Dinolift DINO 135TB Maintenance Instructions Manual
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Dinolift DINO 135TB Maintenance Instructions Manual

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MAINTENANCE
INSTRUCTIONS
• 150TB • 180TB
DINO 135TB
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 • 150TB • 180TB DINO 135TB Manufacturer: Dealer: Dinolift Oy Raikkolantie 145 FI-32210 LOIMAA Tel. + 358 20 1772 400 info@dinolift.com www.dinolift.com...
  • Page 3 TRANSLATION OF THE ORIGINAL INSTRUCTIONS Valid from serial number 135TB 130176 --> 150TB 150023 -->...

  • Page 4: Table Of Contents

    Maintenance instructions • DINO 135TB • 150TB • 180TB 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 ...... 30 4.3.1. Check the frame structures, the boom system, the work platform and the platform carrier 4.3.2. Inspect thoroughly the support outriggers and the outrigger cylinder joints ....31 4.3.3. Inspect the cylinders of the boom, and lubricate the joint bearings ......32 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 135TB • 150TB • 180TB 1.2. SAFETY AND THE ENVIRONMENT 1.2.1. General safety instructions for maintenance During maintenance • The engine must stand still, and the power circuits must be switched off. • All the operating controls must stand in the OFF position.

  • Page 9: Filling Quantities Of Chemical Substances

    1.2.2. Filling quantities of chemical substances Liquid type Volume Kendall Megaflow AW HVI 22 Fuchs Hydraway Bio SE 22 Hydraulic oil options 25 l Fuchs Hydraway Bio SE 32-68 Mobil EAL 32 Hydraulic oil (winter option ) Neste Hydrauli 28 Arctic 25 l Mobilux EP2 NLGI 2 Lubricant Mobil Grease XHP 222 Chain lubricant...
  • Page 10 Maintenance instructions • DINO 135TB • 150TB • 180TB Other materials Steel, aluminium, cast iron Metals Hydraulic pipes and components Recyclable Power pack, axles Recyclable Covers, mud flaps (ABS, PE) Plastics Plastic parts are marked with material Tyres Battery Lead battery Recyclable Electric components Wires, components Partly recyclable.

  • Page 11: Safety-Related Notifications

    Maintenance instructions • DINO 135TB • 150TB • 180TB 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 12: Safety Devices

    Maintenance instructions • DINO 135TB • 150TB • 180TB 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 135TB • 150TB • 180TB 4. 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 breaks the emergency stop circuit.
  • Page 15 6. 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: Maintenance Schedule

    Maintenance instructions • DINO 135TB • 150TB • 180TB 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 DANGER 6 months / 400...
  • Page 17 Maintenance measures 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: Schedule For Inspections Required By The Authorities

    Maintenance instructions • DINO 135TB • 150TB • 180TB 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 19: Lubrication Plan

    2.2. LUBRICATION PLAN...

  • Page 20: Routine Maintenance During Operation

    Maintenance instructions • DINO 135TB • 150TB • 180TB 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.

  • Page 21: Instructions For Daily Maintenance And Inspections

    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. Check visually the condition of the boom and the frame structures. 3.1.2.

  • Page 22: Check The Operation Of The Safety Limit Switches

    Maintenance instructions • DINO 135TB • 150TB • 180TB 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 23: Periodic Service

    PERIODIC SERVICE The measures, included in the maintenance schedule, which 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 chapter, 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 135TB • 150TB • 180TB 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. When the lift is transferred by means of the driving device, it must travel straight. 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 135TB • 150TB • 180TB 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 135TB • 150TB • 180TB 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”.
  • Page 29 9VA2930 9VA0938 9VA2103 9VA0867 DANGER WARNING • leave the lift in this position for a few minutes • repeat the measurement. The height position of the platform's edge should be the same CAUTION as at the beginning. 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 30: Instructions For Annual Maintenance Of The Lift

    Maintenance instructions • DINO 135TB • 150TB • 180TB 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 Of The Boom, And Lubricate The Joint Bearings

    Maintenance instructions • DINO 135TB • 150TB • 180TB point “Lubrication plan”) 7. Lower the outriggers to the support position. 8. check the condition of the cylinder, the piston rods and tightness of the connections 9. check the condition of the cylinder guards 4.3.3.

  • 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 135TB • 150TB • 180TB 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: DANGER •...

