DINO 160XT ®

OPERATING INSTRUCTIONS

Raikkolantie 145
FI-32210 LOIMAA
T. +358 2 762 5900
F. +358 2 762 7160
dino@dinolift.com
www.dinolift.com
DINO 160XT

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OPERATING INSTRUCTION

Valid from serial number 16316 ->

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CONTENTS
REACH DIAGRAM ..........................................................................................................................6

TECHNICAL SPECIFICATION.....................................................................................................7

GENERAL SAFETY REGULATIONS...........................................................................................8

REGULAR INSPECTION..............................................................................................................10

WORKSITE INSPECTION............................................................................................................11

OPERATION OF THE SAFETY DEVICES................................................................................13

OPERATING CONTROLS ............................................................................................................15

OPERATING CONTROLS ON CHASSIS PANEL......................................................................15
OPERATING CONTROLS OF DRIVE SYSTEM........................................................................16
OPERATING CONTROLS OF OUTRIGGERS ...........................................................................16
OPERATING CONTROLS ON THE PLATFORM......................................................................16
OPERATING CONTROLS ON THE PLATFORM......................................................................17
MEASURES TO BE TAKEN IF THE LIFT IS AT RISK OF LOSING ITS STABILITY.....19

START-UP........................................................................................................................................21
OPERATING THE LIFT FROM THE CHASSIS PANEL............................................................26
OPERATING THE LIFT FROM THE PLATFORM PANEL.......................................................27
EMERGENCY DESCENT SYSTEM............................................................................................33

DRIVING DEVICE .........................................................................................................................34

SPECIAL INSTRUCTIONS FOR WINTER USE .......................................................................36

MEASURES TO BE TAKEN AT THE END OF THE WORKING DAY ................................37

PREPARING THE LIFT FOR TRANSPORT .............................................................................38

CONNECTION TO THE TOWING VEHICLE ..........................................................................39

SERVICE AND MAINTENANCE.................................................................................................40

GENERAL SERVICE INSTRUCTIONS......................................................................................40
SERVICE AND INSPECTIONS ...................................................................................................41
LUBRICATION PLAN .................................................................................................................42
LOAD HOLDING AND LOAD REGULATION VALVES .........................................................45
WHEEL BRAKES AND BEARINGS...........................................................................................46
LEVELLING SYSTEM OF THE PLATFORM ............................................................................49
REGULAR SERVICING...............................................................................................................50
INSPECTION INSTRUCTIONS ...................................................................................................64
FIRST INSPECTION.....................................................................................................................64
DAILY INSPECTION (START-UP INSPECTION) ....................................................................65
MONTHLY INSPECTION (MAINTENANCE INSPECTION)...................................................66
ANNUAL INSPECTION (REGULAR INSPECTION) ................................................................67
EXTRAORDINARY INSPECTION .............................................................................................70
TEST LOADING INSTRUCTION FOR REGULAR INSPECTION ...........................................71

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FAULT FINDING............................................................................................................................72

GENERAL INFORMATION OF HYDRAULICS.......................................................................79

OPERATION OF THE ELECTRIC COMPONENTS................................................................80

CHASSIS CONTROL CENTRE (LCB), RELAYS.......................................................................80
CHASSIS CONTROL CENTRE (LCB), SWITCHES ..................................................................82
CHASSIS CONTROL CENTRE (LCB), OTHER ITEMS ............................................................83
PLATFORM CONTROL CENTRE (UCB), RELAYS .................................................................84
PLATFORM CONTROL CENTRE (UCB), SWITCHES.............................................................85
PLATFORM CONTROL CENTRE (UCB), OTHER ITEMS.......................................................86
LIMIT SWITCHES........................................................................................................................86
DRIVING DEVICE CONTROL CENTRE (DCB)........................................................................87
OTHER MARKINGS ....................................................................................................................87
ADJUSTMENT OF THE MOVEMENT SPEEDS.......................................................................88

ELECTRIC COMPONENTS 16048 → .........................................................................................90

WIRING DIAGRAM.......................................................................................................................94

...................................................................................................95
ELECTRIC DIAGRAM 16082

...................................................109
ELECTRIC DIAGRAM; PETROL AGGREGATE 16048

ELECTRIC DIAGRAM HATZ-DIESEL 16048 → ...................................................................111

HYDRAULIC COMPONENTS 16027 → ...................................................................................113

HYDRAULIC DIAGRAM ............................................................................................................114

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REACH DIAGRAM

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TECHNICAL SPECIFICATION

Max. working height 16.0 m

Max. platform height 14.0 m

Max. outreach to the side 9.1 m

Boom rotation continuous

Platform rotation 90°

Turn area refer to reach diagram

Support width 3.80 m

Transport width 1.78 m

Transport length 5.91 m

Transport height 2.20 m

Weight (without aggregate) 1,960 kg

Max. allowed load on platform 215 kg

Max. number of persons + additional load 2 pers. + 55 kg

Max. allowed sideways load (caused by persons) 400 N

Max. lateral inclination of chassis ±0,3°

Max. wind speed during operation 12,5 m/s

Min. ambient temperature during operation - 20 °C

Max. support force on outriggers 16800 N

Platform size 0.7 x 1.3 m

Gradeability 25%

Power supply:
- mains current 230V / 50Hz / 10A
- petrol engine aggregate (optional extra) 4.8 kW (6.5 hp) / 3600 rpm
- diesel engine aggregate (optional extra) 4.4 kW (6 hp) / 2800 rpm

Socket outlets on platform 230V / 50Hz / 16A

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GENERAL SAFETY REGULATIONS

Make yourself familiar with these operating instructions before using the lift!

Keep these Operating Instructions in the place reserved for them.

Make sure that all users of the lift are familiar with these instructions.
Advice the new users and strictly follow all instructions given by the manufacturer.

Make sure you clearly understand all instructions relating to the operational safety of the lift.

Always use chocks under the wheels when disconnecting the lift from the car.

Only specially trained personnel who are well familiar with the device and at least 18-years old are
allowed to operate the lift

AT LEAST 18 YEARS + TRAINING

The max. allowed load on the platform is two (2) persons and at maximum fifty five (55) kg of
additional load, however, the total load must not exceed two hundred fifteen (215) kg.

The platform may only be operated when the chassis is well supported and the wheels are off the
ground.

The loadbearing capacity and the gradient of the base must be taken into account when supporting
the chassis.

Additional support plates of adequate size must be used under the outriggers when working on soft
ground. Only use such additional support plates on which the metallic outriggers will not slide.

The lift may only be moved in the transport position. No persons or load are allowed on the
platform during the transportation.

The weather conditions, such as wind, visibility and rain, must always be taken into account so that
these factors will not adversely affect the safe performance of the lifting operations.

The use of the lift is prohibited if

- the temperature drops under - 20 °C or
- the wind speed exceeds 12,5 m/s

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Do not use ladders, steps or other similar equipment on the platform.

Never throw any objects from the platform.

The lift must not be used for transferring goods or persons between different floors or working
levels.

Never disable the operation of any safety device.

Always make sure before lowering the platform that the area on the underside is clear of any
obstructions.
Avoid damaging the platform by lowering it on the ground or bringing it in contact with any
structures.

When working in busy areas the operating range of the lift must be clearly marked either by using
warning lights or fencing.
Also observe the regulations of the Road Traffic Act.

Beware of the live aerial power lines in the area - observe the minimum safety distances:

Voltage Min. distance below Min. distance at the

(m) side (m)
100 – 400 V hanging cable 0,5 0,5
100 – 400 V open-wire cable 2 2
6 – 45 kV 2 3
110 kV 3 5
220 kV 4 5
400 kV 5 5

Keep the lift clean of any dirt which may impair the safe operation and impede the inspection of the
structures

The device must be serviced and inspected regularly.

Only skilled persons who are familiar with the service and reparation instructions are allowed to
carry out the service and reparation work.

It is strictly prohibited to use a lift which is out of order.

The device must not be modified without the manufacturer´s consent.

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REGULAR INSPECTION

A thorough inspection must be made at least once every twelve (12) months.
The inspection should be made by a person who is technically trained and is familiar with the
function, use and construction of the lift.

Inspections should be recorded in a protocol that should always follow the unit and be stored in the
space reserved for it.

The inspections must be made regularly throughout the operative life of the lift.
The inspections must be made within twelve (12) months from the first or the previous inspection.

If the lift is used in especially severe conditions, inspection intervals should be shorter than
mentioned above.

The general operating conditions of the lift, and safety- and control devices should be established
through regular inspections. Special attention should be paid to factors that influence the operating
safety.
It should also be established if the findings of the previous inspection, or the experiences gained
when using the unit could give cause to further improve the operational safety of the unit.

ATTENTION! Primarily the national legislation must be followed!

Regular inspections and service measures are described more thoroughly in the chapter "Service-
and maintenance".

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WORKSITE INSPECTION

1. General
- Is the lift suited for the intended job?
- Is the performance of the lift sufficient for the job? (reach, loadability etc.)
- Is the position of the lift safe?
- Is the lighting on the worksiite sufficient?

2. Documents
- Are the Operation and Service Instructions for this lift present? (Manufacturer´s instructions)
- Are inspections and servicing carried out in accordance with the instructions and have the
defects affecting the safety been checked as repaired?
(Inspection protocol)

3. Structure (Visual inspection and operational test)

- General condition of the lift
- Operation and protection of the controls
- Emergency stop, signal horn and limit switches
- Electrical appliances and wiring
- Oil leaks
- Load markings and signs

4. Operator
- Is the operator old enough?
- Has the operator received the required training?

5. Special issues on the work site

- Are there any additional regulations relevant to the worksite or the work?

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OPERATION OF THE SAFETY DEVICES

1. Support outriggers (Fig. A)

The safety limit switch RK3 prevents the operation of the outriggers and the driving device when
the boom is raised from the parking support. The switch is located on the parking support of the
towbar.

2. Lifting of the boom (Fig. B)

All support outriggers of the lift must be in the supporting position before lifting the boom. Make
sure that the wheels are off the ground.
The safety limit switches RK11, RK12, RK13 and RK14 are located on the support outriggers.

3. Overload protection switches (Figs. A and C)

The safety limit switches prevent overloading of the lift. At a predetermined position the overload
limit switch RK4 stops extension of the telescope and lowering of the boom.
The overload limit switch RK5 backs up if the RK4 for some reason does not work.
The green light in the platform control centre is lit when the platform is inside the allowed operating
range. The red light comes on as the RK4 stops the movement. When the red light is on, the lift can
be operated in the direction where it stays inside the allowed outreach area. The safety limit switch
RK5 backs up the operation of the RK4 by switching on the buzzer on the platform.

4. The emergency stop pushbutton immediately stops the movement and shuts off the power
unit.
The emergency stop pushbutton must be pulled up before the power unit can be restarted
(button 3 on page 14 and button 22 on page 18).

Ensure the operation of the safety devices - do not lock the chassis panel cover with key while
the lift is in operation.

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OPERATING CONTROLS

OPERATING CONTROLS ON CHASSIS PANEL

1. Selector switch
0 - ignition off
1 -outrigger circuit, hydraulic drive
2 -controlling the boom from the platform
3 -controlling the boom from the chassis
2. Start button
3. Emergency stop button
4A. Green signal light of the outrigger limit
switches.
4B. Red signal light of the safety device
(RK4)
5. Start button of the emergency descent
system
6. Pushbutton "Telescope in"
7. Lever switch for turning
8. Lever switch for boom system
9. Lever switch for telescope
movement
10. Voltage meter
16. Position indicator of chassis
29. Stop button
32. Lever switch for platform inclination
33. Lever switch for articulated arms
34. Hour meter
40. Choke

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OPERATING CONTROLS OF DRIVE SYSTEM

28A. Forward - backward

28A + 28L drive to the left
28A + 28L drive to the right

OPERATING CONTROLS OF OUTRIGGERS

12. Rear outrigger, right.

13. Rear outrigger, left
14. Front outrigger, left
15. Front outrigger, right.
16. Position indicator of chassis

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OPERATING CONTROLS ON THE PLATFORM

Close the chassis control panel cover before operating the platform controls.
The cover must not be locked while the lift is in operation.

