Dino lift DINO 210XTB II Technical specifications

MAINTENANCE
INSTRUCTIONS
DINO 160XTB II •180XTB II •
210XTB II
Dealer:Manufacturer:
Dinolift Oy
Raikkolantie 145
FI-32210 LOIMAA
Tel. [phone]
[email protected]
www.dinolift.com

3
ORIGINAL INSTRUCTIONS
Valid from serial number
160XTB II 160188->
180XTB II 40056->
210XTB II 210035->

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Maintenance instructions •DINO 160XTB II •180XTB II •210XTB II
CONTENTS
1. 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. Materials and recyclability..............................................................................................9
1.3. SAFETY-RELATED NOTIFICATIONS............................................................... 11
1.4. SAFETY DEVICES............................................................................................ 12
2. SERVICING AND MAINTENANCE ........................................................................... 16
2.1. INSPECTIONS REQUIRED BY AUTHORITIES ............................................... 18
2.2. LUBRICATION PLAN ........................................................................................ 19
3. ROUTINE MAINTENANCE DURING OPERATION .................................................. 20
3.1. DAILY MAINTENANCE TASKS......................................................................... 21
3.1.1. Condition of chassis, boom and work platform............................................................21
3.1.2. Check the tyres and tyre pressure...............................................................................21
3.1.3. Check the lights ...........................................................................................................21
3.1.4. Check the hydraulic oil.................................................................................................21
3.1.5. Check the hydraulic hoses, pipes and connectors ......................................................21
3.1.6. Check the operation of safety limit switches................................................................21
3.1.7. Check the emergency descent, emergency stop and sound signal ............................22
3.1.8. Signs, labels and machine plates ................................................................................22
3.1.9. Instruction manuals......................................................................................................22
4. PERIODIC SERVICE.................................................................................................23
4.1. INSTRUCTIONS FOR MONTHLY SERVICE AND INSPECTION .................... 23
4.1.1. Lubricate the greasing points ......................................................................................23
4.1.2. Check and adjust the play between the slide pads and the slide surface ...................23
4.1.3. Check the adjustment of the tow hitch and the overrun brake..................................... 24
4.1.4. Check the driving device..............................................................................................25
4.1.5. Check the condition and attachment of the battery and the wiring..............................25
4.1.6. Check the operation and condition of the platform's levelling system ......................... 25
4.2. INSTRUCTIONS FOR INSPECTIONS EVERY 6 MONTHS............................. 26
4.2.1. Check and lubricate the turning device bearings and the gear ring............................. 26
4.2.2. Lubricate the telescope cylinder bearings ...................................................................26
4.2.3. Lubricate the Flyer-chain .............................................................................................26
4.2.4. Check the attachment of the wheels and the tyre pressures.......................................26
4.2.5. Lubricate the tow hitch and the overrun.......................................................................27
4.2.6. Check the condition of the brakes ...............................................................................27
4.2.7. Lubricate the driving device.........................................................................................27
4.2.8. Check the adjustment of the overload protection device RK4.....................................28
4.2.9. Check the operation of the load regulation valves.......................................................28
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
31
4.3.2. Inspect thoroughly the support outriggers and the outrigger cylinder joints ................31
4.3.3. Inspect the cylinders, and lubricate the joint bearings.................................................32
4.3.4. Inspect thoroughly the Flyer-chains.............................................................................33

