Dinolift DINO 210XTB II Maintenance Instructions Manual
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Dinolift DINO 210XTB II Maintenance Instructions Manual

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MAINTENANCE
INSTRUCTIONS
• 180XTB II •
DINO 160XTB II
210XTB II
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 210XTB II

  • Page 1 MAINTENANCE INSTRUCTIONS • 180XTB II • DINO 160XTB II 210XTB II 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 160XTB II 160188-> 180XTB II 40056-> 210XTB II 210035->...

  • Page 4: Table Of Contents

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 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.
  • Page 5 4.3.5. Inspect thoroughly the turning device ................34 4.3.6. Check electro-hydraulic rotary adaptor ................ 34 4.3.7. Check thoroughly the tow hitch and the overrun ............34 4.3.8. Lubricate the slide and threads of the jockey wheel ............ 35 4.3.9. Check thoroughly the condition of the brakes .............. 35 4.3.10.

  • 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 160XTB II • 180XTB II • 210XTB II 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 30 - 35 l Kendall Megaflow AW HVI 22 Hydraulic oil (winter option) Neste Hydrauli 28 Arctic 30 - 35 l Mobilux EP2 NLGI 2 Lubricant Mobil Grease XHP 222 Chain lubricant Würth HHS Grease 0,6 l (Honda) Engine oil (in platforms with SAE 10W-30...
  • Page 10 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 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 Hydraulic hoses...

  • 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 160XTB II • 180XTB II • 210XTB II 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 13 The green light in the control centre on the platform is lit, when the platform is within the allowed operating range. The reach are limit switch RK4 stops the movements that impair the stability of the lift (extending the telescope and lowering the boom) at a predetermined position. Adjusted values of the limits: 100 mm RK4 - L...
  • Page 14 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 5. Supervision of the telescope chain The extension chains for the telescope are doubled. If the load-bearing chain slackens or breaks, the doubling chain prevents the movements of the telescope, and the safety switch RK7/RK8 breaks the emergency stop circuit.
  • Page 15 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. Lifting cylinder of the boom Load regulation valve Prevents the load from falling...

  • Page 16: Servicing And Maintenance

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II SERVICING AND MAINTENANCE 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 hours*...
  • Page 17 Maintenance item Axles and suspension Driving device Lights 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 18: Inspections Required By Authorities

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 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.

  • Page 19: Lubrication Plan

    2.2. LUBRICATION PLAN...

  • Page 20: Routine Maintenance During Operation

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 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.

  • Page 21: Daily Maintenance Tasks

    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. Check the tyres and tyre pressure Inspect the condition of tyres visually and chack that they are not flat.

  • Page 22: Check The Emergency Descent, Emergency Stop And Sound Signal

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 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. •...

  • Page 23: 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 24: Check The Adjustment Of The Tow Hitch And The Overrun Brake

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 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.

  • Page 25: Check The Driving Device

    4.1.4. Check the driving device Check that the driving device is operating correctly. The platform must travel straight, when the lift is being transferred using the driving device. Check the load holding valves of the driving device for tightness. 4.1.5. Check the condition and attachment of the battery and the wiring. Check visually the condition and attachment of the battery and the visible wiring.

  • Page 26: Instructions For Inspections Every 6 Months

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 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 27: Lubricate The Tow Hitch And The Overrun

    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 28: Check The Adjustment Of The Overload Protection Device Rk4

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 4.2.8. Check the adjustment of the overload protection device RK4 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.
  • Page 29 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. Service instructions for the valves • Remove and clean the valve. •...

  • Page 30: Instructions For Annual Maintenance Of The Lift

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 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 31: Check The Frame Structures, The Boom System, The Work Platform And The Platform Carrier

    4.3.1. Check the frame structures, the boom system, the work platform and the platform carrier check the condition of the chassis • general condition • check the attachment of the tow-bar to the chassis • check the condition of the overrun and its attachment to the chassis. •...

  • Page 32: Inspect The Cylinders, And Lubricate The Joint Bearings

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 4.3.3. 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 •...

