User Manual Nordic Dino NB WB XWB

User manual
Operation, Service and Spare Parts
Nordic Dino NB, WB, XWB

Serial number from: 101
Introduction
Thank you for choosing the most efficient exterior aircraft cleaning system in the world. Back
in 1983 Mr Jan Brunstedt developed the Nordic Dino together with competent engineers.
During the years we created a stronger and more technical robots to meet the modern
demands of efficiency and environmentally friendly procedures. The Nordic Dino will keep
your fleet brilliantly clean and shiny.
This user manual is divided into sections, each intended for one or more categories of user,
as outlined below:
1. Safety warnings
Read all of them and follow the instructions when performing the procedures.
2. Technical data
Includes data for different parts of the machine.
3. Technical description
Primarily intended to give service personnel an insight into the construction and
functioning of the machine.
4. Operation
Intended for personnel using the machine and those responsible for the daily
maintenance of the machine.
5. Service and maintenance
This section is intended for service personnel and deals with the periodic
maintenance procedures and adjustments.
6. Troubleshooting
This section gives service engineers some helpful hints on how to solve some of the
operational problems that may occur.
7. Appendix
In the appendix you will find the electrical, hydraulic schematics, spare parts and
service letters.
8. Lubrication Points Nordic Dino NB, WB, XWB
9. Checklist pre-engine start Nordic Dino, Serial number from 101
10. Contact
NORDIC DINO NB, WB, XWB 1

Revision date: 20200114, Serial nr: from 101
Table of content
Introduction ................................................................................................................................ 1
Safety warnings .......................................................................................................................... 3
Before you start .......................................................................................................................... 4
General operating instructions.................................................................................................... 5
General ....................................................................................................................................... 6
Cover critical parts ..................................................................................................................... 8
Technical description ................................................................................................................. 9
Operation .................................................................................................................................. 12
Wireless Portable Control module (PCM) ............................................................................... 13
How to plan your work ............................................................................................................. 30
How to wash an aircraft ........................................................................................................... 31
Practice runs ............................................................................................................................. 32
To think about ....................................................................................................................... 34
Before washing is started ...................................................................................................... 34
Washing fundamentals ......................................................................................................... 35
You are now ready to start .................................................................................................... 36
Service and maintenance .......................................................................................................... 42
Periodic Maintenance ............................................................................................................... 44
Every week ........................................................................................................................... 44
Periodic maintenance: Every 100 hours or every 2 months ................................................. 45
Periodic maintenance: Every 400 hours or every 8 months ................................................. 50
Mechanical adjustments ........................................................................................................... 51
Adjustment of sensor arms 2 ................................................................................................ 51
Service logbook ........................................................................................................................ 52
Troubleshooting ....................................................................................................................... 53
Appendix .................................................................................................................................. 57
Contact ..................................................................................................................................... 58

Safety warnings
The following warning signs are used on the machine. Read all of them
and follow the instructions when performing the procedures. The
WARNING shown below in red are used to call your attention to some
procedures that could cause death or injury to personnel and/or damage
to equipment.
WARNING: This robot should only be operated by trained personnel

The Nordic Dino is only to be operated by trained personnel.
WARNING: Keep clear of moving parts. Risk of injury.