17. Control lever

IN

DOWN UP
(ARTIC.ARMS) (ARTIC.ARMS)

OUT

UP

TO THE LEFT TO THE RIGHT

(BOOM) (BOOM))

DOWN

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18. Signal lights

- green = inside the allowed outreach range
- red = at the border of the allowed outreach range
20. Start button of the emergency descent system
21. Telescope in
22. Emergency stop
- push to stop
- pull to reset
23. Sound signal
24. Socket outlet 230VAC/ (2 pcs.)
25. Stopping the engine
26. Starting the engine
30. Turning the platform
31. Fuse for turning of the platform
35. Levelling of the platform (pushbutton)
36. Lever for levelling of the platform (is used simultaneously with pushbutton 35)
41. Choke

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MEASURES TO BE TAKEN IF THE LIFT IS AT RISK OF LOSING ITS

STABILITY

The reason for the reduced stability can be a fault in the lift, the wind or other lateral force, collapse
of the standing base or negligence in providing sufficient support. In most cases a sign of the
reduced stability is the inclination of the lift.

1. If there is time, try to find out the reason for the reduced stability and the direction of its
effect. Warn other people on the work site using the alarm signal.

2. Reduce the outreach to the side by retracting the telescope. Avoid abrupt movements.

3. Turn the boom away from the danger zone, i.e. to a position where the stability of the lift is
normal.

4. Lower the boom.

If the stability has been lost as a result of a fault in the lift, repair such a fault immediately.

Do not use the lift until the fault has been repaired and the condition of the lift has been verified.

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Notes

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START-UP

1. Ground stability
- make sure that the ground is even and hard enough to support the lift in a steady level
position.

Soil material Density Max.

ground
pressure
P kg/cm²
Gravel High density 6
Medium density 4
Loose 2
Sand High density 5
Medium density 3
Loose 1,5
Fine sand High density 4
Medium density 2
Loose 1
Sand/ mud High density (very hard to work) 1,00
Medium density (hard to work) 0,50
Loose (easily worked) 0,25

- if the ground is soft, use sufficiently large and sturdy additional plates under the support
outriggers

- observe the effect of ice, possible rain and inclination of the surface on the support
(the support outriggers must not slip on the surface)
- the operation is prohibited if the lift is not properly supported and in a level position

2. Drive or push the lift to the inspected lifting site

- apply the parking brake
- disconnect the lift from the towing vehicle

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3. Connection of power supply to the lift

A. Powered by AC-supply. While the mains voltage is plugged in, the12VDC supplied by a
separate unit.
- connect the mains cable to the power supply
- turn on the main switch (Fig. A)
- for maximum out of the electric motor the voltage must 230 VAC (-10%/ +6%), the frequency
must be 50 Hz and rating of the fuse 10A (the length of the connecting cable has some effect)

B. Powered by combustion engine. While the mains voltage is connected, the12VDC is supplied by
a separate unit.
- do not connect the mains cable (230 VAC)
- turn on the main switch (Fig. A)
- open the fuel cock
- switch on the choke for starting
If the battery is empty start the aggregate by pulling the starter grip keeping the
button at the aggregate bed depressed.
Pull the starter grip lightly until you feel resistance, then pull briskly.
Do not allow the starter grip to snap back against the engine.
- adjust the engine speed to halfway.
Leave the combustion engine running between operations because the battery only recharges while
the engine is running.
Close the fuel cock when stopping the combustion engine.
Note! The fuel cock must be closed when the lift is towed.

C. OPERATION WITH DIESEL ENGINE

- do not connect the mains cable (230 VAC)
- turn on the main switch (Fig. A)
Please refer to separate user manual for the diesel engine delivered with the lift
for instructions concerning the start-up of the engine, when the battery is empty.
Leave the combustion engine running between operations because the battery only recharges while
the engine is running.
To avoid damaging the electronics of the diesel engine; do not disconnect the mains current
while the diesel engine is running!

4. To access the operating controls open the cover on the chassis.

To ensure the operation of the emergency descent system, check the condition of the battery.
The state of charge of the battery is indicated by LEDs.
During charging the red LED is on and the green LED is off.
- when both LEDs light up, the battery is almost fully charged.
- when the battery is fully charged the green LED comes on and the red LED flashes.
- if, after the recharging, both LEDs are illuminated, the battery is in poor condition.

5. Turn the selector switch (1) to position 1 (Fig. B)

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6. Start the engine with button 2 (green).

The electric timer of the lift automatically disconnects the supply voltage (12DVC) 1 hour after the
last stopping of the electric motor or the combustion engine.
Re-activate the power supply by pressing the start button either on the chassis control panel or on
the platform control panel.

Petrol engine - turn off the choke

- adjust the engine speed.

7. Lower the front support outriggers (on the towbar side)

8. Lower the rear support outriggers (do not damage the towbar jockey wheel)

9. Level the chassis with the outriggers with the help of the level gauge (16). (Fig. C)

Make sure that the wheels are clearly off the ground (Fig. D).
- the (green) signal light 4A on the chassis control panel comes on when all outriggers are in the
lower position and the outrigger limit switches circuit is connected.
- make sure all outriggers are firmly supported on the ground

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OPERATING THE LIFT FROM THE CHASSIS PANEL

10. Turn the selector switch (1) to position 3

- now you are able to operate the boom with levers 7, 8, 9, 33 and the platform with lever 32 from
the chassis panel

- test the operation of the emergency descent system as follows:

1. start by lifting the boom up about 1 - 2 metres (with lever 8) and continue by extending the
telescope 1 - 2 metres (with lever 9) keeping the emergency stop button depressed. The
movement should now stop.
2. start the emergency descent power unit (pushbutton 5), retract the telescope (lever 9) and
lower the boom (lever 8).
3. pull up the emergency stop button.
4. lift the boom from the towbar and turn it to the side to enable its lowering.
5. extend the telescope as much as necessary to ensure safe entrance on the platform.

Do not damage the tow bar jockey wheel!

The boom movements are noticeably slower when the emergency descent system is used.
The speed of the boom movements cannot be adjusted continually with the control levers when the
lift is operated from the chassis control panel.

Lock the selector switch (1) in position 1 (support outriggers) before working under the boom
Make sure that neither people nor load are on the platform.

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OPERATING THE LIFT FROM THE PLATFORM PANEL

11. Turn the selector switch (1) to position 2 and take away the key.
Do not lock the chassis control panel cover with the key.

- now you can operate the boom with lever 17 on the platform control panel.
Start by pushing the rocker switch at the end of the control lever and after that move the lever
carefully in desired movement direction. If you move the lever before pushing the rocker switch,
the action is deterred.

- test the operation of the emergency descent system as follows:

- start by lifting the boom about 1 - 2 metres (with lever 17) and continue by extending the
telescope 1 - 2 metres (with lever 9) keeping the emergency stop button depressed. The
movement should now stop.

- start the emergency descent power unit (pushbutton 20), retract the telescope and lower the
boom (lever 17).

- pull up the emergency stop button.

Do not damage the tow bar jockey wheel!

The movement speed of the platform can be continually adjusted with the lever (17).

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12. Test the operation of the outreach limit switch RK4

- platform load about 270 kg.

- drive the boom to a horizontal position.

- extend the telescope.

As the movement stops, the red overload light (18) must come on.
- compare the outreach with the set values given on page 58 of this manual.

12A. Measures to be taken after overloading occurs

- (The overload limit switch RK5 switches off the electric circuit of the operating
controls and switches on the buzzer on the platform)
- retract the platform to inside the operating range of the RK4 by pushing the
"telescope in" button (31 or 36) (the green light comes on)
- after this the lift may be operated normally

Warning!
Do not add load (e.g. another person) onto the platform while the red overload light (18) remains lit.

Example: A person, who is working alone on the platform, extends the telescope, or an empty
platform is driven from the chassis control panel to the maximum reach keeping it close to the
ground. If the overload signal light now comes on, then adding further load onto the platform is not
allowed and the telescope must be retracted.

If the safety devices or the emergency descent system are not working, have them repaired
before operating the lift.

13. Refer to the item "Daily inspections" in the task list for servicing

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14. With the boom slightly lifted and the telescope extended, make sure that the platform
does not lower of itself while the operating controls are not being used.

15. To increase the hydraulic oil temperature, let the engine run for a while when working
under cold weather conditions. Carefully start the operation by driving the movements
slowly back and forth from the lower control panel without any load on the platform.

16. Move the platform to the work object

The platform movements can be controlled from the platform controls with continually adjustable
speed (not from the chassis control panel). Only one movement can be operated at a time. If more
than one lever is operated at the same time, only the movement meeting the least resistance will
operate.

NOTE!
Bringing the platform to the transport position: Always start with complete retraction of the
telescope and continue by bringing the platform perpendicular to the boom before lowering the
boom onto the transport support.

Do not damage the tow bar jockey wheel!

Do not take additional load in the upper position

17. Observe when lifting the platform

- the operating range of the platform depends on the load (see Technical Data) and is
monitored by the safety limit switches RK4 and RK5, which are located under the
protecting cover. The limit switches must not be adjusted or modified. The inspection and
adjustment may only be carried out by an authorized serviceman.

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18. Working a long time in the same position

- there are pushbuttons for both stopping and starting on both the upper and the lower control
panels. When the weather is warm and the platform is kept for a longer period in the same
position, it is not necessary to let the engine run continuously.
- when the weather is cold, it is recommended to let the engine run to keep the hydraulic oil
warm.
- It is recommended to also leave the combustion engine running between the operations, to
ensure the battery remains well charged.
- check the stability and condition of the base regularly during the operation, taking into
account the weather and ground conditions.
- the electric timer of the lift automatically disconnects the supply voltage (12DVC) 1 hour
after the last time the electric or combustion engines were in operation.
Re-activate the power supply by pressing the start button either on the chassis control panel
or on the platform control panel.

19. When moving the platform, remember the following

- be careful of the high voltage power lines

- do not exceed the max. allowed lateral force (400N)

- do not touch open electric wires

- do not throw objects from the platform

- do not damage the lift

- do not take additional load in the upper position

- do not damage other devices

- do not load the platform vertically more than what is

allowed

20. When leaving the lift

- drive the lift to a safe position, preferably to the transport position

- switch off the power unit
- prevent unauthorized use of the lift by locking the control centre cover.

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21. Adjustment of the platform position

From the chassis control centre (LCB)

The position of the platform may be adjusted from the chassis control panel in the following way:

- Turn the selector switch (1) to position 3

- Select the correction movement direction with the control lever (32).

Carry out the adjustment while the boom is in the horizontal position

Carry out the levelling of the platform while the lift is in the support position (the outriggers down)

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From the platform (UCB):

The position of the platform may be adjusted from the platform control panel in the following way:

- Turn the selector switch (1) to position 2

- Press the selector button (35) for platform levelling.
- Select the correction movement direction with the control lever (36).

Carry out the adjustment while the boom is in the horizontal position

Carry out the levelling of the platform while the lift is in the support position (the outriggers down)

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EMERGENCY DESCENT SYSTEM

As a precaution against possible power failure, the lift is equipped with a battery operated
emergency descent system.

1. The setup of the system

- 12V 44Ah
- recharger
- hydraulic unit 12VDC

2. Battery service
- the system incorporates an automatic battery recharger with short circuit and overheat
protection.
- output 72VA
- charging voltage 0…13,8V
- nominal current 6A
- if necessary, top up distilled water above the battery elements.

3. The hydraulic unit comprises

- pressure relief valve, set value 15 MPa (150 bar)
- check valve
- direct current motor 800W

Start the emergency descent system with the pushbutton (20 on the platform and 5 on the chassis).
The emergency descent system can only be operated when the pushbutton is depressed.

Note!

Start by retracting the telescope completely, continue by lowering the boom and finally turn the
boom system.

The emergency descent system can also be used for raising the support outriggers to the transport
position

Note!

Two persons are needed for using the outrigger emergency descent since several tasks have to be
performed at the same time.

Start the emergency descent system with the pushbutton 5 at the ground control panel. Press down
the valve shaft (see picture) and steer the outriggers with the outrigger steering levers. All of these
have to be carried out simultaneously.

If the emergency descent system does not work, try to ask for help
from other people present on the site so that they can make the lift
engine or the emergency descent unit operational by, for example,
changing the battery.

Always check the condition of the emergency descent system battery

before putting the lift into operation. (page 22)

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DRIVING DEVICE

The hydraulic driving device is intended for moving the lift within the work area if the towing
vehicle cannot be used.