  • Page 33: Inspect Thoroughly The Flyer-Chains

    4.3.4. 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. 3.

  • Page 34: Inspect Thoroughly The Turning Device

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 4.3.5. 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: •...

  • Page 35: Lubricate The Slide And Threads Of The Jockey Wheel

    4.3.8. Lubricate the slide and threads of the jockey wheel Lubricating the slide and threads of the jockey wheel Reference number of the point in the lubrication plan: 10. 4.3.9. Check thoroughly the condition of the brakes 1. remove the wheels 2.

  • Page 36: Change The Hydraulic Oil And The Filter

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 4.3.13. Change the hydraulic oil and the filter Protect your skin against exposure to hydraulic 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.

  • Page 37: Check The Battery, The Electrical Appliances And The Wiring

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

  • Page 38: Check The Operation Of The Safety Limit Switches

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 4.3.18. Check the operation of the safety limit switches Check the operation of the safety limit switches for the outriggers and the boom from the chassis control panel LCB: 4.

  • Page 39: Checking The Operation Of The Overload Limit Switches Rk4 And Rk5

    4.3.19. Checking the operation of the overload limit switches RK4 and RK5 LIMIT SWITCHES RK4, RK5 PRESSURE SPRING ADJUSTMENT SCREW ARTICULATED ARM LIFTING CYLINDER Check the operation of the overload limit switches from the chassis control panel LCB. For the test, keep the same carefully weighed test load, placed at the distance of 100 m from the rear edge of the platform, as in the previous test.

  • Page 40: Inspecting The Condition And Functionality Of The Operating Controls

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 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 a jump lead between the point 23 of the relay SR4, and the point 14 of the relay SR3 in the chassis control centre (LCB).

  • Page 41: Test Loading

    4.3.22. Test loading The operation of the limit switches RK4 and RK5 must always be checked before the test loading! As required, refer to the point “Checking the operation of the overload limit switches RK4 and RK5” for instructions. 1. Place the lift on an even surface with good carrying capacity. Drive the outriggers to their lowest position.

  • Page 42: Adjusting The Movement Speeds

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 4.4. ADJUSTING THE MOVEMENT SPEEDS Devices required for the adjustment: • multimeter with possibility to measure direct current (A) • screwdriver with narrow tip 1. Disconnect the conductor 523 from the connector K25B.22 on the cover of the LCB centre.
  • Page 43 position counter-clockwise). The descending ramp is not used. 9. Adjusting the minimum current (Q1: LCB control) Turn the speed selection switch to ‘Rabbit’ position. Adjust the minimum current via the screw 2 on the control card. Adjust the setting to 150 mA. The movement speeds are adjusted using the adjustable resistors on the circuit card in the main control centre.
  • Page 44 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 13. Platform levelling (Q1: LCB control) From LCB conrtol centre, drive the platform levelling down and measure the time. The time should be 35-40 seconds. As necessary, adjust it with adjustment screw A.

  • Page 45: Adjusting The Overload Limit Switches

    4.5. 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”. The adjustment of the limit switches shall be carried out so that the last movement of the platform's rear edge will be lifting.

  • Page 46: Maintenance Of The Batteries

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 4.7. MAINTENANCE OF THE BATTERIES The electrolyte is very corrosive - always use protective clothing and eye protectors Charging of the batteries generates hydrogen gas. Keep away from open flame. EXPLOSION HAZARD! Always keep the batteries well charged •...
  • Page 47 Test the condition of the batteries regularly • Specific weight of the liquid 1,277 = Battery 100 % charged • Battery voltage 29.6V = Charging voltage 25.46V = Voltage of batteries that are 100 % charged. Charger disconnected, the voltage has been stabilizing for a few hours 20.88V = voltage of 0 % charged batteries.

  • Page 48: Fault Finding

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II FAULT FINDING 5.1. PROBLEMS WITH POWER SUPPLY FAULT REMEDY 1. The electric motor does not start, although the selector switch is in position 1b or 1c and one of the movements is operated or the start button at the battery housing on the left-hand side is depressed Mains switch turned off.

