4 251 12 14 11 22 24 21 Hatz K4 12 14 11 22 24 21 18 13 18 16 24 24 Hatz K5 216 Honda Hatz 032 20 O...

Page 63: ...und RU Valve block 058 051 279 15 N A rev B Rev C Rev D rev E rev F rev A B C D E F G H J K L M N O P R S A B C D E F G H J K L M N O P R S 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30...

Page 64: ...X2 13 14 23 24 33 34 41 42 16 K 11 17 L 12 16 K SR2 13 14 051 Pnk Y e l 33 N 16 N LCB 601 272 262 271 270 Yel Blk 020 002 Rk11 blk Rk11 red Rk11 blk wht R11 red wht Rk12 blk Rk12 blk wht Rk13 blk Rk13...

Page 65: ...Negative Ground 007 360 Foot switch X2 19 390 009 Red C1 P12 C9 5 C9 6 Basket Basket C9 1 C9 3 C9 2 C9 4 034 012 002 014 005 010 X2 6 302 252 016 417 301 017 312 403 REMOVED WITH HATZ POISTETAAN HATZI...

Page 66: ...nsor power Ground 2 1 Inputs Outputs 308 309 322 323 324 325 326 053 046 308 047 048 054 049 050 051 052 MC024 010 Up Dn Up Dn Up Dn Up Dn A rev B Rev C Rev D rev E rev F rev A B C D E F G H J K L M N...

Page 67: ...010 Boom RK17 4 blk 107 106 110 111 101 102 112 113 147 124 Negative Ground 016 252 245 242 Rk16 bro 258 259 243 262 A rev B Rev C Rev D rev E rev F rev A B C D E F G H J K L M N O P R S A B C D E F G...

Page 68: ...egative Ground Negative Ground 275 236 236 K3 14 11 254 254 POISTETAAN HATZILLA REMOVED WITH HATZ 2 36 G A rev B Rev C Rev D rev E rev F rev A B C D E F G H J K L M N O P R S A B C D E F G H J K L M N...

Page 69: ...eel drive S40 23 S41 13 S43 11 12 S42 11 12 Turn left Turn right backward Drive forward Drive C8 3 C8 4 C8 1 C8 2 126 122 152 151 001 002 004 003 DCB S44 S41 S40 S42 S43 Up Out Up Dn In Dn Platform le...

Page 70: ...ive T1 Y1 A2 3 sec C 3 1 10 off delay T1 TU2R3 S6 24 Time relay adjustents 601 604 603 603 605 606 606 606 606 606 602 602 606 605 177 270 176 Off delay A rev B Rev C Rev D rev E rev F rev A B C D E F...

Page 71: ...11 085 4 15 N 4 15 N 5 16 N 172 169 167 166 221 165 228 271 272 168 A rev B Rev C Rev D rev E rev F rev A B C D E F G H J K L M N O P R S A B C D E F G H J K L M N O P R S 11 12 13 14 15 16 17 18 19 2...

Page 72: ...561 580 591 592 581 593 582 594 583 010 010 010 515 515 515 515 515 515 515 515 6 4 1 5 2 S41 6 4 1 5 2 S42 6 4 1 5 2 S43 6 4 1 5 2 S44 1 2 3 4 Y X Y X RK12 RK13 RK11 RK14 177 A rev B Rev C Rev D rev...

Page 73: ...50 10CCB 074 531 532 533 534 535 536 546 514 512 513 566 5 6 4 V9 S40 21 22 V10 595 Negative Ground 023 584 563 pressing of rollers 5 33 N LCB 025 026 A rev B Rev C Rev D rev E rev F rev A B C D E F G...

Page 74: ...118 18 4 205 207 209 212 213 214 078 044 Negative Ground Boom 185 185 185 185 185 381 381 077 Yellow Articulated arms Telescope Boom Boom rotation Dn In Dn Up Out Up 210 208 211 SL1 X1 78 Negative Gro...

Page 75: ...mm2 014 Start control unit re start preventer CDI ignition box 015 REGULATOR 35 31 17 024 034 032 031 023 042 019 035 035 037 038 040 041 026 033 007 009 043 016 017 018 045 Blk 044 042 039 039 046 24...

Page 76: ...ow White Brown 419 418 CAN CAN GND POWER Danfoss display D3 D4 D2 D3 D4 D2 D1 417 D2 POWER POWER GND GND X2 16 301 Pnk Yel 432 432 CAN CAN CAN CAN X20 H X20 L L L H H L H MC024 010 MC050 010 120ohm J1...

Page 77: ...ctions GROUND START HatzWB 30 87a 87 32 M 30 87a 87 19 21 N 30 87a 87 19 28 N K33 87 30 3 34 3 36 29 J 007 A rev B Rev C Rev D rev E rev F rev A B C D E F G H J K L M N O P R S A B C D E F G H J K L M...

Page 78: ...Violet P S7 1 2 SPV 1 2 B 10000 F H1 1 H1 1 14 X2 Red X3 1 2 4 Brown 24 15 3 1 14 Gray HatzWB HatzWB K43 30 87 K42 87 30 18 34 J 18 32 J A rev B Rev C Rev D rev E rev F rev A B C D E F G H J K L M N O...

Page 79: ...g no Object ID Job no Electrical position Dino 260XTD Electric circuit diagram 26350 3 2 2015 HTK 7 7 2017 20 20 4CB6947 LCB 28 8 2017 4CB6947 A_HS_led _260XTD Honda Hatz Trackunit Model ME301 2 ME401...