When loading and off-loading from a trailer, make sure that you do not stand behind the
trailer. Stay away from the trailer to avoid injuries.
WARNING: Never leave the machine running whilst unattended and do not obstruct
aircraft when parked.
WARNING: Do not stand within the operating area - risk of injury.
Make sure that you do not stand within the operating area (both on the ground and when
working from access platforms) of the Nordic Dino. Do not stand under the brush unit.
WARNING: Keep clear of moving parts - risk of injury.
Make sure that you keep clear when the arms on the Dino are moving, risk of being struck
or trapped. Do not stand within the operating area of the
WARNING: Keep clear of moving parts - risk of injury.
Keep hands away from the mast turn section (on the bottom of the arm package) when the
machine is operating
WARNING: Keep your feet clear - risk of injury.
Whilst operating the Nordic Dino, make sure you keep your feet away from the wheels.
WARNING: Never use external batteries or booster/charging systems.
The advanced electronic/hydraulic systems installed in the Nordic Dino range are easily
damaged by incorrect polarity, short circuit, static discharge and overvoltage conditions,
therefore, the machine MUST NEVER be started or operated using external batteries or
booster/charging systems. Failure to comply will invalid the manufacturer’s warranty.
WARNING: Safety precautions when working with batteries.
Risk for explosion when working with hydrogen gas.
It is totally forbidden to smoke or have a naked flame around the battery
Avoid short circuit and sparks.
Avoid corrosive acid use safety gloves and glasses.
WARNING: The catalytic converter gets very hot.
When checking oil level on the engine, keep your hands away from the exhaust system,
especially the catalytic converter. Risk of injury.
WARNING: When using the Dino machine outside, never operate the machine in winds
exceeding 20 m/s.

Before you start
The picture below represents a typical airport environment. Lots of vehicles and people trying
to finish their assignments as quickly as possible so that the aircraft can leave on time. When
you work in this kind of environment it is important to be careful so that you do not create
accidents that will create unnecessary delays and cost to the paying customer.
Always talk to the mechanic on duty before you start washing an aircraft.

General operating instructions
Washing instructions
Draw up a program for washing the aircraft, consulting the crew responsible for those areas
not covered by the Dino machine. The manual crew starts by washing the high areas that the
Dino will not reach, for example the tail section and the top of the fuselage (on wide bodies).
The machine starts by washing the underside of the fuselage and the underside of the wings.
When the manual crew have finished the top of the fuselage, the machine can begin
washing the underside of the tail section and work its way forward. The machine operator
usually completes washing his sections before the manual crew have finished their sections
and he (or she) can therefore park the machine and begin hosing down those parts of the
aircraft that has been washed by the Dino machine.
WARNING: Keep your feet clear - risk of injury.

Whilst operating the Dino, make sure you keep your feet away
from the wheels.
Before starting, check the following:

• Doors and hatches on the aircraft are closed.
• Safety equipment is in place and that any necessary masking of the aircraft has been
carried out.
• The floor is free from hoses, cables, and other obstructions within the working area
of the machine.
Before the machine is started, check the following:

• There is enough oil in the engine and in the hydraulic tank.
• There is sufficient diesel fuel in the tank.
• The safety systems are working properly.
• There is no damage to the machine.
• There is sufficient detergent in the tanks.
We recommend you run a 10% detergent mixture in the main tank and a 50% detergent
mixture in the spray tank.

General
The following warning signs are used on the machine. Read all of them
and follow the instructions when performing the procedures. The
WARNING shown below in red are used to call your attention to some
procedures that could cause death or injury to personnel and/or damage
to equipment.
WARNING: Keep all the equipment that you use with flammable solvents away from
sources of heat.
WARNING: Do not use the detergent in a higher concentration than is recommended.
WARNING: Always use personal protective equipment when cleaning aircraft. The
detergent used may cause injury to the skin and eyes.
Wear rubber gloves and glasses to prevent injury to your skin and eyes.
Always wear a safety harness when operating access platforms.
Mix the detergent according to the manufacturer’s recommendation.
Use water at a maximum of 38-degree C.
Maximum spray nozzle pressure can be checked by holding a hand, protected by two pairs of
rubber gloves, 20 cm from the nozzle. The pressure must feel gentle and soft.
Remove loose material (dust and dirt) by hand or by using a non-metallic scraper.
WARNING: Keep the spray nozzle more than 30 cm away from the surface of the aircraft to
avoid damage.
When cleaning larger area, spray the detergent solution with “non-atomizing” low pressure
spray guns.
Start applying the detergent from the bottom and work upwards.
Do not apply detergent to larger areas than it is possible to rinse before it dries.

