Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 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.
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4.3. INSTRUCTIONS FOR ANNUAL MAINTENANCE OF THE LIFT ...... 30 4.3.1. Inspect thoroughly the support outriggers and the outrigger cylinder joints ....31 4.3.2. Check the frame structures, the boom system, the work platform and the platform carrier 4.3.3. Check thoroughly the tow hitch and the overrun ............32 4.3.4.
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.
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.
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 1.2. SAFETY AND THE ENVIRONMENT 1.2.1. General safety instructions for maintenance Exercise particular caution always when carrying out service- and maintenance operations. A faulty lift, or a lift from which covers, safety devices or other parts have been removed, may operate in an unexpected way.
1.2.2. Filling quantities of chemical substances Liquid type Volume Kendall Megaflow AW HVI 22 Fuchs Hydraway Bio SE 22 Hydraulic oil 30-35 l Fuchs Hydraway Bio SE 32-68 Mobil EAL 32 Hydraulic oil (winter option ) Neste Hydrauli 28 Arctic 30-35 l Mobilux EP2 NLGI 2 Lubricant Mobil Grease XHP 222 Chain lubricant...
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Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 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...
1.3. 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.
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Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 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.
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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. A - A ~32 mm DOUBLING CHAIN...
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Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 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...
1.4. 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. This is a general safety alert symbol and it is used to alert you about a potential hazard.
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 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 Maintenance Competent person who is familiar with the lift hours*...
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Maintenance measures 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...
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 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.
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 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.
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.
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 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.
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.
Maintenance instructions • DINO 160XT II • 180XT II • 210XT 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.
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.
Maintenance instructions • DINO 160XT II • 180XT II • 210XT 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.
4.2.4. Check the attachment of the wheels and the tyre pressures Check the wheel bolts for tightness. Tightness of the bolts: 160XT II = 90 Nm 180XT II, 210XT II = 325 Nm Check the tyre pressures. The correct pressures are marked on the wheels and on the jockey wheel bracket.
Maintenance instructions • DINO 160XT II • 180XT II • 210XT 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.
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9VA3241 9VA0867 9VA0938 9VA2103 DANGER WARNING CAUTION 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. Service instructions for the valves •...
Maintenance instructions • DINO 160XT II • 180XT II • 210XT 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.
4.3.1. Inspect thoroughly the support outriggers and the outrigger cylinder joints Check the mechanical structure of the outriggers and the welded seams. The structures must not show signs of deformations or cracks. No fractures or cracks are allowed in the welded seams. Check the footplates for deformations, cracks or breaches Also check that the footplate can turn freely on its joint.
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 4.3.3. Check thoroughly the tow hitch and the overrun Check: • attachment of the tow hitch • clearance • condition of the tow-ball coupling • condition of the locking device •...
4.3.8. 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: • general condition DANGER • play and attachment of the angular gear •...
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 4.3.9. 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.
4.3.10. 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 • drive the lift cylinder to its lower position from the chassis control panel 2.
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 4.3.11. 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 •...
4.3.13. Inspect 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 •...
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 4.3.17. Check the operation of the safety limit switches Check the operation of the limit switches for the outriggers and the boom from the chassis control panel LCB: 1.
4.3.18. Check 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.
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Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 6. If the stroke is too long, adjust the limit switch and secure it with a seal wire. In case the outreach limit switch (RK4) fails, overloading of the boom is prevented by a second safety limit switch (RK5).
DANGER 4.3.19. Test loading WARNING The operation of the limit switches RK4 and RK5 must always be checked before the CAUTION test loading! As required, refer to the point “Checking the operation of the overload limit switches RK4 and RK5” for instructions. NOTICE 1.
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 4.3.20. Check the lights Check the condition of the lights and the reflectors. Replace any burned-out bulbs or lights, and damaged reflectors. 4.3.21. 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. 4.3.22.
4.4. ADJUSTING THE MOVEMENT SPEEDS 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 centre.
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Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 8. Adjusting the descending ramp (UCB control mode, the power unit is not running) Turn at first the adjustment screw 6 on the control card to its minimum position (extreme position counter-clockwise). The descending ramp is not used. 9. Adjusting the min. current of the control card (UCB control mode, the power unit is not running) 9.1 The intensity of current increases as the screw is turned clockwise.