- start the aggregate

- adjust the engine speed to ¾ of the maximum (petrol engine) The running speed of the
aggregate affects the driving speed.

- Turn the selector switch 1 outriggers to position (1)

- make sure that the platform is in the transport position and the outriggers are in the upper
position.
- make sure that the mains cable is long enough to cover the whole travel distance (power
supply from mains)
- press the driving device against the wheel

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- release the parking brake

- press the button switches to move the lift

forward / backward 28A

to the left 28A + 28L

to the right 28A + 28R

- do not drive the jockey wheel into obstacles or potholes

- apply the parking brake after the driving is finished

- disconnect the driving device from the wheel

Note!
Be careful not to damage the jockey wheel tube by extending it too much.
As the lift is moved with the driving device, the suitable length for the jockey wheel stem can be
achieved by adjusting the gap between the lower surface of the towbar/brake rod and the wheel to 1
- 3 cm. Thus the wheel can turn freely.

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SPECIAL INSTRUCTIONS FOR WINTER USE

- the lowest permissible operating temperature of the lift is - 20 °C.

- if the temperature is below zero, let the power unit run for a few minutes before starting the
movements.

- start with a few movements to warm-up oil in the cylinders and to ensure proper operation
of the valves.

- check that the limit switches and the emergency descent devices are operational and clean
(from dirt, snow, ice, etc.).

- protect the control panel and the platform from snow and ice whenever they are not in use.

Always keep the lift free from dirt, snow, etc!

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MEASURES TO BE TAKEN AT THE END OF THE WORKING DAY

1. Retract the telescope boom completely.

2. Check that the platform is perpendicular to the boom.

3. Lower the boom/platform onto the support on the towbar.

the limit switch on the transport support prevents operation of the support outriggers if
the platform is not down.

4. Close the cover on the platform control panel.

5. Turn the selector switch to position 0.

6. If you want to charge the battery, keep the mains cable connected, otherwise disconnect the
lift from the mains supply.

7. Make sure that the covers are locked

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PREPARING THE LIFT FOR TRANSPORT

1. Retract the telescope boom completely.

2. Check that the platform is perpendicular to the boom.

3. Lower the boom/platform onto the support on the towbar.

the limit switch on the transport support prevents operation of the support outriggers if the
platform is not down.

4. Close the cover on the platform control panel.

5. Turn the selector switch 1 outriggers to position (1)

6. Lift the support outriggers

- at first the rear support outriggers (do not damage the rear lights)
- then the front support outriggers (do not damage the jockey wheel)

7. Apply the parking brake.

8. Make sure that the driving device is disconnected.

9. Turn the selector switch to position 0 and disconnect the lift from the power supply.

10. Make sure that the covers are locked

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 DINO 160XT

CONNECTION TO THE TOWING VEHICLE

1. Lift up and push forward the ball coupling handle (in the driving direction). Now the ball
coupling is released.

2. Press the ball coupling onto the twoball using only a little force. The connection and locking
take place automatically.

NOTE! ALWAYS MAKE SURE AFTER THE CONNECTION THAT THE BALL
COUPLING IS PROPERLY LOCKED!

Clean and lubricate the ball coupling regularly.

3. Connect the emergency stop wires and light plug to the vehicle. Check the cable for
chafing and proper operation of the wires.

4. Check the operation of the lights!

5. Carefully release the parking brake and make sure that its locking is in order and that its
handle stays in the lower position.

6. Lift up the jockey wheel to the transport position.

No load allowed on the platform during towing of the lift.

In particular, if you are parking or disconnecting the lift from the towing vehicle on a slope, apply
the parking brake as firmly as possible. After having applied the parking brake, push the lift
backwards to make the reverse automatics release the brake-shoes. The spring cylinder pulls the
parking brake tighter. Thus the brakes of the vehicle are again properly on.
Adjust the brakes according to the service instructions.
Place chocks under the wheels as an additional precaution.

If you leave the lift standing for a longer period of time, for example over the winter, we
recommend propping it up to release any load from the wheels.

NOTE!
- Check:
- transport position of the outriggers
- locking of the ball coupling
- operation of the lights
- parking brake
- condition and pressure of the tyres
- rear axle. 450 kPa (4,5 bar)
- jockey wheel 250 kPa (2.5 bar)
- safety wires
- locking of the brakes after transportation
- attachment of the jockey wheel
- that the driving device is disconnected from the wheel

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 DINO 160XT

SERVICE AND MAINTENANCE

GENERAL SERVICE INSTRUCTIONS

- carry out the servicing and inspection of the lift in accordance with the instructions.

- when it comes to more demanding repair works turn to a specialist or contact the distributor
or the manufacturer of the lift.

- do not modify the lift without written consent from the manufacturer.

- any such faults which may affect the operational safety of the unit must be repaired before
the lift is next used.

- do not let oil spill on the ground.

- keep the lift clean, especially the platform.

- clean up the lift before service and inspection.

- use genuine spare parts.

- 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).

- the device may be lifted with two slings, each with a load-carrying capacity of at least 2,000
kg or slinging at the four lugs (see picture).
Be careful not to damage the device during the lifting!

185 mm

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 DINO 160XT

SERVICE AND INSPECTIONS

1. The first service after 20 hours of operation

- change the pressure filter element
- adjust the brakes according to the instructions on page 46.
- check the the wheel bolts for tightness after about 100 km of driving (90 Nm)

2. Daily service
- check the oil level in the hydarulics, top up if necessary.
- check the hydraulic connections.
- check the structure visually.
- check the operation of the emergency descent and emergency stop functions
- check the operation of the safety devices.

3. Weekly service
- check the tyre pressure (450 kPa, jockey wheel 250 kPa)
- grease the fulcrum pins (refer to lubrication plan, page 42).
- check the sliding surfaces of the telescope and apply silicon if necessary.
- check the clearance between the slide pads and surfaces and adjust the pads if necessary
- put a load of about 270 kg onto the platform and move the boom to level position.
Continue by extending the telescope until the red signal light lights up and the movement
stops. Measure the stroke in accordance with the instruction on page 57 and compare it with
setting of the outreach limit RK4. If the stroke exceeds the allowed value, contact the service
person.

4. Service every six months

- change the hydraulic oil and the filter cartridge.
- check the condition of the brakes.
- check the the wheel bolts for tightness (90 Nm)
- grease the gear ring of the turning device.

5. Periodic service every 12 months ín accordance with the instructions for regular servicing
below in this manual

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.

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 DINO 160XT

LUBRICATION PLAN

42
 DINO 160XT

Every 50 hours

1. Bearings of the safety device

2. Bearings of the outrigger cylinders
3. Bearings of the outriggers
4. Bearings of the outrigger foot plates
5. Bearings of the boom and the articulated arms
6. Bearings of the platform
7. Bearings of the levelling cylinders (except the bearing on the rodside of the upper levelling
cylinder)
8. Bearings of the lifting cylinder
9. Sliding surfaces/rolls of the telescope
10. Jockey wheel slide and threads

Twice a year

11. Bearing of the telescope cylinder

12. Driving device
13. Overrun brake - overrun
14. Turning device bearings* and gear ring
15. Bearing on the rodside of the upper levelling cylinder

Lubricant Esso Beacon EP2 or equivalent.

The overload protection device joint (point 1) must absolutely be lubricated regularly and always
immediately after the lift has been washed.

Moving parts of the mechanism of the outrigger limit switch system must be lubricated every 50
hours.

If necessary, apply a thin grease film on moving parts of the ball coupling.

Always lubricate the lift and apply a protective grease film immediately after the washing.

*Remove the crescent-shaped covers from the underside of the lift in order to enable lubrication of
the turning bearing nipples (4 pieces).

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 DINO 160XT

44
 DINO 160XT

LOAD HOLDING AND LOAD REGULATION VALVES

Check of operation

1. To check the tightness of the outrigger cylinder load holding valves measure the height position
of the chassis from the floor separately at each outrigger.

2. To check the tightness of the load regulation valves on the boom cylinder and the cylinders of
the articulated arms drive the boom to a position in which its movement can be reliably
measured. Observe the posible movement of the boom in a few minutes time.

3. To check the tightness of the load regulation valve on the telescope cylinder extend the
telescope and stop the movement at any position, measure the stroke and observe in a few
minutes time that the stroke does not change. (Note! Drive the boom to an almost vertical
position)

4. To check the tightness of the load regulation valve on the platform levelling system, put a load
of 100 - 200 kg on the platform and measure the distance from the rear edge of the platform to
the floor. Observe for a few minutes that its height position does not change.

Service instructions

1. Disconnect and clean the valve.

2. Check the O-rings and replace, if necessary.

3. Put the valves carefully in place

4. Replace the valve, if necessary.

5. Do not change the settings of the valves

Support the platform, boom, articulated arms and outriggers in a position, in which the load does
not rest on the repaired structure. Make sure to relieve the residual pressure from the cylinders

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 DINO 160XT

WHEEL BRAKES AND BEARINGS

Adjustment of the brakes

Jack up the lift so that the wheels will rise off the ground and support it in this position.

Make sure that the wheels can rotate freely.

The brake rods must be slack (with

the handbrake released).

Check the attachment of the brake

rods.

Turn the adjustment wheel behind the hole indicated by the arrow until the wheel no longer can be
turned by hand.

Turn the adjustment wheel counterclockwise until the wheel starts turning again but still feels
"sticky".

ADJUSTMENT

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 DINO 160XT

Adjust the braking force with the nuts

keeping the brake balancer
perpendicular to the towbar so that
both wheels will brake.

ADJUSTMENT NUTS

PEREPENDICULAR

Tightening the brake system too much will cause overheating of the brakes during transportation
and increase the required towing force.

We recommend performing a braking test after the adjustment. Check the flawless operation by
braking 2-3 times in the course of the test run.

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 DINO 160XT

Adjustment of the bearing clearance

The wheel bearings are lubricated for life and do not need any service.
(The bearings need no additional lubrication and cannot be adjusted)

Service intervals

500 km (running in)

5,000 km Adjustment of the brakes, lubrication of the moving parts of the overrun
brake.

13,000 - 15,000 km or every six months

a) check the brake linings for wear
b) check the operation of the overrun brake
c) lubricate the sliding parts of the overrun brake

The service-life of the double row angular contact compact bearings is long and they are
maintenance-free. Thanks to this, bearing breakdowns under normal operating conditions are very
rare . However, should a bearing failure, due to exceptional operating conditions, occur, the entire
brake drum assembly with pressed-in bearings and locking nut must be replaced.

NOTE!
Assign a specialized workshop for the work.

The wheels should be turned at least once every 3 months to keep the lubricating film intact.

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 DINO 160XT

LEVELLING SYSTEM OF THE PLATFORM

1. The platform is levelled using a so called Slave Cylinder System.

- The slave cylinder located under the platform is controlled by a master cylinder.
- The platform keeps its level position only if the valves in the system are tight.
- The levelling system comprises the following parts:

25 MPa
(250 bar)
2 3 (3600 psi) 4 5

21,5 MPa
(215 bar)
(3100 psi)

1. Master cylinder
2. Slave cylinder
3. Load regulation valve
4. Double load regulation 25 MPa
valve (250 bar)
1 5. Electrically actuated (3600 psi)
directional valve

- If the platform, viewed by the operator, drifts forwards, the reason can be::
1) a leak in the slave cylinder double load regulation valve (on the piston rod side) in the
direction of the electric directional valve (which is not tight)
2) an internal leakage in the cylinder.
- If the platform, viewed by the operator, drifts backwards, the reason can be:
1) a leak in the load regulation valve (4) on the piston (bottom) side of the slave cylinder in the
direction of the electric directional valve (5) (which is not tight).
2) an internal leakage in the cylinder.

The leak will cause drifting of the platform until the load regulation valve (3) under the platform id
closed. The closing is caused by dropping of the pressure on the piston rod side to the opening ratio,
which is 5:1

If the valves are not tight, refer to the service instructions in the chapter "load holding and load
regulation valves"

Settings of the load regulation valves:

- The opening pressure of the double load regulation valves (4) is 25 MPa (250 bar)
- The opening pressure of the load regulation valve (3) under the platfor is21,5 MPa (215 bar)
Do not change the preset values.