WARNING: To prevent scratches on the surface, soak the brushes in the detergent before
you use them.
Let the detergent soak.
Rub the surface with a soft brush.
Start from the bottom and work upwards.
After cleaning, rinse with low pressure, warm (use water at a maximum of 38-degree C)
water until all residual detergent is removed.
On smaller surfaces, use cloths or swabs.
WARNING: Make sure the mixture of water and detergent does not get on the brake heat
sinks. Contamination can cause damage and reduce brake performance.
Make sure the brakes are properly covered
Avoid spraying water on wheels, wheel brakes, bearings, cables, pulleys and electrical
connectors.
WARNING: DO NOT clean the tyres with the aircraft detergent.
WARNING: Avoid the Airflow sensor.
This is a critical airflow sensor - all aircraft are equipped

with two or even three of them - mounted on the nose
under the cockpit windows and protruding from the
fuselage by about 10 centimetres. On some aircraft
(like the A-320 and the DC-9) these sensors are
mounted on the middle of the front fuselage. These are
critical to the safe operation of the aircraft and the
Dino brush must not come close to it. If you suspect
that there is anything wrong with these, report it to the
engineer on duty as soon as possible.

Cover critical parts
Before you start washing you must put covers over the pitot tubes and static ports These
devices are also of crucial importance to the safe operation of the aircraft and washing
should not start until the masking of these has been carried out. In some cases (on remote
parking areas for instance) the original set of covers will not be available. If using hazard
tape, make sure you are using a bright colour. This to make sure that you do not miss any
tape when you are removing it after completion of the wash. The examples in this manual
are taken from the Boeing 737. Location and design may vary slightly but in principle they
look like the ones in these examples.
Engines: Do not spray water into the engine air intake. Note that engine air intakes may not
always be covered.
Brakes: Most modern aircraft are equipped with carbon fibre brakes –these are very
sensitive to detergent. Always cover brakes and wheels when washing.
GPU: Make sure that the GPU is disconnected before you start washing.

Technical description
The Nordic Dino wash system consists of three principal elements:
A self-powered, fully mobile platform.
A multi-position brush unit for aircraft exterior washing mounted on an arm package.
A wireless portable control module (PCM) designed for one-man operation of the machine.
Main parts:
Power unit (Diesel or Electric).
CANBUS controlled hydraulic and electronic control systems with remote access option.
Detergent and spray systems.
Electronic, safety and emergency systems.
The unit is constructed using a rigid steel chassis and incorporates the following
equipment.
Main tank and spray tank for water and detergent mixture (See technical data).
A Kubota diesel engine, mounted in a sound insulated compartment, powering a hydraulic

pump and a 24-volt alternator for charging the main batteries.
Six steerable wheels driven by hydraulic motors for propulsion and with hydraulic cylinders
for steering. Three propulsion speeds are available, operation, manoeuvring and transport
speed. To improve manoeuvring around the aircraft, four-wheel steering is provided, in two
steering modes, normal steering and crab steering.
Hydraulically driven pumps for detergent and polish.
A main electrical control panel with wireless communication to the portable control module
(PCM).
Hinged aluminium covers on gas springs in an attractive durable surface.
Power unit (Diesel option):

A Kubota engine which powers the electronically controlled load sensing hydraulic pump
and a 24-volt alternator for charging the two 12-volt batteries. This new engine provides
ample power and improved reliability with lower fuel consumption and exhaust emissions.
Power unit (Electric option):

A rechargeable and removeable lead/acid battery pack which powers the electronically
controlled load sensing hydraulic pump via an electric motor. Charging of the two 12-volt
batteries is achieved using an inverter connected to the main battery pack. An optional,
additional lead/acid battery pack can be supplied to increase productivity.

Hydraulic power is used as driving media for:
Driving & steering functions.
Mast rotation and arm functions.
Brush unit functions.
Operation of detergent & spray systems.
High quality components are used throughout the system to give trouble free operation with
a low level of maintenance.
Electronically controlled load sensing hydraulic system:

Using CANBUS technology, each function is controlled by an electronic valve and sensors in
the system automatically monitors hydraulic flow and pressure to provide the most efficient
operation and operator control. The various safety systems built into the machine provides
optimum protection.
Detergent and spray systems:
Tanks: The detergent and spray tanks are manufactured from stainless steel. They are
dimensioned to hold enough fluid for several hours of operation.
Pumps: A hydraulically driven pump is provided for each detergent and spray tank system.