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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. Inspect the axle and the suspension ...........................................................................35
4.3.11. Inspect thoroughly the driving device ..........................................................................35
4.3.12. Check the lights ...........................................................................................................35
4.3.13. Changethehydraulicoilandthelter .........................................................................36
4.3.14. Inspect thoroughly the hydraulic hoses, pipes and connections..................................36
4.3.15. Check the battery, the electrical appliances and the wiring .........................................37
4.3.16. Measure hydraulic pressures.......................................................................................37
4.3.17. Check the attachment and condition of the safety devices..........................................37
4.3.18. Check the operation of the safety limit switches..........................................................38
4.3.19. Checking the operation of the overload limit switches RK4 and RK5..........................39
4.3.20. Inspecting the condition and functionality of the operating controls ............................40
4.3.21. Inspect the anti-corrosion treatment ............................................................................ 40
4.3.22. Test loading..................................................................................................................41
4.4. ADJUSTING THE MOVEMENT SPEEDS......................................................... 42
4.5. ADJUSTING THE OVERLOAD LIMIT SWITCHES........................................... 45
4.6. SPECIAL INSPECTION .................................................................................... 45
4.7. MAINTENANCE OF THE BATTERIES ............................................................. 46
5. FAULT FINDING ........................................................................................................ 48
5.1. PROBLEMS WITH POWER SUPPLY............................................................... 48
5.2. OPERATIONAL PROBLEMS RELATED TO MOVEMENTS............................. 49
5.3. DRIFTING OF BOOM OR OUTRIGGERS........................................................ 51
5.4. PROBLEMS RELATED TO TOWING................................................................ 53
6. HYDRAULIC SYSTEM .............................................................................................. 55
6.1. GENERAL INFORMATION OF HYDRAULICS ................................................. 55
6.2. HYDRAULIC DIAGRAM.................................................................................... 55
7. ELECTRIC SYSTEM ................................................................................................. 57
7.1. ELECTRIC COMPONENTS.............................................................................. 57
7.2. ELECTRIC DIAGRAM....................................................................................... 64

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Maintenance instructions •DINO 160XTB II •180XTB II •210XTB II
1. TO THE MAINTENANCE PERSONNEL
This maintenance instruction manual is meant to give additional instructions on maintenance,
adjustments and repairs of DINO lift to professional maintenance staff familiar with the basic
structure and functions of lift.
These maintenance instructions are an addition to the operating instructions accompanying
the platform. It is essential, that also the person responsible for the maintenance is familiar
with the operating and safety instructions given in the operating instructions manual before
working with the platform.
Perform all service tasks and repairs according to instructions and health and safety
regulations.
Take extra care during all service- and maintenance operations. A faulty machine may cause
severe, unforeseen risks.
If you are not certain of the parts, tools or actions please consult your dealer or
manufacturer.
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.
Please consult your dealer or the manufacturer for more information and detailed
instructions.
The operator must be given instructions and consent from the manufacturer for all
such specic work methods or operating conditions which the manufacturer has not
explicitly dened in operating or maintenance instructions.
The device must neither be altered without the manufacturer’s consent nor be
used, repaired or tested in a way that does not meet the requirements set by the
manufacturer.

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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.
The warranty period starts from the date of delivery from factory. The warranty for
accessories and their parts manufactured by external suppliers is limited to the warranty
granted by their manufacturers, unless otherwise stipulated.
The warranty covers only the cost of constructional parts and components used in the
equipment. The warranty does not cover:
• damage or loss caused by transportation
• damage or loss caused by misconduct, misapplication or accident damage, failure or
losscausedbynegligenceofinstructions,manufacturerspeciedserviceprogram,
maintenance or storage
• normal wear of the equipment and damage resulting therefrom, nor wearing parts and
materials,suchasrubbertyres,seals,hoses,ttings,batteries,lters,etc.
• damage, failure or loss caused by maintenance or repair work performed by unauthorised
service personnel
• damage, failure or loss caused by the purchaser’s acts or omissions causing alterations
ormodicationstothestructure,congurationorqualityoftheproduct
• anyindirectdamageorlosssuchaslossofprotanddowntimecosts,etc.
• any claims by a third party.
• any damage caused to other property.
Warranty claims and damaged parts shall be processed according to Dinolift instruction of
warranty procedure. Contact the distributor for further instructions. No claim will be accepted
ifDinoliftnoticationandwarrantyproceduresarenotfollowedornon-originalpartsorparts
not approved by the Supplier have been used.
For more information on warranty procedures, contact the distributor or
Dinolift Oy
After Sales Services
Raikkolantie 145
FI-32210 Loimaa
Finland.
[email protected]