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 DINO 160XT

REGULAR SERVICING

The lift shall be serviced regularly at intervals of 11 - 12 month.

Under demanding conditions where moist, corrosive substances or corrosive climate may speed up
the deterioration of the structure and induce malfunctions, the inspection must be performed more
often and the influence of corrosion and malfunctions must be reduced by using appropriate
protective means.

Only technical specialists who are familiar with the structure and the operation of the lift are
allowed to maintain the lift.

We recommend to turn to the service personnel of the dealer.

Schedule for regular servicing

1. Clean the lift thoroughly before the service

The hydraulic and electric appliances must not be dismantled if they are not clean. Any
contaminants in the system may cause malfunctions later on. Wash the lift externally.

Note! Be careful not to direct the high pressure water jet straight to the electric appliances, such as
the control panels on the chassis and on the platform, relays, solenoid valves and limit switches.

- use pressure air to dry the electric devices, hydraulic connectors etc.before opening them.

- apply appropriate moisture repellent to the electric appliances after the drying.

- always protect the piston rods with e.g. CRC3-36 anti-corrosive agent after washing with a
solvent.

Remember cleanliness!

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 DINO 160XT

2. Change the hydraulic oil and replace the filter

(protect your skin against the hydraulic oil)

- drain the tank through the plug opening with the cylinders of the lift completely retracted.

- clean and rinse the oil tank with a suitable agent.

- replace the pressure filter

- install the draining plug

- refill the tank with fresh oil, the oil volume required for change is 20 litres
Factory filling Neste Hydrauli 28 Super or Esso Univis J26 or environmentally friendly Raisio
Biosafe Hydraulic oil 32 NE.
Never mix different oil sorts.

- if required, top up hydraulic oil to the level with the upper edge of the level eye while the lift is
in the transport position.

3. Check the hydraulic hoses and pipes

Replace any externally damaged hoses or clashed pipes. Check the connections..

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 DINO 160XT

4. Inspect the joints of the support outriggers

- lower the outriggers slightly

- swing the outriggers back and forth in the horizontal plane and check the joints for play.

- check the operation and condition of the outrigger limit switch mechanisms.

- replace any worn out parts

- lubricate the joints (refer to the lubrication plan).

Lower the outriggers to support position

5. Inspect the cylinders, and lubricate the joint bearings (refer to the lubrication plan).

- extend completely the lift cylinder from the lower (chassis) control panel and inspect the
condition of the piston rod and tightness of the connections.
- retract completely the lift cylinder from the lower (chassis) control panel and inspect the
tightness of the connections.
- retract and extend the telescope cylinder from the lower (chassis) control panel and inspect the
condition and tightness of the cylinder.
- lubricate the joints of the lifting, telescope and levelling cylinders.
- extend the articulated arm cylinders from the lower control panel and inspect their condition and
tightness.
- inspect the outrigger cylinders and lubricate their joints.

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 DINO 160XT

6. Inspection of the boom and the chassis

- extend the telescope and inspect the platform and its attachment, the articulated arms and the
boom.

- inspect the boom joints and the sliding pad play, readjust if necessary. Lubricate the sliding
surfaces.

- check the condition, locking and

adjustment of the Flyer-chains..

- secure the attachment of the unloaded

Flyer-chain to the boom by pulling the
chain by hand while the boom is fully
extended.

- inspect the turning device and its attachment, lubricate the turning bearing and the gear
ring. Remove the crescent-shaped covers from the underside of the lift in order to enable
lubrication of the turning bearing nipples (4 pieces).

Note! Excess grease pressure may press out the turning bearing seal.

- check the play at the turning bearing: Max.permissible axial play is about 1 mm.

- check the tightening torque of the attachment bolts of the turning device: 280 Nm (M16)
150 Nm (M12)

If you have to turn open or tighten the attachment bolts, do not forget to use bonding adhesive
(tighten crosswise)

- check the chassis with the weld seams, especially around the turning device and attachment
points of the outriggers.

- inspect the outriggers.

- check the towbar, in particular its attachment to the chassis.

- lubricate the boom and the outrigger joint bearings.

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 DINO 160XT

7. Check the overrun

- attachment of the overrun

- clearance

- condition of the towball coupling

- condition of the locking device

- operation of the overrun brake

8. Inspection of the axle and suspension

- check the attachment of the axles

- check condition rubber absorbers and torsion arms.

9. Inspection of the safety devices

- check the attachment and the external condition of the limit switches.

- from the towbar (transport position of the platform, RK3 )

- safety device (RK4 and RK5)

- support outriggers (RK11, RK12, RK13 and RK14)

- boom (RK7 ja RK8)

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 DINO 160XT

10. Operation of the safety devices when controlled from the chassis control panel

- lift the platform slightly up from the transport position.

- the outriggers must not operate in any position of the selector switch

- lift the boom and test the following:

1. emergency stop (3)
2. emergency descent, retraction of telescope (6)
3. emergency descent, lowering of the boom (5 and 8)

- bring the boom to the transport position and lift the outriggers with the driving device
connected.

- the boom must not operate in any position of the selector switch

- disconnect the driving device and lower the outriggers (bring the lift to a level position)

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 DINO 160XT

- put a load of about 270 kg onto the platform

100

270 kg

- Lift the boom and extend the telescope. The movement will stop as the red outreach limit
signal light lights up (at max. outreach)

Now:
- the lifting of the boom should be operational, the lowering of the boom must NOT be
operational.
- the retraction of the telescope should be operational, –the extension of the telescope must
NOT be operational.

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 DINO 160XT

TESTING OF THE LOAD LIMIT SWITCHES RK4 AND RK 5

Put a carefully weighed load (270 kg) on the platform. Place it at a distance of 100 mm from the
rear edge of the platform.

100 mm

270 kg

Drive to boom to a horizontal plane from the chassis control panel.

Lift and lower the rear edge of the platform using the position control.

1. Lowering the rear edge of the platform

2. Raising the rear edge of the platform

Drive the platform with the position control to a horizontal plane so that that the last stage of the
adjustment procedure is lifting of the rear edge.

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 DINO 160XT

Adjustment method I

Extend the telescope until it stops. (Do not correct the position of the platform)

Measure the length of the telescope extension´s protruding part (L). The length shall be 2,000 mm
±50 mm.
Make sure that a red signal light on the platform is flashing .

- the second overload limit switch (RK5) will back up if the first switch (RK4) fails.

- disable the RK4 for testing by disconnecting the conductor from the terminal 43 and
connecting the terminals X3:12 ja X1:41 in the chassis control panel with a jumper lead.

X3:12
X1:41, X1:43
- retract and extend the boom and measure the length of the telescope extension´s protruding
part. The measure must be 2,250 mm ±50 mm.

- if the protruding part is too long, adjust the limit switches and secure their position with a
seal.

NOTE! Remember to resume the operation of the RK4 by connecting the conductor to
terminal 43 and removing the jumper lead.

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 DINO 160XT

ADJUSTING THE OVERLOAD LIMIT SWITCHES

Always check the operation of both limit switches in connection with the service.

Adjustment method II

- make sure that the RK5 surely trips before the RK4 by adjusting the RK4.

- extend the boom and measure the length of one protruding part.of the telescope extension
(stroke)

- the measure must be 2,000 mm ±50 mm.

- tighten the locking nut and check once more the settings.

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 DINO 160XT
- set the RK4 to operate earlier than the RK5.

- extend the boom and measure the stroke length.

- the measure must be 2,000 mm ±50 mm.

- tighten the locking nut and check once more the settings.

- apply a safety wire to the adjustment screws in such a way that it will be impossible to turn
the screws outwards from the limit switches.

- apply a seal on the wire.

- put the cover in place.

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 DINO 160XT

11. Measuring the pressure

- connect the pressure gauge to the measuring point

- the max. pressure of the warm (40 - 60 °C) oil is 21 -21.5 MPa (210 -215 bar)

- the turning pressure is 6 MPa (60 bar)

- if you have to readjust the pressure, secure the new setting with a seal.

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 DINO 160XT

12. Check the operating controls on the platform.

- check the overall condition of the electric appliances inside the box and spray with moisture
repellent, if necessary.

- check the cables and the tightness of the cable clamps.

- test the sound signal (23), emergency stop (22) and emergency descent (20).

- test all movements

- test the operation of the overload limit switches before lifting the boom.

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 DINO 160XT

13. Warning signs and adhesives

- make sure that all warning signs and adhesives are legible, replace if necessary.

14. Check the condition of the driving device.

- remove the wheels

- clean the brake system and check the settings.

- check that the brake-shoes move and their return springs operate in a due manner.

- replace worn out linings, if necessary,

- check the condition of the driving device and lubricate the joints.

- put the wheels in place and tighten the wheel bolts (325 Nm)
(remember to re-check the tightness after about 100 km drive)

- check the pressure in the tyres. 450 kPa (4,5 bar) on the rear axle
250 kPa (2.5 bar) on the jockey wheel

- check the play on the overrun brake and the parking brake.

- check the safety wires.

15. Check the condition of the lights and reflectors.

16. Repeat the anti-corrosion treatment using e.g. Tectyl 210R anti-corrosion agent.

17. Test-run with a load of 270 kg following the loading instructions. Check the structures
after the test-run.

18. Draw up a test protocol, save your own copy and give the other copy to the customer.

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 DINO 160XT

INSPECTION INSTRUCTIONS

All lifting equipment and lifting gear used at a construction site must always be inspected before
use. The condition of the lifts and related lifting gear should be inspected in a maintenance
inspection which is carried out on the works site from time to time, if possible, once a week.
Keep a journal of notable shortcomings and defects and inform the foreman of them.

FIRST INSPECTION

The initial inspection and test loading of the Dino access platforms is performed by the
manufacturer. A protocol which accompanies the lift is drawn up of the inspection.

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 DINO 160XT

DAILY INSPECTION (START-UP INSPECTION)

To be always performed at a new work site and in the beginning of every working day. The
inspection is performed by the user. In the inspection attention shall be paid to the following
issues:

- establish the load-bearing capacity of the ground at the lifting site (see theguidelines in the
table "maximum permissible ground pressure for different soil materials" on page 21)

- verify the standing stability of the lift.

- control the due operation of the level display.

- test the operation of the emergency stop system both from the platform and the chassis
control panels.

- test the operation of the emergency descent system both from the platform and the chassis
control panels.

- test the alarm signal.

- check the warning and signal lights.

- check the operation and cleanliness of the lights and reflectors.

- check the condition of the operating controls and test the working movements.

- check the condition of the access routes, the platform gate and the handrails.

- check the operation of the outreach limit switches (refer to the service instructions).

- check the operation of the limit switches, which block the boom movements (refer to the
service instructions).

- check the operation of the limit switches, which block the outrigger movements (refer to the
service instructions).

- check the hydraulic connections for leaks.

- test the brakes.

- check the structure visually.

- observe the location of the nearby power lines (refer to the safety distances on page 9)

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 DINO 160XT

MONTHLY INSPECTION (MAINTENANCE INSPECTION)

The inspection shall be performed by a person who is well familiar with the lift.
Contents of the inspection:

- perform the measures of the daily inspection.

- check the attachment points of the boom system and the platform.

- check the operation and condition of the platform levelling system.

- perform the visual inspection of the load-bearing structures.

- frame
- turning device
- telescope (fully extended)
- support outriggers and the joints.
- welded seams for cracks, corrosion or breaches.
- are the possible repair weldings duly executed.

- check that the platform does not "drift" (refer to the service instruction).

- check that the outriggers do not "drift" (refer to the service instruction).

- level of the hydraulic oil.

- check the electro-hydraulic rotating adapter for leaks and seizures.

- check the tyres and the tyre pressures.

- check wheel bolts and the rims.

- check the turning gear play.

- check that the driving device operates in due manner.

- check the condition and the clamping of the electric wiring.

- check the condition and the attachment of the battery.

- check the condition of the overrun

- make sure that all signs, warnings and pictorials for operating and monitoring appliances are
in place, in good condition and clean.

- check that the lift is clean all over.

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 DINO 160XT

ANNUAL INSPECTION (REGULAR INSPECTION)

The inspection shall be performed by a skilled technician or an expert inspection body with
documented evidence of competence according to requirements presented on page 10. In the
inspection special attention has to be paid to the condition of the steel structures, the safety
devices and the operating system.