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13.3 Lower the boom to its lowermost position (over a distance of 2 m). The lowering should take about 20 seconds. As necessary, adjust it with the trimmer TR11. 13. Lowering the articulated arms (LCB control mode) Drive the “articulated arms down” movement and simultaneously adjust the intensity of current using the adjustable resistor TR12 to I =1250 mA (or 100 mA lower than setting lower...
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 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 adjustment values from the table in the chapter “Safety devices”.
4.7. INSPECTION DISASSEMBLED DANGER Inspections must be performed in accordance with local, state or federal regulations, legislation, directives, standards. The manufacturer recommends following inspections. WARNING Inspection disassembled should be carried out after 10 years. If the condition of the lift is found to be inferior during the annual inspection, the inspection disassembled should be performed. After the first 10 years, the inspection is recommended to be repeated every 5 CAUTION...
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Maintenance instructions • DINO 160XT II • 180XT II • 210XT II Boom system 1. Remove the covers 2. Disassemble the telescopic boom and wash the parts 3. Check the boom for straightness, twists, deformations, dents, buckles or signs of wear (visual inspection) 4.
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6. Inspect the welded seams highlighted in the picture by applying the magnaflux method. 7. Inspect all other welded seams visually.
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Maintenance instructions • DINO 160XT II • 180XT II • 210XT II Check: 8. the condition and attachment of the Flyer chain brackets 9. the condition, wear-out grade, corrosion and play of the Flyer chains (wash if required). The axial play of the Flyer chains must not exceed 1 mm/10 links 10.
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Turning device 1. Remove the covers 2. Clean the gear rings of the turning bearing and the swing gear Inspect: 3. the retainer ring for the gearwheel of the swing gear 4. the welded seams highlighted in the picture by applying the magnaflux method. 5. Inspect all other welded seams visually. Check: 6.
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Maintenance instructions • DINO 160XT II • 180XT II • 210XT II Articulated arms 1. Inspect the welded seams of the bushing housings and brackets of the articulated arms highlighted in the picture by applying the magnaflux method. 2. Inspect all other welded seams visually. Check: 3. the arms for straightness, deformations, dents, buckles, frost damage or signs of corrosion.
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Chassis 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 Underside...
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Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 210XT, 260XT Underside 3. Inspect 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 plate. 5.
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twists, dents, deformations or signs of corrosion. If you observe signs of corrosion, measure the thickness of the plate. 6. Inspect the welded seams highlighted 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 outrigger joints 9.
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Maintenance instructions • DINO 160XT II • 180XT II • 210XT II Platform and the platform carrier 1. Inspect the welded seams highlighted in the picture by applying the magnaflux method Check 2. that there are no deformations, dents, buckles, twists or signs of corrosion in the platform carrier 3. the welded seams of the platform, and that there are no signs of deformations, bends, corrosion or any excess material that increases the weight 4.
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Pins All pins must be checked and replaced if necessary. The pins that cannot be inspected in the machine, shall be removed for the inspection. 1. inspect all the pins for cracks (ultrasonic test). Check: 2. welded seams of the pin caps 3.
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II INSTRUCTIONS FOR FAULT-FINDING 5.1. PROBLEMS RELATED TO POWER SUPPLY AND START-UP FAULT REMEDY 1. Electric motor cannot be started by depressing the start button, although the selector switch 1 is in position LCB or UCB The emergency stop button has jammed in the Pull up the button and re-start the motor from the lower position.
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FAULT REMEDY 3. Power unit does not start Battery is flat. Recharge the battery. The mains cable is plugged. Disconnect the plug from the mains. No supply of direct-current (12VDC), because the Switch on the main switch. main switch is disengaged. 4. Power unit cranks but does not start Fuel tank is empty.
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 5.2. 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...
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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.
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 5.3. DRIFTING OF BOOM OR OUTRIGGERS FAULT REMEDY 13. Boom drifts slowly downward Load regulation valve is leaking. Remove and clean the valve. 9VA0867 Check the condition of the o-rings. Install the valve carefully –...