Electronic, safety and emergency systems
The Dino washing machine is equipped with a safety system that works independently of the
main control system. The system handles the sensor arms, sensing bars and emergency
stops. If any of the safety systems is activated, the control system will shut down
automatically and all functions will stop. The system must be manually reset using the blue
illuminated ’SYSTEM OVERRIDE’ pushbutton switch on the MECP.
As seen from the photo above, there are three sensor arms which automatically control the
brush pressure on the surface being washed. In addition, pneumatic sensing bars are
installed on all three arms as well as on the brush package. If any of these sensing bars
contacts the washing surface or any other object, the control system shuts down
automatically.

Operation
Always check the following BEFORE operating the Nordic Dino;
1. Ensure the engine oil, coolant, diesel, and hydraulic oil are at the correct level.
2. Ensure there is sufficient cleaning liquids in the main and spray tanks.
3. Ensure the Wireless PCM battery is fully charged.
4. Carry out a visual inspection of the machine to check for damage to the chassis and arm
structures.
5. Check the chassis earth straps.
6. Carry out a full function test.
WARNING: The pneumatic sensing bars, brush sensor micro

switches, emergency stop systems and sensor arms MUST be
checked before the machine is positioned near an aircraft.
Reset the systems using the blue ‘RESET’ pushbutton switch
on the MECP.
VERY IMPORTANT:
The advanced electronic/hydraulic systems installed in the new Gen2 Nordic Dino range are
easily damaged by incorrect polarity, short circuit, static discharge and overvoltage
conditions, therefore, the machine MUST NEVER be started or operated using external
batteries or booster/charging systems. Failure to comply will invalid the manufacturer’s
warranty and risk injury to personnel.
In addition, in the event of removal or replacement of the CANBUS shaft encoders used on
the chassis, arms and brush unit systems, they MUST be correctly installed and calibrated to
ensure the safe operation of the machine.
Shaft encoder calibration procedures are given in ’Shaft Encoder Monitor-14’, later in this
section.

Wireless Portable Control module (PCM)
Pos. Description
1 Spray tank pump toggle switch

2 PCM activation toggle switch (switches OFF after 10 seconds of inactivity)
3 Brush rotation toggle switch
4 Main tank pump toggle switch
5 Brush bend/straighten toggle switch
6 Drive speed selector toggle switch
7 Emergency stop/PCM power OFF actuator
8 Left joystick:
To activate functions, move joystick as indicated:
▲Lower arm DOWN
▼Lower arm UP
◄Telescope OUT/middle arm UP
►Telescope IN/middle arm DOWN
9 Middle joystick:
To activate functions, move joystick as indicated:
▲Upper arm DOWN
▼Upper arm UP
◄Brush unit tilt LEFT
►Brush unit tilt RIGHT
10 Right joystick:
To activate the drive functions and steering functions, move joystick as indicated:
▲FORWARD
▼REVERSE
◄Crab steering LEFT
►Crab steering RIGHT
11 PCM power ON pushbutton switch with battery condition-red LED

12 Wash position toggle switch: UNDER/UPPER
13 Steering adjusts centre position toggle switch
14 Arm selector toggle switch: LOWER/(TELESCOPE/MIDDLE)/UPPER
15 Mode selector toggle switch: MANUAL/AUTO
16 Steering selector toggle switch: centre position

Wireless Portable Control Module (PCM) Control 1.
Wireless Portable Control Module (PCM) Control 2.

Wireless Portable Control Module (PCM) Control- 3

Wireless Portable Control Module (PCM) battery 4
The removable/rechargeable battery is located in the base of the PCM.
A spare rechargeable battery is

housed in the charger compartment
on the LH rear side of the chassis.