Clean the lift before the inspection.

The inspection incorporates the following measures and checks:.

- perform the measures of the daily and monthly inspection.

- check thoroughly the hydraulic system.

- the power unit

- connect the pressure gauge to the measuring point in the hydraulic system.
- drive one of the movements against its end stop to make the oil flow through the
relief valve.
- observe the pressure reading in the gauge; when the oil is warm the pressure should
be 21 - 20,5 MPa (210 -215 bar)

- load-holding check-valves on the outriggers

- lift the device off the ground with the outriggers and measure the distance to the
chassis at each outrigger.
- step on the platform and extend the telescope keeping the boom level. turn the boom
round a few times, stop at the initial position and check that the distance between the
ground and the outriggers has not changed.
- lift the outriggers from the ground and leave them in this position for about 10
minutes.
Make sure that the outriggers have not lowered of themeselves.

- load-holding check-valve on the lift cylinder

- lift the boom from the lower control panel to an angle of about 45° and extend the
telescope. Observe the boom about 10 minutes and make sure it does not lower.

- load regulation valve of the telescope cylinder

- lift the boom from the lower control panel and extend the telescope slightly; leave it
in this position for about 5 minutes.
- make sure that the telescope does not retract of itself.

- load regulation valve of the levelling system

- put a load of about 120 kg on the platform
- lift and lower the boom 4 - 5 times
- make sure that the position of the platform does not change.

- electric directional valves

- operate all boom and turning movements and check that they all work properly and
that the movements stop as soon as the grip on the levers is released.

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 DINO 160XT

- manually operated directional valves

- check that the valves of the support outriggers and the driving device work properly
and no movements are executed while the spools are in neutral position.

- rotary adaptor
- check the adaptorl for oil leaks.
- check that the lever arm neither seizes nor is loose.

- cylinders
- lower the outriggers to the support position and check the condition of the piston
rods and wiper rings. check the cylinders for external oil leaks.
- lift the boom to its upper position and check the condition of the piston rod and the
wiper ring.of the lift cylinder.
- lift the articulated arms up and check the condition of the piston rods and the wiper
rings.of the cylinders.
- check the condition of the piston rod and wiper ring of the master cylinder in the
slave cylinder system.
- lower the boom and check the condition of the piston rod and wiper ring of the slave
cylinder under the platform.

- hoses
- check the hoses for leaks and chafing.

- pipes
- check that there are no dents, leaks, trace of corrosion or chafing at the clamps.
Check that the pipes are properly fastened.

- connections
- check the hose and pipe connections for leaks.

- inspect thoroughly the electric system

- check that the control panel boxes are dry, clean and tight.
- check the condition of the cable connections and their protection against moisture.
- check the condition and attachment of the limit switches.
- check tightness of the limit switch lead-throughs.
- check the connections of the electric valves
- check the connections of the solenoid valves.
- perform visual inspection on all electric wiring.
- check condition of the power supply plug.
- check the condition of the electric motor.

- check the fixing points of the hydraulic cylinders.

- check the fixing and condition of the outrigger cylinder bearings and pins.
- check the fixing and condition of the lifting cylinder bearings and pins.
- check the fixing and condition of the arm cylinder bearings and pins.
- check the fixing and condition of the telescope cylinder bearings and pins. Check
condition of the gas springs.
- check the fixing and condition of the master and slave cylinder bearings and pins.

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 DINO 160XT

- check the condition of the boom joint.

- check the boom joint pin and the fixing and condition of the bearings.
- check the condition and fxing of the articulated arm joint pins and bearings.

- check the support outriggers and their footplates.

- check the mechanical structure of the outriggers and the welded seams. The structure
must not be deformed or cracked. No fractures or cracks allowed in the welded
seams.
- check the footplates for deformations, cracks or breaches. Also check that the
footplate can turn freely on its joint.

- inspect the boom.

- extend the telescope and check that there are no permanent deformations, dents or
traces of substantial wear in the boom.
- also check the welded seams for wear, cracks or fractures.
- check the condition of the boom attachment. make sure that there are no cracks or
fractures.
- check the platform brackets for cracks or fractures.
- check the locking of the platform fulcrum pin.
- check the condition and attachment of the flyer-chain, the locking of the pins and the
tightness of the spring.
- check the condition of the cable chain, its clamp brackets as well as the tightness of
the screw connections.
- check the play and attachment of the gliding surfaces on the boom.

- inspect the platform

- general condition
- check that there are no deformations, traces of substantial wear or dents in the
platform.
- check that the handrails, steps, gate and the fixing of the gate are in order.
- check that the locking device of the gate and the gas spring are in order.
- check the condition of the platform floor plate.
- check the platform carrier for severe deformations or dents.

- check all protective covers

- check the condition of the support outrigger cylinder covers.
- check the condition of the slave cylinder cover.
- check the condition of the boom end cover, turning device covers, chassis control
panel cover, safety device cover, platform control panel cover and the rear light
cover.

- visual inspection of all screw connections

- inspect the turning device

- general condition
- check the play and fastening of the angle drive.
- check the condition of gear ring.
- check the play in the turning bearing.
- check the tightness of the turning bearing attachment screws (M16 280 Nm, M12
150 Nm)
- check the attachment of the turning motor.

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- check the condition of the chassis.

- general condition
- check the attachment of the towbar to the frame.
- check the condition of the overrun and its attachment to the chassis.
- check the axle and its attachment to the chassis.
- check the attachment and condition of the brake wires and rods.
- check the rims, the tightness of the wheel bolts, the tyres and the tyre pressure.
- check the condition of the driving device, attachment of the parts and condition of
the covers for electric components.
- check the condition of the boom transport support.

- perform a test run, test all operating controls, control the outreach with a load of 270 kg on the
platform according to the instructions on page 57.

- also check the operation of the limit switches during the test run (refer to service instructions)
- the load-sensing limit switches on the safety devices.
- the limit switches on the outriggers, which block the movement of the boom.
- the limit switches on the towbar, which block the use of the outriggers.

- after the test run make sure that the test loading has not caused any defects, such as fractures or
permanent deformations of dangerous nature, on the steel structures or other loaded parts.

- the regular inspection shall be recorded in a protocol which contains the following articles:

1. inspection form
2. data of repair weldings
a) date of repair
b) repaired by whom
c) what was repaired?

- after the inspection has been completed the performance date of the inspection shall be marked
in the inspection plate affixed to the lift.

EXTRAORDINARY INSPECTION
(INSPECTION AFTER AN EXCEPTIONAL SITUATION)

An extraordinary inspection shall be performed if the lift has been subjected to such severe damages
which may affect its load-bearing capacity or otherwize impair its safe operation.

- in this case the lift shall be inspected according to the instructions for the annual inspection.
- the lift shall be subjected to a test loading and a stability test.
- a protocol shall be drawn up of the test.

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TEST LOADING INSTRUCTION FOR REGULAR INSPECTION

1. Place the lift on an even surface with good carrying capacity. Drive the outriggers to their
lowest position (the minimum support width)

2. Turn the boom to the side from the towbar and lower it on the ground.

3. Put a weighed load of 270 kg on the platform.(I)

4. Lift the boom to as high as it goes and extend the telescope to its full length (maximum
lifting height).

5. Lower the boom until the safety device stops the movement.

6. Turn the boom round over 360°.

7. Retract the telescope and lower the boom to the horizontal position.

8. Extend the telescope until the safety limit switch RK4 will stop the movement. Establish the
standing stability in this situation by turning the lift round over 360°.

9. Carry out the same procedure with a platform load of 120 kg (II).

10. Compare the outreach with the reach diagram. if necessary, readjust as instructed on page 59
"adjutment of the overload limit switches".

After the above mentioned test loadings (case I and case II) and the subsequent inspection have
been completed without finding any defects in the structure or stability of the lift, the lift may be
used provided that the reach and platform load restrictions on page 6 of this manual are observed.

The max. allowed platform load is 215 kg.

- The lift shall be subjected in connection with the first i.e. start-up inspection to a test loading
with an overload of 25% and after that the supporting structures shall be thoroughly
inspected.

- In conjunction with every annual inspections the lift shall be subjected to a test run with the
maximum permissible and after that the supporting structures shall be thoroughly inspected.

- The first inspection shall be recorded in the start-up inspection protocol. the test runs shall be
recorded in the protocols for the annual and regular inspection.

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FAULT FINDING

FAULT REMEDY

1. The electric motor does not start although the start button is pressed and the selector
switch is in position 1, 2 or 3.
The emergency stop button is stuck. Pull up the button and re-start the engine with
the start button.

Fuse F1 blown. Replace the fuse (10A).

No mains supply (230VAC) to the selctor Check the extension cords, possible distribution
switch. boards and fuses.

The fault current safety switch has tripped. Reset the fault current safety switch.

Voltage supply to the switch OK, but no Check the operation of the selector switch and
transmission forward. replace it, if necessary.

Voltage supply to the selector switch and Check the operation of the engine control
transmission forward OK. contactor and thermorelay as well as operation of
the relays which control the operation of the
contactors.
The telescope chain limit switch RK7 has Compare the outreach with the reach diagram. if
disconnected the contactor circuit. necessary, readjust as instructed on page 53.
"adjutment of the overload limit switches".

No direct-current voltage (12VDC). Mains switch disconnected, swith on the switch.

2. None of the platform movements operate though the electric motor is running and the
selector switch is in position 2 or 3.
The outrigger signal light is not lit. Check the operation of the safety limit switches
RK11, RK12, RK13 and RK14.

The yellow signal light for outrigger limit Check the operation of the safety relay SR2 for
switches is lit, but the boom movements do not the outrigger circuit.
operate.
The boom has been overloaded. Retract the platform with the buttons 6 or 21 to
within the designated operating range of the
platform (the green light in the platform control
panel lights up)

3. The outrioggers do not move.

The boom does not rest on the transport support. Drive the boom onto the transport support..
The selector switch is in wrong position. Turn the selector switchto position 1.
The limit switch of the boom support has not Drive the boom in a due manner onto the
closed.. transport support and check the operation of the
limit switch RK3.

4. The platform cannot be turned.

The automatic fuse F10 has tripped. Reset the automatic fuse with the reset button.

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FAULT REMEDY

5. No power supply to the lift though the mains switch is on and the selector switch is in
position 1, 2 or 3.
The power supply has not been activated. Press the start button to activate the power
supply.
One of the fuses F1, F11 or F12 blown Change the fuse an press the start button.
The battery is empty. Recharge the battery.

Check whether the fault is in the electric system or in the hydraulic system.

6. Disturbances in platform movements - only one of the movements is operational

Irregular and indefinite malfunctions Check that both hydraulic oil and filters have
been changed.

Thoroughly clean the solenoid valve spools and

housings. (requires utmost cleanliness - the
disturbing contaminants cannot be spotted with
the naked eye)

The malfunction can also be caused by

temporary contact failures in the joysticks.

Spray with moisture repellent

Lifting or lowering of the boom and extension of The boom has been overloaded, start by
the telescope are not operational, red light on the retracting the telescope and try again (automatic
platform is lit and the buzzer sounds in the reset).
chassis control panel.

7. The boom drifts slowly downwards

The "lock valve" i.e. the pressure activated check Disconnect and clean the valve.
valve leaks.
Check the condition of the o-rings.

Install the valve carefully - the correct

tightening torque is 60 Nm.

Replace the valve, if necessary.

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FAULT REMEDY

8. The aggregate does not start..

The battery is empty Recharge the battery.

The mains cable is plugged. Disconnect the plug from the mains.

No direct-current voltage (12VDC). Mains switch disconnected, swith on the switch.

9. The aggregate cranks but does not start..

The fuel tank empty Fill the fuel tank

Turn off the choke (petrol engine) Turn on the choke (cold engine)

Throttle lever on idling. Increase the engine revolutions.

10. The boom cannot be lifted

Refer to item 4.

The electric valve open

Remedy as instructed above in conjunction with

the seizure of the electric valve spool.

The lift turns as the lifting movement is The solenoid valve is jammed in turning
activated. position.

Wash carefully the spool and the block.

11. The telescope not operational

Refer to item 4.

Check that the electric valve of the telescope is

not in the open position in the centre.

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FAULT REMEDY

12. The telescope slowly drifts downwards

The load regulation valve leaks. For remedy, refer to item 7 (lock valve)

13. The platform drifts backward

The double load regulation valve on the bottom For remedy, refer to item 7 (lock valve)
side leaks.