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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.
If, during maintenance, it is necessary to disable a safety device, make sure that it is
returned to use and works correctly before using the device.
Beware of sudden and unexpected movements.
Support the platform, boom system, articulated arms and support outriggers in a position in
which the load does not rest on the structure under repair or cause any other danger (e.g.
transport position or use of supporting structures)
While removing hydraulic cylinders, note, that
• they may be oily and slippery
• the cylinders are heavy. Use a suitable crane and lifting accessories for lifting.
Do not let oil spill to the ground
Used oils and oily waste must be properly disposed of. Note the national and local recycling
and waste policies and regulations.
Remember when handling batteries:
Electrolytic liquid is highly corrosive - Always wear protective clothing and eye wear.
Thebatteryemitsanexplosivegaswhilecharging-keepawayfromopename.Explosion
hazard.
Use genuine spare parts. Doing so, you ensure the correct functioning and structural safety
even after major repairs.

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1.2.2. Chemicals
Type Volume
Hydraulic oil Mobil EAL 32
KendallMegaowAWHVI22
30 - 35 l
Hydraulic oil (winter option) Neste Hydrauli 28 Arctic 30 - 35 l
Lubricant Mobilux EP2 NLGI 2
Mobil Grease XHP 222
Chain lubricant Würth HHS Grease
Engine oil (in platforms with
power pack) SAE 10W-30
0,6 l (Honda)
1,1 l (Hatz)
Formorespecicengineoilinformationandrecommendations,seetheengines’operation
manual.
Thehydraulicoilusedinthedeviceismarkedonauidlevellabelonthereservoir.
1.2.3. Materials and recyclability
Tyres
Type Radial M+S Size 225/70R15C
225/75R16C*
HA-oils (in tread) No Tyres can be recycled.
Note the national and local regulations
and policies.
Zinc (in tread) N/A
Cadmium (in tread) No
*Option

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Maintenance instructions •DINO 160XTB II •180XTB II •210XTB II
Other materials
Metals
Steel, aluminum, cast iron
RecyclableHydraulic pipes and components
Power pack, axles
Plastics Covers, mudguards (ABS, PE) Recyclable
Tyres
Battery Lead battery Recyclable
Electrical
components Wires, components Recyclable
Hydraulic hoses Not recyclable. Hazardous waste.
Oils and lubricants Usedoils,oilyltersetc. Not recyclable. Hazardous waste.
The ability for energy / material recycling depends on local recycling possibilities.
Surface treatment
Primer zinc rich epoxy (solvent borne)
Surface nish two pack polyurethane paint

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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. Observe the additional instructions given in form of text or symbols that
follow this symbol.
Red DANGER-message warns for an imminent or potential hazardous situation which, if not
avoided, may result in death or serious injury.
Orange WARNING -message is used in connection with potential risk factors, which if not
avoided, under certain conditions, may result in death or serious injury.
Yellow CAUTION -message is used to warn about a hazardous situation which, if not
avoided, could result in minor or moderate injury.
Bluenotice-messageisusedtodrawyourattentiontospecialnoticationsorinstructions
that are related to the operation or maintenance. Such messages include, for example,
instructions that are related to reliability of the machine or aim to avoid material losses.