Wireless PCM battery and charger 5
The location of the PCM battery charger and emergency connecting cable on the LH rear side
of the chassis.

Main electrical control panel (MECP) and E.STOP 8
Chassis rear panel showing location of MECP and main emergency stop actuator.
MECP showing safety override pushbutton, brush adjustments and SMS selector switch.

MECP display: Main Menu/Engine starting 9
1.Turn the battery isolator and key switch ON. Wait for the control system to ‘boot up’.
2. To start the engine, press the ‘ENGINE’ followed by the ‘START’ keypads

3. Whilst the engine is running, the ‘digital dashboard’ is displayed, as shown above.
4. Ensure the PCM battery has sufficient charge, then press the PCM power ON pushbutton
switch-the battery condition red LED will light up.
5. Press the blue ‘SAFETY OVERRIDE’ pushbutton switch on the MECP and then the PCM
activation switch on the PCM.
NOTE: The PCM activation function switches OFF after 10 seconds of inactivity and has to be
reset by operating the toggle switch again. The engine speed will also return to idle after a
prolonged period of inactivity.
6. The brush balance, pressure and bend/straighten set points can be adjusted using the
three potentiometers mounted on the MECP. The normal position for these is at ‘12o’clock.
7. The blue ‘SAFETY OVERRIDE’ pushbutton switch will have to be reset after activation of
the following safety systems:
I. The sensor arm limit switch circuit.

II. The pneumatic sensing bar circuit.
III. The emergency stop circuit.

Model Information 11
From the main menu, press the ‘INFO’ keypad to display the Nordic Dino model information.

Setup Mode: Steering centring/velocity/parameter 12
1. From the main menu, press the ‘SETUP’ keypad to enter SETUP. You can also adjust the
front and rear steering centre position, using the appropriate keypads.
2. The velocity/parameter settings are changed using the appropriate keypads as shown on
the display.

Liquid Level Gauge (Main and Spray tanks) 13
From the main menu, press the ‘LIQUID LEVEL GAUGE’ keypad to display the spray and main
tank liquid levels.

Sensor Mon 1: Shaft Encoder Monitor 14
From the main menu, press the “SENSOR MON-1” keypad to display the shaft encoder
angulat movement in degress.
Calibration of shaft encoders:
1. In the event of removal or replacement of any shaft encoders, the following systems
MUST be in their ‘HOME’ position, PRIOR to calibration, as indicated below:
‘HOME’ POSITIONS:
A. The front and rear steering must be in the STRAIGHT-AHEAD position.

B. The lower arm must be fully DOWN or stowed position.
C. The middle arm/telescope must be fully DOWN/IN or stowed position.
D. The upper arm must be fully DOWN or cylinder EXTENDED position.
E. The brush unit must be VERTICAL.
Once in the correct position, the relevant shaft encoder can be calibrated using the ‘O’ key
(password protected).

Sensor Mon 2: Pressure Sensor Monitor 15
From the main menu, press the “SENSOR MON -2” keypad to display the hydraulic pressure
in each valve block in BAR.

Valve Mon: Proportional Valve Monitor 16
From the main menu, press the “VALVE MON” keypad to display the proportional valve
spool feedback position in %.

Emergency procedures: PCM cable connection 17
In the event of a PCM battery failure, the machine can be moved using a cable connection
between the Nordic Dino and PCM.
1. Locate the cable assembly in the PCM battery charger box on the LH rear side of the
chassis.
2. Switch OFF the power at the key switch, lift the hinged rear cover to access the
connector located next to the PCM battery charger and connect the cable to both the PCM
and Nordic Dino.
3. Switch ON the power at the key switch, start the machine and move it to a safe location.
IMPORTANT: This is for temporary use ONLY.