The load regulation valve under the platform For remedy, refer to item 7 (lock valve)
leaks.

FAULT REMEDY

14. The platform drifts forward

The double load regulation valve on the rod side For remedy, see above
leaks.

15. The outriggers do not operate though the selector switch is in position 1.
The boom does not rest on the transport support. Drive the boom onto the support.

The electric valve of the boom/outriggers must For remedy, refer to item 4
not operate (remains in the centre position)

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FAULT REMEDY

16. The outrigger does not stay in the support position (see illustration)
The load regulation valve on the bottom side For remedy, refer to item 5 (lock valve)
leaks. Tightening torque 55 Nm.

15

14

17. The outrigger does not stay in the transport position (see illustration)
The load regulation valve on the rod side leaks. For remedy, see above

18. The driving device does not operate though the selector switch is in position 1.
The boom does not rest on the transport support. Drive the boom onto the support.

The electric valve of the boom/outriggers must For remedy, refer to item 4
not operate (remains in the centre position)

19. Too low braking force.

Too much play in the brake system. - Adjust the brakes (refer to page 46).

The brake linings not yet run-in. Pull on the parking brake slightly and drive 2 - 3
kilometres.

Brake linings "glazed" or dirty or there is oil on Change new sets of brakeshoes.
the friction surfaces. Clean the friction surfaces of the brake drum.

Overrun brake - movement of the overrun sticky. Lubricate

Brake rod jammed or bent. Repair

Brake wires rusty or broken. Replace wires.

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FAULT REMEDY

20. Braking uneven and jerky

Too much play in the brake system Adjust the brakes (refer to page 46).

Shock absorber of the overrun device faulty. Replace the shock absorber

Reverse automatics - the brake-shoe jams. Change the brake-shoe in the carrier.

21. The brakes drag (only one of the wheels brakes)

Brake units wrongly adjusted. Readjust the brake units according to
instructions.

For remedy, refer to item 17

22. The lift brakes when as the engine speed is decreased

Shock absorber of the overrun device faulty. Replace the shock absorber

23. Reversing forced or impossible

The brakes have been adjusted too tight. Adjust the brakes as instructed on page 46.

24. The wheel brakes overheat.

The brake system wrongly adjusted.. Adjust the brakes as instructed on page 46.

Wheel brakes dirty. Clean the wheel brakes.

Overrun brake - force transmission lever on the Dismantle, clean and lubricate the transmission
towhead jams. rod.

The hand brake not completely released. Release the parking brake completely.

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FAULT REMEDY

Inner parts of the ball coupling dirty. Clean and lubricate.

The towball of the towing vehicle too large. Measure the towball. According to DIN74058
the diameter of the ball must be max. 50 mm and
min. 49.5 mm. If the measure is different or the
ball is nor perfectly spherical, it must be
replaced.

Always, when you change brake-shoes, replace all shoes on the axle.
Always when assembling the brakes make sure to install the springs, the brake-shoes and the
expander in the right way.
When adjusting the brakes, turn the wheels forward (in driving direction)!

Naturally the possible reasons for malfunctions are many, but the following are the most
common:

- low supply voltage (long and thin supply cable)

- the battery is empty (low voltage)

- contaminants in the hydraulic system.

- loose electric connection or a contact failure caused by moisture.

Keep the lift clean and protect it against moisture.

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GENERAL INFORMATION OF HYDRAULICS

The movements require simultaneous operation of two electric valves, i.e:

- change-over valve and boom

OUTRIGGERS / BOOM
- change-over valve and telescope (PROPO)
TELESKOOPPI SISÄÄN
- change-over valve and platform

- change-over valve and turning ARTIC. ARMS

- change-over valve and articulated

arms BOOM

TELESCOPE

LEVELLING

TURN

Press the pin at the end of the electric valves.

If the movements operate, the fault is in operating contrsols of the electric system or the valve
spools are dirty, which causes the jamming (refer to fault finding scheme, item 6).

If none of the movements operate, the fault is in the hydraulic system.

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OPERATION OF THE ELECTRIC COMPONENTS

CHASSIS CONTROL CENTRE (LCB), RELAYS

K1: START CONTACTOR (M1) OF THE ENGINE

Control circuit fuse F1 10A

K2: AUXILIARY RELAY FOR EMERGENCY STOP BUTTON.

Switches off the mains supply (230VAC).
Control circuit fuse F1 10A

K3: AUXILIARY RELAY FOR SWITCHING OFF THE "BOOM DOWN" MOVEMENT
Safety limit switch RK4 controls the relay which switches off the spool control circuit of the
relay K7.
Control circuit fuse F1 10A

K4: AUXILIARY RELAY FOR SWITCHING OFF THE "TELESCOPE OUT" MOVEMENT
Closing tip of the safety limit switch RK4 controls the relay which switches off the spool
control voltage of the relay K10, delay 2,5 s.
Control circuit fuse F1 10A

K5: TURNING OF THE BOOM TO THE LEFT

Control circuit fuse F7 1.6A (Platform control panel) and F4 10A (Chassis control panel)

K6: TURNING OF THE BOOM TO THE RIGHT

Control circuit fuse F7 1.6A (Platform control panel) and F4 10A (Chassis control panel)

K7: AUXILIARY RELAY FOR "BOOM DOWN" MOVEMENT

Control circuit fuse F7 1.6A (Platform control panel) and F4 10A (Chassis control panel)

K8: AUXILIARY RELAY FOR "BOOM UP" MOVEMENT

Control circuit fuse F7 1.6A (Platform control panel) and F4 10A (Chassis control panel)

K9: AUXILIARY RELAY FOR "TELESCOPE IN" MOVEMENT

Control circuit fuse F7 1.6A (Platform control panel) and F4 10A (Chassis control panel)

K10: AUXILIARY RELAY FOR "TELESCOPE OUT" MOVEMENT

Control circuit fuse F7 1.6A (Platform control panel) and F4 10A (Chassis control panel)

K11: LEVELLING OF THE PLATFORM

Levelling of the platform forward.
Control circuit fuse F7 1.6A (Platform control panel) and F4 10A (Chassis control panel)

K12: LEVELLING OF THE PLATFORM

Levelling of the platform backward.
Control circuit fuse F7 1.6A (Platform control panel) and F4 10A (Chassis control panel)

K18: SENSOR RELAY FOR AC SUPPLY

When the lift is connected to an AC supply, the relay switches off the start circuit and
switches on the stop circuit of the combustion engine. The relay spool is controlled by the
AC-voltage.

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K19: FUNCTION RELAY FOR OUTREACH LIMIT SWITCH RK4
Switches off the "telescope out" movement commanded by the RK4. Delay about 1,2s.
Control circuit fuse F1 10A

K21: Change-over relay for control voltage of the Propo-card.

As the relay is activated the control voltage to the Propo-card is supplied through additional
resistors. Thus the voltage level is changed in accordance with the adjusted resistor settings.
As the relay is not activated the control voltage is supplied to the joystick by means of which
the control voltage is adjusted to desired value with the help of adjustable resistors inside the
joystick .
Control circuit fuse F7 1.6A (Platform control panel) and F4 10A (Chassis control panel)

K22: CONTROL RELAY FOR ADDITIONAL MOVEMENT SPEED RESISTORS

The relay is used for changing the Propo-card control voltage over to the adjustable resistor of
the boom/platform levelling.
As the relay is active the control voltage is supplied through the TR2 resistor (movement
speed of the boom from the chassis control panel)
As the relay is not active the control voltage is supplied through the TR3 resistor (platform
levelling)
Control circuit fuse F7 1.6A (Platform control panel) and F4 10A (Chassis control panel)

K23: ARTICULATED ARMS DOWN

Control circuit fuse F7 1.6A (Platform control panel) and F4 10A (Chassis control panel)

K24: ARTICULATED ARMS UP

Control circuit fuse F7 1.6A (Platform control panel) and F4 10A (Chassis control panel)

K26: RPM-RELAY
Controls the speed of the combustion engine. Increases the speed during performance of the
control movement.
Control circuit fuse F7 1.6A (Platform control panel) and F4 10A (Chassis control panel)

K30: AUXILIARY RELAY FOR DRIVING DEVICE POWER SUPPLY.

The relay is controlled by the limit switch RK3
Fuse F2 10A

K31: PREVENTION OF DUAL CONTROL

The relay is controlled by the emergency descent buttons S11 and S13
Control circuit fuse F3 10A

K42: PREVENTION RELAY FOR RESTART OF ELECTRIC MOTOR

Prevents the electric motor from starting after the failure in AC power supply by switching
off the control voltage from the control contactor of the motor.

K44: PREVENTION RELAY FOR RESTART OF ELECTRIC MOTOR

Connects the voltage to relay K42 if the voltage in the control circuit of the contactor is
switched off.

SR2: SAFETY RELAY WHICH MONITORS THE OPERATION OF OUTRIGGERS

The safety relay resets as soon as all outrigger safety limit switches (RK11, RK12, RK13
and RK14) have closed. After that it is possible to operate the boom.

SR3: SAFETY RELAY WHICH MONITORS THE OVERLOADING OF BOOM

Safety limit switch RK5 controls the operation of the safety relay.

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Overloading of the boom: SR3 is disconnected. The safety relay is automatically reset upon
return inside the normal outreach range. The delay adjusted with the
capacitors affects the tripping moment of the SR3.

If the RK5 fails: SR3 is disconnected. The safety relay is not automatically reset, thus the
due operation of the electrical equipment must be checked. The delay
adjusted with the capacitors affects the tripping moment of the SR3.

CHASSIS CONTROL CENTRE (LCB), SWITCHES

S1: LOCKING EMERGENCY STOP SWITCH.

Stops all other functions except the emergency descent and the sound signal, which remain
operational.

S2: START SWITCH

Controls the contactor of the electric motor and start solenoid of the combustion engine if the
combustion engine is used.

S3: STOP SWITCH

Disconnects the control voltage from the control contactor of the electric motor and the stop
relay of the combustion engine.

S13:START SWITCH FOR EMERGENCY DESCENT

Controls the solenoid of the emergency descent unit which starts the unit and supplies the
control voltage to the control lever while the the emergency descent system is in operation.

S16: TURNING OF THE BOOM TO THE RIGHT - LEFT

Non-locking lever switch (chassis control panel).

S17: BOOM UP-DOWN

Non-locking lever switch (chassis control panel).

S18: TELESCOPE IN-OUT

Non-locking lever switch (chassis control panel).

S19: ARTICULATED ARMS DOWN-UP

Non-locking lever switch (chassis control panel).

S20: PLATFORM LEVELLING FORWARD-BACKWARD

Non-locking lever switch (chassis control panel).

S32: TELESCOPE IN
Non-locking button switch. After the SR3 has tripped, the telescope can be retracted by
depressing the button.

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CHASSIS CONTROL CENTRE (LCB), OTHER ITEMS

F1: 10 A CONTROL FUSE FOR START CIRCUIT AND OUTREACH MONITORING

CIRCUIT

F2: 10 A CONTROL FUSE FOR DRIVING DEVICE

F3: 10 A CONTROL FUSE FOR EMERGENCY DESCENT CIRCUIT

F4: 10 A FUSE FOR CONTROL LEVERS AND JOYSTICK ON THE CHASSIS AND
PLATFORM CONTROL PANELS

F5: Propo-card FUSE 1.6A

F8: 1.6A FUSE FOR TIMER CARD ACTIVATION CIRCUIT

F10: TIMER CARD FUSE 16A

H3: YELLOW LED SIGNAL LIGHT

Indicates the operation of the outrigger limit switches RK11-RK14.

H4: RED LED SIGNAL LIGHT

Indicates the tripping of the SR3.

HM1: HOUR METER

Measures the running hours of the machine.

Q1: TURN SWITCH WITH KEY

Selector switch for choice of operating location.
1 = Chassis
2 = platform
3 = chassis panel

T1: POWER SOURCE

Feeds the 12 VDC control voltage to the system as the machine is being powered by AC-
supply.

TC: TIMER CARD

Control card for supply voltage
Connects the control voltage from the power source when powered by AC mains current and
connects the control volatge feed from the battery when powered by the battery.
Breaks the supply voltage feed from the lift after the preset delay (normally 1 hour)
Start buttons S2 and S6 are used for re-activation of the control voltage.