  • Page 35: Check Thoroughly The Tow Hitch And The Overrun

    4.3.7. Check thoroughly the tow hitch and the overrun Check: 1. attachment of the tow hitch 2. clearances 3. condition of the tow-ball coupling 4. condition of the locking device 5. check that the mechanism of the overrun brake moves freely: •...

  • Page 36: Inspect Thoroughly The Driving Device

    Maintenance instructions • DINO 135TB • 150TB • 180TB 4.3.11. Inspect thoroughly the driving device Check that the valves of the driving device operate properly and no movement occurs when the spool in the neutral position. 4.3.12. Check the lights Check the condition of the lights and the reflectors. Replace any burned-out bulbs or lights,...

  • Page 37: Change The Hydraulic Oil And The Filter

    DANGER WARNING 4.3.13. Change the hydraulic oil and the filter CAUTION Protect your skin against exposure to hydraulic oil. Used oil can be harmful to the skin. NOTICE 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 38: Check The Battery, The Electrical Appliances And The Wiring

    Maintenance instructions • DINO 135TB • 150TB • 180TB 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 39: Check The Attachment And Condition Of The Safety Devices

    4.3.17. Check the attachment and condition of the safety devices Check the attachment and the condition of the limit switches externally. • from the tow-bar (transport position of the platform, RK3) • on the safety device (RK4 and RK5) • on the support outriggers (RK11, RK12, RK13 and RK14) •...

  • Page 40: Check The Operation Of The Overload Limit Switches Rk4 And Rk5

    Maintenance instructions • DINO 135TB • 150TB • 180TB 4.3.19. Check 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 41 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 1. Disable the RK4 by connecting two jump leads in the chassis control panel housing. •...

  • Page 42: Inspecting The Condition And Functionality Of The Operating Controls

    Maintenance instructions • DINO 135TB • 150TB • 180TB 4.3.20. Inspecting the condition and functionality of the operating controls Check the 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 43: Test Loading

    DANGER 4.3.23. Test loading WARNING The operation of the limit switches RK4 and RK5 must always be checked before the CAUTION test loading! If necessary, see point “4.3.19. Checking the operation of the overload limit switches RK4 and RK5” for instructions. NOTICE I.

  • Page 44: Adjusting The Movement Speeds

    Maintenance instructions • DINO 135TB • 150TB • 180TB 4.4. ADJUSTING THE MOVEMENT SPEEDS Measuring devices required for the adjustment: • multimeter with possibility to measure direct current (A) • screwdriver with narrow tip for adjusting the trimmer 1. Disconnect the conductor 523 from the connector K25B.22 on the cover of the LCB...
  • Page 45 7. Adjusting the ascending ramp on the control card (Q1: control from the LCB centre) Turn first the adjustment screw 5 on the control card to its minimum position (extreme position counter-clockwise). After that, turn it 1/5 round clockwise. 8. Adjusting the descending ramp on the control card (Q1: control from the LCB centre) Turn first the adjustment screw 6 on the control card to its minimum position (extreme position counter-clockwise).
  • Page 46 Maintenance instructions • DINO 135TB • 150TB • 180TB 13. Adjusting the levelling speed of the platform (Q1: control from the LCB centre) Operating from the chassis control centre, tilt the platform outward, and measure the total time it takes. This time should be 35-40 seconds.

  • Page 47: 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 48 Maintenance instructions • DINO 135TB • 150TB • 180TB BLANK...

  • Page 49: Maintenance Of The Batteries

    DANGER WARNING 4.7. MAINTENANCE OF THE BATTERIES CAUTION Electrolytic liquid is highly corrosive – always wear protective clothing and eye guards. NOTICE The batteries generate hydrogen gas during charging – naked flame prohibited, danger of explosion DANGER Always keep the batteries well charged •...
  • Page 50 DANGER Maintenance instructions • DINO 135TB • 150TB • 180TB WARNING Test the condition of the batteries regularly • Specific weight of the liquid CAUTION 1.277 Battery 100 % charged NOTICE If maintained well, the batteries will last 4-5 years of normal operation. Incorrect use...

  • Page 51: Instructions For Fault-Finding

    INSTRUCTIONS FOR FAULT-FINDING 5.1. ERROR CODES IN BATTERY GAUGE CODE xx DESCRIPTION REMEDY Internal current measurement error in the Switch off the current and retry controller. Error in the internal safety circuit for the Switch off the current and retry controller.