Emergency procedures: Standby Moving System/SMS - 18
In the event of engine failure, the machine can be operated using the SMS and moved a
short distance to a safe location.
1. Switch OFF the power at the key switch and turn the ENGINE/OFF/SMS switch from
ENGINE to the SMS position.
2. Switch ON the power at the key switch ONLY and move the Nordic Dino to a safe location
using the PCM.
NOTE: The SMS operates using the 24VDC battery pack and therefore has limited capacity.
DO NOT operate the machine over long distances.
IMPORTANT: Before the machine is returned to service, ensure the ENGINE/OFF/SMS switch
is returned to the ENGINE position.
Operation: Emergency procedures; Manual operation of some hydraulic valves 3
Some of the hydraulic valves can be manually operated using a 10mm open ended spanner
on the hexagonal nut on the side of the valve body-these include valves mounted on the arm
assemblies.

Emergency procedures: Park brake release - 19
In the event of engine and electrical failure, the machine can be towed to a safe location. To
do this, the drive system park brake MUST be released as follows:
a. With the power switched OFF, remove the chassis cover from the LH side of
the arm turret to expose the park brake release system.
b. Referring to the enclosed photo, move the park brake release valve from the
OPERATIONAL position to the RELEASE position.
c. Remove the park brake release pump handle from it’s storage and place in
the pump handle mounting.
d. Operate the pump until very stiff resistance is encountered – this charges the
park brake accumulator circuit and releases the park brake. NOTE; the
accumulator will only hold sufficient pressure for a short time so additional
pumping may be necessary).
e. Move the machine to a safe and secure location.
f. To re-engage the park brake, remove and store the pump handle, return the
park brake release valve lever to the OPERATIONAL position and refit the
chassis cover BEFORE returning the Nordic Dino to service.
IMPORTANT: Before the machine is returned to service, ensure the hand lever on the ‘brake
release’ valve is returned to the right (service) position and test the function of the park
brake.

How to plan your work
A typical wash crew consists of:
1 Dino operator.
1 groundman (the groundman washes areas around antennas and drain masts and hoses
down the areas covered by the Dino machine).
A manual crew:
1-2 access platform operators (washing tail section and fuselage over the wings).
2-3 groundmen (washing low belly parts, engine pylons and flap sections reachable from the
ground).
Draw up a program for washing the aircraft, consulting the crew responsible for those areas
not covered by the Dino machine. In order not to block each other, start the two crews in
each end of the aircraft. For example, the Dino crew on the front left section and the
manual crew on the rear right section. Rotate the crews clockwise or counter clockwise
around the aircraft.
If you are washing outside in high temperatures, start by hosing down the entire section to
be washed – the fuselage gets very hot and the water/detergent residue dries very quickly.
The access platform operator(s) start by washing the tail section including the top of the
horizontal
stabilisers and the tail cone section. When this is finished, the sky-lift moves to the left side
fuselage section over the wing.
Do not stand within the operating area:
Make sure that you are not within the operating area of the Nordic Dino (both on the ground
and when working from access platforms).
The manual crew: Start by washing the low belly sections, area’s around the drain masts,
antennas, engine pylons and engines on the right wing. When the right wing is done, the
manual crew move to wash the same areas on the left wing.
The Dino crew: Start by washing the front left fuselage section. When the left side is done,
move around to the right front fuselage section.

How to wash an aircraft
Use the method described earlier in this section to operate the Gen2 Nordic Dino machine,
using the wireless PCM, as follows:
Driving and steering of the Dino is accomplished using the right, four-way joy-stick lever
marked Forward/Reverse/Left/Right.
Caution: The drive function will operate as soon as the drive/steer joystick is moved from
the neutral position.
The Manual-Automatic switch allows manual or automatic operation of the arm and brush
packages. In auto mode, the brush pressure and position are controlled automatically with
the help of the sensor arms on the brush package.
Manual positioning of the arms are made possible by using the two, four-way joy-sticks
positioned centre and left on the portable control module. The left joystick controls the
lower arm/telescope/middle arm and mast rotation functions and the middle joystick
controls the upper arm/brush unit functions.
An arm selector switch ‘Upper/Telescope (Middle)/Lower’ selects which arm is active in auto
mode.
A wash position switch ‘Under/Over’ tells the control system whether we are washing in
under or over wash position.