TR1: ADJUSTABLE RESISTOR

Adjustable resistor for lowering speed of the boom.

TR2: ADJUSTABLE RESISTOR

Adjustable resistor for movement speed when operated from the chassis panel.

TR3: ADJUSTABLE RESISTOR

Adjustable resistor for movement speed for operation from the chassis panel.

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U1: VOLTAGE METER

As the control voltage is connected the voltage meter indicates the alternating voltage reading.

PLATFORM CONTROL CENTRE (UCB), RELAYS

K13: CONTROL RELAY FOR SIGNAL LIGHTS WHICH INDICATE THE STATE OF
LOADING OF THE PLATFORM
The relay is controlled by the opening contactor of the safety limit switch RK4.

K14: PLATFORM TURN TO THE LEFT

Controlled by the non-locking lever switch S36.
The control movement is stopped by the inductive end limit switch RK9 of the linear motor.

K15: PLATFORM TURN TO THE RIGHT

Controlled by the non-locking lever switch S36.
The control movement is stopped by the inductive end limit switch RK10 of the linear motor.

K16: CHANGE-OVER RELAY FOR OPTIONAL FUNCTIONS

As the relay is active the lifting-lowering movements of the articulated arms are switched over to
the joystick movements in the X-direction. As the relay is not active the joystick movements in the
X-direction control turning of the boom to the left and right.

K17: CHANGE-OVER RELAY FOR OPTIONAL FUNCTIONS

As 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

K20: ACTIVATION OF THE JOYSTICK´S CENTRE POSITION.

Switches off the voltage from the joysticks´s micro-switches if the dead-man-switch DMK
has not been pressed while the joystick is in the centre position.

K25: ACTIVATION OF THE JOYSTICK´S CENTRE POSITION.

Pressing the dead-man-switch DMK breaks the control voltage from the spool of the relay
K20 which would otherwize disconnect the control voltage from the micro-switches on the
joystick.

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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 out - in and
articulated arms up - down.

S4: LOCKING EMERGENCY STOP SWITCH.

Stops all other functions except the emergency descent and the sound signal, which remain
operational.

S5: STOP SWITCH

Disconnects the control voltage from the control contactor of the electric motor and the stop relay of
the combustion engine.

S6: START SWITCH

Controls the contactor of the electric motor and start solenoid of the combustion engine if the
combustion engine is used.

S10: SOUND SIGNAL SWITCH.

S11: EMERGENCY DESCENT SWITCH

Controls the solenoid of the emergency descent unit which starts the unit and supplies the control
voltage to the control lever while the the emergency descent system is in operation.

S12: PLATFORM LEVELLING FORWARD-BACKWARD

Control switch, non-locking lever switch.
The levelling is operated by pressing the button S29 and tuning the lever switch S12.

S29: SELECTOR SWITCH FOR LEVELLING OF PLATFORM

Non-locking button switch.
Switches on the control voltage to the switch S12 as the button is pressed.

S31: TELESCOPE IN
Non-locking button switch, pressing the button retracts the telescope movement.

S36: PLATFORM TURN TO LEFT AND RIGHT

Non-locking lever switch.
Controls the relays K14 and K15.

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PLATFORM CONTROL CENTRE (UCB), OTHER ITEMS

H1: GREEN LED SIGNAL LIGHT
The platform inside the operating range.
H2: RED LED SIGNAL LIGHT
The platform at the border of the operating range.

F6: AUTOMATIC FUSE FOR PLATFORM TURN 4A

F7: JOYSTICK FUSE 1.6A

PR: SOCKET OUTLET ON THE PLATFORM 230VAC 16A.

ÄM2: BUZZER
Indicates the operation of the safety limit switch RK5 and the emergency stop switches S1
and S4.

LIMIT SWITCHES

RK3: LIMIT SWITCH FOR THE BOOM SUPPORT

Prevents the operation of the outriggers and the driving device if the boom does not rest on
the support in the transport position.
Controls the relay K30.

RK4: SAFETY LIMIT SWITCH FOR THE ADJUSTED OPERATING RANGE

The operation of the limit switch stops the "boom down" movement and the "telescope out"
movement.

RK5: BACKUP LIMIT SWITCH FOR THE SAFETY LIMIT SWITCH RK4.
Trips after the preset delay (2,4 seconds) the safety relay SR3 which controls the sound
signal AM2 and switches off the control voltage to the limit switch RK4.

RK7: SAFETY LIMIT SWITCH FOR THE TELESCOPE CHAIN.

Operation of the safety limit switch stops the electric motor. The limit switch switches off
the control voltage to the contactor K1 after which only the emergency descent unit will
operate.

RK8: "TELESCOPE IN THE INNER POSITION" SAFETY LIMIT SWITCH

The limits switch closes as the telescope movement is completely retracted.
If the RK4 or RK5 has failed the boom cannot be lowered until the telescope movement has
been completely retracted and the tips of the limit switch RK8 have closed.

RK9: INDUCTIVE LIMIT SWITCH

Limits the turning of the platform to the left, disconnects the control voltage circuit of the
relay K14.

RK10: INDUCTIVE LIMIT SWITCH

Limits the turning of the platform to the right, disconnects the control voltage circuit of the
relay K15.

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..

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DRIVING DEVICE CONTROL CENTRE (DCB)

S24: DRIVING STRAIGHT, FORWARD AND BACKWARD

Non-locking lever switch.

S25: TURNING TO THE LEFT

Non-locking button switch.

S26: TURNING TO THE RIGHT

Non-locking button switch.

OTHER MARKINGS

B1: BATTERY 12VDC 44AH

E1: THERMORELAY FOR THE ELECTRIC MOTOR

F9: MAIN BATTERY FUSE 125A

J1: PLUG

M1: ELECTRIC MOTOR 230VAC 1,5kW

M2: EMERGENCY DESCENT MOTOR 12VDC

MAX. OPERATING TIME 10 MIN.

M3: MOTOR FOR PLATFORM TURN

PL: ROTARY ADAPTOR

The elctric circuits between the chassis and the turning device are transmitted through the
electric rotary adaptor.

SR1: Solenoid of the emergency descent unit

When energized, starts the emergency descent unit M2

T2: Battery recharger

Charging voltage 13,8VDC 6A
Charges the battery if the mains supply is connected

VVK: FAULT CURRENT SWITCH 25A 30 ms.

ÄM1: SOUND SIGNAL

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ADJUSTMENT OF THE
MOVEMENT SPEEDS

1. Measuring devices required for the

adjustment
- volt-ohm-milliammeter
- measuring adapter (for measuring of
current)

2. Disconnect the socket from the Propo-

valve and connect the measuring
adapter between the valve and the
socket.

3. Connect the measuring conductors to

the direct current range of the volt-
ohm-milliammeter (max. measuring
current Imax=2A).

4. Turn the key-switch to position 3.

5. Check that the adjustable resistors TR9, TR10, TR11 and TR12 on the circuit card have
been turned counterclockwise to their extreme positions.

6. Adjustment of min. current of the Propo-card

- the min. current is adjusted with the screw 2

- the intensity of the current increases as the screw is turned clockwise

1. Maximum current Imax
6
2. Minimum current Imin
5
3. Frequency adjustment
4. Intensity of frequency
5. Ascending ramp
6. Descending ramp 4 3

2 1
2 1

- adjust thew min. current to Imin=500mA

7. Adjustment of max. current for the Propo-card

- the max. current is adjusted with the screw 1

- drive the "boom up" movement

- carry out the adjustment during the lifting, the current increases as the screw is
turned clockwise

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- adjust the max. current to Imax=1800mA

8. The movement speeds are adjusted with the adjustable resistors in the main control
centre. The speed of the following movements can be adjusted.
- TR9 = levelling of the platform
- TR10 = the speed of movements
when controlled from the chassis
control panel (affects the speed of all
movements when controlled from
the chassis panel)
- TR11 = lowering of the boom
- TR12 = lowering of the articulated
arms

9. Adjustment of the movement speed when

controlling from the chassis panel.
- Drive the "boom up" movement
- Adjust the intensity of the current during the lifting with the adjustable resistor TR10 to
Iala=1500mA
-
10. Lowering speed of the boom is adjusted as follows:
- Lower the boom and at the same time adjust the intensity of the current with the adjustable
resistor TR11 to Ilasku= 1250mA
- Check the lowering speed of the boom, raise the boom until the (floor of the) platform is at
height of 2,8 metres.
- Lower the boom to its lowermost position (over a distance of 2 m), the lowering should take
about 12 seconds.

11. Levelling of the platform

- Lift the boom as much as is required to prevent the platform from clashing with the chassis
during the movement.
- Activate the platform levelling movement
- Adjust the intensity of the current during the levelling with the adjustable resistor
TR9 to Ilevelling= 800mA
- The time required for turning the platform from its upper position to its lower
position should be about 23 seconds.

12. Frequency adjustment

- Turn at first the adjustment screw 3 to the minimum position (to extreme position counter-
clockwise) and after this turn it 1/4 turn clockwise.

13. Adjustment of the frequency

- Turn at first the adjustment screw 4 to the minimum position (to extreme position counter-
clockwise) and after this turn it 1/4 turn clockwise.

14. Adjustment of the ascending ramp

- Turn at first the adjustment screw 5 to the minimum position (to extreme position counter-
clockwise) and after this turn it 1/5 turn clockwise.

15. Adjustment of the descending ramp

- Turn the adjustment screw 6 to the minimum position (to extreme position counter-
clockwise), the descending ramp is not in use.

16. Finally remove the measuring adapter and re-connect the Propo-card plug to its socket.

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ELECTRIC COMPONENTS 16048 →

Electric components 4CB2460-4CB2473

Boom=Boom CH=Chassis DCB=Driving device centre HN=Honda LCB=Chassis control centre

OT=Outrigger PL= Platform RU= Turning device UCB=Platform control centre

ID Diagram Position Spare part nr. Designation Description of operation

B1 123 RU 48.2276 Battery Battery
CC1 833 RU 48.2340 Control card Control card for propo-valve
E1 134 LCB 48.2169 Thermorelay Thermorelay for the electric motor
F1 223 LCB 48.3030 Fuse 1.6A Electric supply control circuit fuse
F2 226 LCB 48.647 Fuse 10A Start circuit fuse

F3 229 LCB 48.647 Fuse 10A Chassis control centre fuse

F4 231 LCB 48.3035 Fuse 5A Control switch fuse
F5 233 LCB 48.3030 Fuse 1.6A Control card fuse
F6 1131 LCB 48.647 Fuse 10A Fuse for solenoid valves
F7 236 UCB 48.647 Fuse 10A Emergency descent circuit fuse
F8 128 LCB 48.647 Fuse 10A Control fuse for combustion engine
F9 812 UCB 48.3030 Fuse 1.6A Joystick fuse

F10 1229 LCB 48.3036 Fuse 4A Platform swing motor fuse

F11 126 RU 48.3041 Fuse 125A Battery main fuse
F12 218 LCB 48.3038 Fuse 16A Timer card fuse
H1 933 UCB 48.2204 LED signal light Outreach signal light, inside the range
H2 932 UCB 48.2203 LED signal light Outreach signal light, at the border
H3 422 LCB 48.2152 LED signal light Support outrigger circuit signal light, limit switches closed
H4 934 LCB 48.2207 LED signal light Signal light for safety relay SR3, the safety relay has
tripped, the outreach safety limit switch RK5 has tripped.
HM1 321 LCB 48.0111 Hour meter Hour meter which measures the running time of the engine
J1 111 CH 48.2085 Socket Plug
JST 811 UCB 48.2195 Joystick Joystick, operation of the boom
K1 335 LCB 48.2162 Contactor Control contactor for the electric motor
K2 323 LCB 48.2216 Relay Auxiliary relay for the emergency stop button
K3 512 LCB 48.2374 Change-over relay Turning of boom , to left
K4 516 LCB 48.2374 Change-over relay Turning of the boom, to right
K5 520 LCB 48.2374 Change-over relay Lowering of the boom
K6 523 LCB 48.2374 Change-over relay Boom down, retardation relay
K7 527 LCB 48.2374 Change-over relay Lifting of the boom
K9 612 LCB 48.2374 Change-over relay Telescope in
K10 617 LCB 48.2374 Change-over relay Telescope out
K11 622 LCB 48.2374 Change-over relay Lowering of the articulated arms
K12 625 LCB 48.2374 Change-over relay Articulated arms down, retardation
K13 628 LCB 48.2374 Change-over relay Raising of the articulated arms
K15 717 LCB 48.2374 Change-over relay Levelling of the platform backward.
K16 721 LCB 48.2374 Change-over relay Levelling of the platform forward.
K17 635 LCB 48.2374 Change-over relay Activation of the joystick´s centre position
K18 714 LCB 48.2374 Change-over relay Selector relay, platform levelling/chassis control panel
K19 726 LCB 48.2374 Change-over relay Selector relay, control from chassis/platform
K20 918 LCB 48.2374 Change-over relay Blocking relay of the "telescope out" movement
K21 922 LCB 48.2374 Change-over relay Blocking relay for the boom
K22 926 LCB 48.2375 Change-over relay Blocking relay of the "telescope out" movement
K23 1017 LCB 48.2374 Change-over relay Control of supply voltage to the driving control centre on
the chassis
K24 1022 LCB 48.2375 Change-over relay Centre-position activation of joystick