  • Page 52: Problems Related To Power Supply And Start-Up

    Maintenance instructions • DINO 135TB • 150TB • 180TB 5.2. PROBLEMS RELATED TO POWER SUPPLY AND START-UP FAULT REMEDY 1. The electric motor does not start from its start button or if any of the movements is activated The correct operating location has not been Select the correct operating location using the selected.

  • Page 53: Operational Problems Related To Movements

    5.3. OPERATIONAL PROBLEMS RELATED TO MOVEMENTS FAULT REMEDY 6. None of the platform 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) Make sure that all the outriggers are steady Green signal light for the outriggers is not supported on the ground.
  • Page 54 Maintenance instructions • DINO 135TB • 150TB • 180TB 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.

  • Page 55: Drifting Of Boom Or Outriggers

    5.4. DRIFTING OF BOOM OR OUTRIGGERS FAULT REMEDY 13. Boom drifts 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, replace the valve.
  • Page 56 Maintenance instructions • DINO 135TB • 150TB • 180TB FAULT REMEDY 15. Platform drifts backward Double load regulation valve on the bottom side For remedy, refer to item 13. is leaking. Load regulation valve under the platform is For remedy, refer to item 13.

  • Page 57: Problems Related To Towing

    5.5. 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. Brake-shoes "glazed", dirty or oil on the friction Replace the brake-shoe sets.
  • Page 58 Maintenance instructions • DINO 135TB • 150TB • 180TB 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 Remove, clean and lubricate the transmission overrun jams.

  • Page 59: 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 60: Hydraulic Components

    Maintenance instructions • DINO 135TB • 150TB • 180TB 6.3. HYDRAULIC COMPONENTS REF. ITEM DC power unit of 2 kW pressure filter swing motor valve block for driving device manual directional valve drive motor load regulation valve load regulation valve lock valve...

  • Page 62: Electric System

    Maintenance instructions • DINO 135TB • 150TB • 180TB ELECTRIC SYSTEM 7.1. ELECTRIC COMPONENTS 135TB #130172, #130176-->, 150TB #150023->, 180TB #180011-> 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.
  • Page 63 CENTRE POSITION ACTIVATION OF THE JOYSTICK Switches off the voltage from micro-switches of the joystick, if the dead-man-switch DMK has not been pressed while the joystick is in the centre position. BASIC SPEED FROM THE CHASSIS CONTROL PANEL Switches on the accelerator control for the engine controller from the chassis control panel.
  • Page 64 Maintenance instructions • DINO 135TB • 150TB • 180TB Overloading of the boom: SR3 is disconnected. The safety relay is automatically reset upon return to the normal outreach range. The delay adjusted with the capacitors affects the tripping moment of the SR3.
  • Page 65 Position 1: slow boom movements Position 2: boom movements at full speed TELESCOPE IN Non-locking button switch. After the SR3 has tripped, the telescope can be retracted by depressing the button. TURN SWITCH WITH KEY Selector switch for choosing the operating location. 1a = Off 1b = chassis control panel 1c = platform control panel...
  • Page 66 Maintenance instructions • DINO 135TB • 150TB • 180TB VOLTMETER When the control voltage is connected, the voltage meter indicates the alternating voltage. PLATFORM CONTROL CENTRE (UCB), RELAYS CONTROL RELAY FOR SIGNAL LIGHTS INDICATING THE STATE OF LOADING OF THE PLATFORM The relay is controlled by the opening point of the limit switch RK4.
  • Page 67 PLATFORM CONTROL CENTRE (UCB), OTHER ITEMS GREEN LED SIGNAL LIGHT The platform inside the operating range. RED LED SIGNAL LIGHT The platform at the border of the operating range. JOYSTICK FUSE 1.6A AUTOMATIC FUSE FOR TURNING OF THE PLATFORM 4A SOCKET OUTLET ON THE PLATFORM, 230VAC 10A, automatic fuse on the door of the main electric cabinet.

  • Page 68: Electric Diagram

    Maintenance instructions • DINO 135TB • 150TB • 180TB RK11-RK14 LIMIT SWITCHES ON THE OUTRIGGERS The limit switch closes as soon as sufficent force is exerted on the outrigger. Prevents the operation of the boom unless the outriggers are not firmly supported on the ground and all limit switches are not closed. RK16 INDUCTIVE LIMIT SWITCH Slows down the lifting and lowering movements of the boom and the turning movement if the boom's length is about ?? m.

  • Page 69: El-Skema

    7.3. EL-SKEMA...
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