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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.
RK3
2. Supervision of supporting
The lift’s all support outriggers 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, RK12, RK13, RK14
3. Overload control of the boom
The outreach limit switch RK4 and overload limit switch RK5 prevent the lift from being
overloaded by limiting the outreach of the lift to the side.
The limit switches are located under the cover at the top end of the lifting cylinder. During
operation, the cover must be intact and in place.
RK4, RK5

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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
w
W RK4 - L RK5 - L
160XT/XTB II 270 kg 1925 mm 2175 mm +0 / -50 mm
180XT/XTB II 215 kg 2300 mm 2570 mm +0 / -50 mm
210XT/XTB II 80 kg 3025 mm 3525 mm +0 / -50 mm
The red warning light for overloading will illuminate as soon as the RK4 has stopped the
movement. While at the outreach limit, the red warning light and the green signal light will
ash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 backs up, if the RK4, for some reason, does not work.
Once the RK5 is activated, the red warning light for overloading in both control centres will
be continually illuminated, and a warning buzzer will sound on the platform.
The operation of the overload limit switches is based on monitoring of the boom's lifting
torque.
PRESSURE SPRING
LIFTING CYLINDER ARTICULATED ARM
LIMIT SWITCHES RK4, RK5
ADJUSTMENT
SCREWS
The limit switches must never be readjusted, nor the operation of the mechanism be
impeded. Risk of turning over the lift!

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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.
~ 3 mm
~32 mm
~
40
mm
AA
A - A
A
B
A
B
C
C
LIMIT SWICH RK7
EXTENSION 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 cylinder controls the slave cylinder that inclines the work platform.
The levelling system comprises the
following parts:
1. Master cylinder
2. Slave cylinder
3. Load regulation valve
4. Double load regulation valve
5. Electric directional valve
21,5 Mpa
215 bar
3100 psi
MP
MV T
P
MP
MV
21,5 Mpa
215 bar
3100 psi
1
2
3
4
5

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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.
Outrigger cylinders Lock valves Prevent the inching of the
outriggers in either direction.
Lifting cylinder of the boom Load regulation valve Prevents the load from falling
Lifting cylinder of the
articulated arms Load regulation valve Prevents the load from falling
Telescope cylinder Load regulation valve Prevents the inching of the
telescope in either direction.
Levelling system Load regulation valves Prevents 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 control station. Once the button has been
depressed, only the emergency descent functions remain operational.
The emergency stop button locks in the lower position, and it must be released before
starting the power unit.
If the unit does not start, make sure that the emergency descent button is not in the lower
position at any of the control stations.

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Maintenance instructions •DINO 160XTB II •180XTB II •210XTB II
2. SERVICING AND MAINTENANCE
Maintenance item A B C D E
1Condition of chassis structures, boom and work platform C C C I
2Bearings of the overload protection device joint G C/G C/G
3Bearings of outriggers and outrigger cylinders G C/G I/G
4Bearings of outrigger footplates and moving parts of
outrigger limit switch system G C/G I/G
5Bearings of boom and articulated arms G C/G C/G
6Bearings of the platform G C/G C/G
7Bearings of the levelling cylinders G C/G C/G
8Bearings of the lifting cylinder G C/G C/G
9Sliding surfaces / rolls of the telescope C/G C/G C/G
10 Bearings of the telescope cylinder C/G C/G
11 Condition of cylinders I
12 Flyer-chain G I/G
13 Slide pads and sliding pad clearances C C C
14 Turning device G I/G
15 Electro-hydraulic rotating adaptor C
16 Tyres and tyre pressures C C I I
17 Coupling / overrun device C G I/G
18 Jockey wheel slide and threads I/G
19 Brakes C C
Maint. Schedule Person responsible Reference
ADaily Operator Operating
instructions
B1 month / 100
hours* Competent person who is familiar with the lift Maintenance instructions
C6 months / 400
hours* Competent person who is familiar with the lift Maintenance instructions
DAnnually / 800
hours*
Skilled technician who is well familiar with the
structure and operation of the lift
Maintenance
instructions
EAs needed Skilled technician who is well familiar with the
structure and operation of the lift
Maintenance
instructions
* Service must be performed every indicated month or operating hour interval, whichever comes
rst.
In addition to daily maintenance, every user must do a worksite inspection before operating
the lift.
C = Check (general checking of condition).
I = Thoroug Inspection. Performed according to separate prochedure described in
maintenance instructions.
G = Grease
D = Do the replacements, repairs or other maintenance tasks described in the instructions