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Electric components 4CB2460-4CB2473

Boom=Boom CH=Chassis DCB=Driving device centre HN=Honda LCB=Chassis control centre

OT=Outrigger PL= Platform RU= Turning device UCB=Platform control centre

ID Diagram Position Spare part nr. Designation Description of operation

K25 1026 LCB 48.2374 Change-over relay Control relay for control card
K26 1033 LCB 48.2374 Change-over relay Control relay of combustion engine speed
K27 1135 LCB 48.2374 Change-over relay Control of supply voltage to the driving control
centre on the chassis
K28 1413 LCB 48.2374 Change-over relay Control relay for reserve power unit
K29 1416 LCB 48.2374 Change-over relay Blocking relay of dual operation, electric
motor/emergency descent motor
K30 111 HN/HZ LCB 48.2374 Change-over relay Control of alternator of the Honda engine
K31 114 HN/HZ LCB 48.2374 Change-over relay Switch-off of combustion engine
K32 117 HN/HZ LCB 48.2374 Change-over relay Switch-off of combustion engine
K33 120 HN/HZ LCB 48.2374 Change-over relay Relay for optional equipment
K34 327 LCB 48.2374 Change-over relay Blocking relay for re-start if the control voltage is
switched off
K35 331 LCB 48.2375 Change-over relay Blocking relay for re-start if the control voltage is
switched off
K390 535 LCB 48.2375 Change-over relay Change-over relay for secondary operations of
joystick
K391 535 LCB 48.2375 Change-over relay Change-over relay for secondary operations of
joystick
K40 125 HN LCB 48.2374 Change-over relay Control relay for choke
K41 113 LCB 48.2133 Change-over relay Selector relay, main power unit/combustion
engine
K42 123 HN/HZ LCB 48.2277 Change-over relay Start relay of combustion engine
K50 931 UCB 48.2367 Change-over relay Control relay for the outreach signal lights
K51 1222 UCB 48.2367 Change-over relay Turning of the platform, to left
K52 1224 UCB 48.2367 Change-over relay Turning of the platform, to right
M1 134 RU 47.828 Electric motor AC electric motor
M2 130 RU 47.2318 Power unit (reserve power DC motor for emergency descent
plant)
M3 1229 PL 48.2332 Linear motor Turning motor of the platform.
PL 114,419, CH 48.3550 Rotary adaptor (electric part)Rotary adaptor, electric transmission between the
1133,1316 chassis and the turning device
PR 115 UCB 48.2145 Socket outlet Socket outlet on the platform 230VAC 16A.
Q1 128, 221, LCB 48.2316 Turn switch Turn switch with key, choice of operating location
416, 1133 LCB/OK/AK
RK3 1133 CH 48.1936 + 48.2142 Limit switch Limit switch for boom support NC
RK4 918 Boom 48.2068 + 48.2142 Limit switch Limit switch for outreach control NC/NO
RK5 915 Boom 48.2068 + 48.2142 Limit switch Limit switch for outreach control NC
RK7 335 Boom 48.2116 Limit switch Limit switch for chain NC, opens if the chain is
slack
RK8 1112 Boom 48.1936 + 48.2142 Limit switch Limit switch, the telescope fully retracted NC
RK9 1222 PL 48.2170 Stroke limiter Inductive end limit switch for turning motor of
platform NC
RK10 1224 PL 48.2170 Stroke limiter Inductive end limit switch for turning motor of
platform NC
RK11 422 OT 48.2248 Limit switch Outrigger limit switch NC, closes as the outrigger
is on the ground
RK12 426 OT 48.2248 Limit switch Outrigger limit switch NC, closes as the outrigger
is on the ground
RK13 426 OT 48.2248 Limit switch Outrigger limit switch NC, closes as the outrigger
is on the ground
RK14 422 OT 48.2248 Limit switch Outrigger limit switch NC, closes as the outrigger
is on the ground
S1 312 LCB 48.2311+48.2313 Locking emergency stop button Emergency stop button, NC
+48.2303

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S2 314 LCB 48.2309+48.2312 Push button, green Engine start button NO
+48.2302
S3 312 LCB 48.2310+48.2313 Push button, red Engine stop button NC.
S4 316 UCB 48.2311+48.2313 Locking emergency stop button Emergency stop button, NC
+48.2303
S5 316 UCB 48.2310+48.2313 Push button, red Engine stop button NC.

Electric components 4CB2460-4CB2473

Boom=Boom CH=Chassis DCB=Driving device centre HN=Honda LCB=Chassis control centre

OT=Outrigger PL= Platform RU= Turning device UCB=Platform control centre

ID Diagram Position Spare part nr. Designation Description of operation

S6 318 UCB 48.2309+48.2312+48.2302 Push button, green Engine start button NO
S10 1420 UCB 48.2309+48.2312 Push button, green Sound signal control button NO.
S11 1417 UCB 48.2309+48.2312 Push button, green Emergency descent motor start button
NO, platform
S12 1217 UCB 48.616+48.1007 Lever switch Platform levelling forward/backward,
platform
S13 1413 LCB 48.2309+48.2312 Push button, green Emergency descent motor start button
NO, chassis
S16 511 LCB 48.616 + 48.1007 Lever switch Turning of boom , to right/left, chassis
S17 519 LCB 48.616 + 48.1007 Lever switch Lifting/lowering of the boom, chassis.
S18 611 LCB 48.616 + 48.1007 Lever switch Telescope in/out, chassis
S19 620 LCB 48.616 + 48.1007 Lever switch Articulated arms down/up, chassis
S20 715 LCB 48.616 + 48.1007 Lever switch Platform levelling forward/backward,
chassis
S21 1316 DCB 48.2304 + 48.2312 Turn switch Current switch for driving device
S22 1324 DCB 48.2309+48.2312 + 48.2302 Push button, green Turning the chassis to the left-to the right
S23 1330 DCB 48.2309+48.2312 + 48.2302 Push button, green Turning the chassis to the left-to the right
S24 1319 DCB 48.2309+48.2313+48.2303 Push button, green Drive to the rear
S25 1316 DCB 48.2309+48.2313+48.2303 Push button, green Drive to the front
S29 1217 UCB 48.2309+48.2312 Push button, green Dual operation button for levelling of the
platform, platform
S31 1427 UCB 48.2309+48.2312 Push button, green Retraction of the telescope, is used if the
safety limit switch RK5 has tripped,
platform
S32 1424 LCB 48.2309+48.2312 Push button, green Retraction of the telescope, is used if the
safety limit switch RK5 has tripped,
chassis
S36 1220 UCB 48.616 + 48.1007 Lever switch Turning of the platform , to left/right,
platform
SR1 1434 RU Solenoid Emergency descent motor solenoid
SR2 416 LCB 48.2264 Safety relay Support outrigger circuit safety relay, is
active if the outrigger limit switches are
closed
SR3 915 LCB 48.2264 Safety relay Safety relay for outreach control safety
limit switch, is active if the limit
switches RK4 and RK5 are closed
SPV 124 RU 48.2139 Mains switch Disconnects the battery from the system
T1 125 LCB 47.863 Power source Power source, supplies the control
voltage when powered by AC.
T2 120 RU 48.2130 Battery charger, automatic battery charger 230VAC 6A
TC 214 LCB 48.3506 Timer card Time card disconnects the power supply
to the lift after a preset delay if the
contactor no longer is active
TR9 830 LCB Adjustable resistor Adjustment of the levelling speed of the
platform
TR10 830 LCB Adjustable resistor Adjustment of the lowering speed of the
boom
TR11 830 LCB Adjustable resistor Universal adjustment of the movement
speed when controlling from the chassis
panel.

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TR12 830 LCB Adjustable resistor Speed adjustment of articulated arms
descent
U1 128 LCB 48.2063 Voltmeter Voltage meter
VVK 113 CH 48.2128 Fault current switch Fault current switch, switches off the
AC-feed in case of fault current
ÄM1 1420 RU 48.049 Sound signal Sound signal, operation with push button
S10
ÄM2 936 UCB 48.0108 Sound signal Buzzer, operates if the emergency stop
button is depressed and the safety limit
switch RK5 trips.

Hatz- diesel components (Optional) 4CB2476-4CB2477

Boom=Boom CH=Chassis DCB=Driving device centre HN=Honda LCB=Chassis control centre

OT=Outrigger PL= Platform RU= Turning device UCB=Platform control centre

ID Diagram Position Spare part nr. Designation Description of operation

G3 114 HZ
M4 230 HZ Linear motor Adsjustment motor of the engine speed
S6 125 HZ Temperature sensor The switch earths the circuit if the engine
overheats
S7 123 HZ Oil pressure sensor The switch earths the circuit if the oil
pressure drops
STM1 119 HZ Starter Starter of the diesel engine
Y4 129 HZ Stop solenoid The current is switched off as the engine
is stopped, the valve is closed
GL 133 HZ Glow plug Glow plug of the diesel engine

Honda components (Optional) 4CB2474-4CB2475

ID Diagram Position Spare part nr. Designation Description of operation

S37 121 HN Push button, green By-pass button for stop circuit of Honda
engine
SR4 215 HN Solenoid Choke solenoid

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WIRING DIAGRAM

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ELECTRIC DIAGRAM 16316

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105
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ELECTRIC DIAGRAM; PETROL AGGREGATE 16316

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ELECTRIC DIAGRAM HATZ-DIESEL 16048 →

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HYDRAULIC COMPONENTS 16027 →

Ref.nr. Spare part nr. Designation Quantity

1 47.171 Pressure filter 1
2 47.2049 Hydraulic pump 1
3 47.2273 Hydraulic motor 1
5 47.2659 Flow control valve 4

6 47.2576 Flow control valve 4

7 47.2858 Double load-regulating valve 2
Manually operated directional
8 47.2720B 1
valve
9 47.2319 Hydraulic motor 2
10 47.2722 Load-regulating valve 1

11 47.2722 Load-regulating valve 1

12 47.2722 Load-regulating valve 1
13 47.2733 Priority valve 1
14 47.2807B Solenoid valve 1
15 47.2749 Pressure relief valve 1

16 47.2808 Pressure relief valve 1

17 47.2769 Double load-regulating valve 1
18 47.377 Check valve, pressure activated 8
19 47.2318 Power unit (reserve power plant) 1
20 47.2865 Solenoid valve 3

21 47.2869 Solenoid valve 1

22 47.2888 Solenoid valve 1
23 47.2865 Solenoid valve 1
24 47.2766 Load-regulating valve 2
25 4CB1944 Rotary adaptor 1

26 3CB2257 Cylinder (telescope) 1

27 DL6.018 Cylinder (lifting) 1
28 DL7.006 Cylinder (outrigger) 4
29 DL10.007 Cylinder (master) 1
30 DL10.005 Cylinder (slave) 1

31 47.811 Electric motor 1

32 Pressure relief valve 1
33 47.190 Breather 1
34 DL6.026 Cylinder (articulated arms) 2
35 47.2893 Magnet and flow distribution valve 1

36 47.2053 Hydraulic pump 1

37 47.877 Combustion engine (Honda) 1

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HYDRAULIC DIAGRAM
16027 →

114
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Notes

115