  • Page 49: 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 50 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 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 51: 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 52 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 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 53: 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 54 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II 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 55: Hydraulic System

    HYDRAULIC SYSTEM 6.1. GENERAL INFORMATION OF HYDRAULICS Activation of any of the movements requires that three electric valves be in operation simultaneously. The retraction of the telescope is an exception, as it requires simultaneous operation of two valves only. The valves are: the flow regulation valve (PR), the selection valve boom/chassis (1B) and the control valve for the movement in question. Using the selection valve boom/chassis is not required for retraction of the telescope.
  • Page 56 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II...

  • Page 57: Electric System

    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. CHASSIS CONTROL CENTRE (LCB), RELAYS START CONTACTOR FOR THE ENGINE (M1) Control circuit fuse F3 5A.
  • Page 58 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II K11: LOWERING THE ARTICULATED ARMS Control circuit fuse F9 1,6A (Platform control centre) and F4 10A (Chassis control centre). K12: RETARDATION OF THE “ARTICULATED ARMS DOWN” MOVEMENT Reduces the maximum speed of the “articulated arms down” movement; once the relay is active, the control voltage is supplied via the adjustment trimmer TR4.
  • Page 59 K23: CHANGE-OVER RELAY ON THE CHASSIS Controls the solenoid valve for selecting the chassis. SELECTOR RELAY FOR THE BOOM, CENTRE POSITION ACTIVATION OF THE K24: JOYSTICK Switches on current to the selector of valve of the boom. Switches off current from the control functions on the chassis. Depressing the dead-man-switch DMK switches off the control voltage from the spool of the relay K17, which would otherwise disconnect the control voltage to the micro- switches on the joystick.
  • Page 60 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II CHASSIS CONTROL CENTRE (LCB), SWITCHES LOCKING EMERGENCY STOP SWITCH Stops all other functions except the emergency descent and the sound signal, which remain operational. START SWITCH – in the battery compartment on the right-hand side. Starting the electric motor while the outriggers are in use.
  • Page 61 CHASSIS CONTROL CENTRE (LCB), OTHER ITEMS 10A FUSE FOR EMERGENCY STOP CIRCUIT 10A FUSE FOR SELECTOR VALVES AND LIMIT SWITCHES FOR OUTRIGGERS 5A FUSE FOR ENGINE CONTROLLER AND OUTREACH LIMITS 10A FUSE FOR CONTROL LEVERS AND JOYSTICK IN THE CHASSIS AND PLATFORM CONTROL CENTRES F11: 10A FUSE FOR SOCKET OUTLETS...
  • Page 62 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II PLATFORM CONTROL CENTRE (UCB), SWITCHES DMK: DEAD-MAN-SWITCH JST: JOYSTICK As the right side of the rocker switch is depressed, the movements are: boom up - down and turn right – left) As the left side of the rocker switch is depressed, the movements are: telescope in–...
  • Page 63 ÄM2: BUZZER Indicates the operation of the safety limit switch RK5 and the emergency stop switches. LIMIT SWITCHES RK3: LIMIT SWITCH ON THE BOOM SUPPORT Prevents the operation of the outriggers and the driving device if the boom is not resting on the support in the transport position.

  • Page 64: Electric Diagram

    Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II S44: EMERGENCY STOP BUTTON OTHER MARKINGS SPEED CONTROLLER FOR THE ELECTRIC MOTOR M1 150A FUSE FOR THE BATTERIES F12: 15A SUPPLY FUSE FOR THE MAIN CENTRE G1-G4: BATTERIES 24 VDC (4 x 6 VDC 225Ah) PLUG ELECTRIC MOTOR 24VDC 3kW ROTARY ADAPTOR...
  • Page 65 160XTB II: 160184 ->, 180XTB II: 40054 ->, 210XTB II 210035 ->...
  • Page 66 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II...
  • Page 68 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II...
  • Page 70 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II...
  • Page 72 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II...
  • Page 74 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II...
  • Page 76 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II...
  • Page 78 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II...
  • Page 80 Maintenance instructions • DINO 160XTB II • 180XTB II • 210XTB II...

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