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20 Axles and suspension I
21 Driving device C G I
22 Lights C C C I
23 Hydraulic oil C C C D
24 Hydraulichoses,pipesandttings C C C I
25 Condition and attachment of battery, electrical devices and
wiring C C I
26 Hydraulic pressure I
27 Condition of safety limit switches C
28 Operation of safety limit switches C C C I
29 Operation of overload protection device C I D
30 Load holding and load regulation valves C C
31 Platform levelling system C C C
32 Platform control devices C I
33 Emergency descend, emergency stop and
sound signal CCCC
34 Signs, labels and machine plates C C C C
35 Instruction manuals C C C C
36 Test loading I
37 Corrosion protection C D
38 Movement speed adjustment D
39 Special inspection D
Maintenance item A B C D E
Alwayslubricatetheliftandapplyaprotectivegreaselmimmediatelyafterthewashing.
Special inspection is required if the lift has been damaged in a manner which may affect
its load-bearing capacity or safe operation. For further instructions, see the maintenance
instuctions manual.
If the platform has a combustion engine power pack, check the engine manual for
information on maintenance prochedures required by the engine.
If the lift is operated under demanding conditions (in exceptionally humid or dusty
environment, corrosive climate, etc.), the intervals between the oil changes and the other
inspections shall be shortened to meet the prevailing conditions in order to maintain the
operational safety and reliability of the lift.

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Maintenance instructions •DINO 160XTB II •180XTB II •210XTB II
2.1. INSPECTIONS REQUIRED BY AUTHORITIES
Always check the local, state or federal regulations about aerial platform inspections
and inspector qualications from local 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rsttimeand
beforerststart-upaftermajorrepairsandalterations.
A thorough inspection and a test loading of the lift must be carried out at least once every
twelve (12) months.
The platform should undergo a major inspection within ten (10) years after having
been originally put into service. A major inspection includes non-destructive testing and
inspection while dis-assembled.
A special inspection should be done if the platform has been exposed to exceptional
circumstances which may have affected the structural integrity of critical components.
The inspections should be carried out on regular basis throughout the service life of the lift.
If the lift is used under extreme 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 regular inspections. Particular attention shall be paid to
changes which affect the operational safety.
Duringinspectionsthenoticationsgiveninpreviousinspections,practicalexperience
from use and information on performed repairs should be taken into account and can be
implemented for better safety.
Major and special inspections shall be carried out by a competent person or competent
body, who is familiar with the operation and structure of the lift. The competent person sould
periodically update their knowledge and be able to demonstrate their competency if so
required.
A report should be made of the inspections and the reports should be kept with the unit
stored in the space reserved for it.

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

20
Maintenance instructions •DINO 160XTB II •180XTB II •210XTB II
3. 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specic
measurements and adjustment values. They are separately described in maintenance
instructions manual. Please contact your maintenance partner, dealer or manufacturer.
Make sure that all service and maintenance prochedures are performed in time and
according to instructions.
Any faults which may affect the operational safety of the unit must be repaired before the lift
is used for the next time
Keep the lift clean. Clean the lift carefully before any service and maintenance operations or
inspections. Impurities may cause serious problems in for example in the hydraulic system.
Use original spare parts and service kits. See spare part list for detailed information on spare
parts.
The rst service after 20 hours of operation
• changethepressurelterelement
• adjust the brakes according to the instructions (see point “Wheel brakes and bearings”)
• check the wheel bolts for tightness after about 100 km of driving
If the lift is operated under demanding conditions (in exceptionally humid or dusty
environment, corrosive climate, etc.), the intervals between the oil changes and the
other inspections shall be shortened to meet the prevailing conditions in order to
maintain the operational safety and reliability of the lift.
The performance of the periodic servicing and the inspections is absolutely
mandatory, because their negligence may impair the operational safety of the lift.
The guarantee will not remain valid, if the servicing and the periodic inspections are
not performed.