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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. leaking. 16. Platform drifts forward Double load regulation valve on the rod side is For remedy, refer to item 13.
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 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.
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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. rod. Parking brake not completely released. Release the parking brake completely.
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II 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.
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Vakiokone / Standard machine / Standardmaschine / Standardmaskin / Standard maskine...
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Maintenance instructions • DINO 160XT II • 180XT II • 210XT II Automaattitasauksella / Automatic levelling / Automatische Nivellierung / Automatik nivellering / Automatisk avbalansering / Automatisk nivellering...
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 (M1) FOR THE ENGINE Control circuit fuse F2 10A.
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Maintenance instructions • DINO 160XT II • 180XT II • 210XT II K15: LEVELLING THE PLATFORM Levelling the platform backward Control circuit fuse F9 1,6A (Platform control centre) and F4 10A (Chassis control centre). K16: LEVELLING THE PLATFORM Levelling the platform forward Control circuit fuse F9 1,6A (Platform control centre) and F4 10A (Chassis control centre).
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K25: CONTROL RELAY FOR THE 1B-VALVE Switches the voltage of 12VDC to the selector valve of the boom. K25B: CONTROL RELAY FOR THE PR-VALVE When driving the chassis, switches the voltage of 12VDC directly to the PR-valve. When driving the boom, the points direct the adjusted current from the control card to the PR-valve.
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Maintenance instructions • DINO 160XT II • 180XT II • 210XT II K391: CHANGE-OVER RELAY FOR OPTIONAL FUNCTIONS When the relay is active the in-out movements of the telescope are switched over to the joystick movements in the Y-direction. As the relay is not active lifting-lowering movements of the boom are switched over to the joystick movements in the Y-direction K40: CONTROL OF THE COMBUSTION ENGINE CHOKE...
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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 Controls the contactor of the electric motor and start solenoid of the combustion engine if the combustion engine is used.
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Maintenance instructions • DINO 160XT II • 180XT II • 210XT II CHASSIS CONTROL CENTRE (LCB), OTHER ITEMS 1.6A FUSE FOR ACTIVATION CIRCUIT OF THE TIMER CARD 10A CONTROL FUSE FOR START CIRCUIT AND MONITORING CIRCUIT OF THE OUTREACH 10A CONTROL FUSE FOR THE DRIVING DEVICE 5A FUSE FOR CONTROL LEVERS AND JOYSTICK IN THE CHASSIS AND PLATFORM CONTROL CENTRES 1.6A CONTROL FUSE FOR THE DRIVING DEVICE...
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TR12: ADJUSTABLE RESISTOR Adjustment of the articulated arms’ lowering speed. VOLTAGE METER As the control voltage is connected the voltage meter indicates the alternating voltage reading. PLATFORM CONTROL CENTRE (UCB), RELAYS K41b: SENSOR RELAY FOR THE AC SUPPLY When the AC-supply is connected, the start/stop automation is operational. CONTROL RELAY FOR SIGNAL LIGHTS INDICATING THE STATE OF LOADING OF K50: THE PLATFORM...
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Maintenance instructions • DINO 160XT II • 180XT II • 210XT II S11: EMERGENCY DESCENT SWITCH Controls the solenoid for the emergency descent unit which starts the unit and supplies the control voltage to the control levers while the the emergency descent system is in operation.
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CONTROL CENTRE FOR THE DRIVING DEVICE (DCB) S24: DRIVING STRAIGHT FORWARD AND BACKWARD Non-locking lever switch. S25: TURNING TO THE LEFT Non-locking pushbutton. S26: TURNING TO THE RIGHT Non-locking pushbutton. 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.
Maintenance instructions • DINO 160XT II • 180XT II • 210XT II OTHER MARKINGS BATTERY 12VDC 44AH THERMORELAY FOR THE ELECTRIC MOTOR F11: MAIN BATTERY FUSE 125A PLUG ELECTRIC MOTOR 230VAC 1.5kW EMERGENCY DESCENT MOTOR 12VDC Max. operating time 10 min. ROTARY ADAPTOR The electric circuits between the chassis and the turning device go through the electric rotary adaptor.
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