Practice runs
If you are not familiar with the Dino, we recommend that you practice by washing a
vertical surface such as a wall or a hangar door. Make sure that the area used for practice
runs does not contain light fixtures, junction boxes or sharp objects - proceed as follows:
Position the Dino, 2 metres from the surface to be washed - the chassis should be parallel to
the surface.
Raise the arms so that the brushes are approx. 3 metres from the ground.
Rotate the lower arm fully right by turning the left joystick to the right.
Raise the lower arm to an angle of 45 degree by pulling the left joystick backwards.
Raise the upper arm to a horizontal position by pulling the centre joystick backwards.
Adjust the brush package so that the sensor arms are parallel to the washing surface.
Turn the centre joystick left or right with the button depressed.
Place switch (wash position switch) in the "over" position.
Place switch (arm select switch) in the "lower" position.
Place switch (auto-man) in the "auto" position.
Start washing the surface by driving the Dino forwards and reverse parallel to the washing
surface. Raise or lower the arms to cover additional areas. Continue practicing until you feel
confident about the manual and automatic features of the system.
Having gained proficiency with the Dino system by practicing as described in the previous
paragraphs, proceed to move the Dino to an aircraft.
Most of the aircraft exterior surfaces are cleaned with the Dino
- exceptions are:
Nose cone.
Cock-Pit windows.
Parts of the belly section and under wing areas (due to low ground clearance).
Fuselage sections of the wings.
Tail section, including the vertical stabiliser.

WARNING: Do not operate the brushes over antennas and drain masts - damage may
occur.
When you approach any of these devices, select manual mode and lift the brushes from the
surface until they are well clear and drive past. Revert to auto mode and continue to wash.
WARNING: Do not stand within operating area

Make sure you are not within the operating area of the Nordic Dino (both on the ground and
when working from access platforms).
Washing the front fuselage

Always start by washing the lower part of the fuselage.
Position the Dino approx. 5 metres in front of the left side front fuselage.
Rotate the lower arm full right by turning the left joy-stick to the right..
Raise the upper arm approx. 1 metre using the centre joy-stick pulled backwards.
Raise the lower arm to max up position by pulling the left joy-stick backwards.
Lower the upper arm by pushing the centre joy-stick forward.
Tilt the brush package to a position parallel to the upper arm—move the centre joy-stick to
the left.
Rotate the brush package so that the sensor arms are facing the wash surface—rotate the
centre joystick left or right.
Drive the machine into position for washing. Use the right joystick.
Select ‘under/upper’, then "auto" mode - the upper arm will now elevate automatically until
the sensor arms make contact with the fuselage and will continue to maintain proper brush
pressure as long as the system is in auto mode.
Start the brush rotation by selecting "brush rotation”.
Select "main tank on”, this starts the detergent pump.

To think about
If you are washing the top surface of the wings it is very important that the Dino operator
has a clear view of the area to be washed. If possible, try to wash the majority of the over-
wing section (section 1 in the illustration) from the trailing edge, since the visibility is much
better from that position.
The entire tail section including the top of the horizontal stabilizers (section 2 in the
illustration) has to be washed manually since the Dino machine cannot reach these sections.
This is a very time-consuming section, so it is important to start washing this area as soon as
the aircraft is available for wash.
Before washing is started
Ensure PITOT TUBES & STATIC

PORTS are covered
Ensure undercarriage/wheels are

covered
.
Ensure engine intakes are
covered.
The fuselage section over the wings (section 3 in the illustration) is also”out of reach” of the
Dino machine so that section has to be washed manually. Always remember to wear a safety
harness when working on top of the wings or from an access platform.
When washing the engines (nr 4 in the illustration) remember not to direct the water jet into
the air intake.

Washing fundamentals
The following pages show you
how to set up the machine for the
different fuselage sections.
Further down in the text you will
find a more detailed description,
section by section.

You are now ready to start
When washing it is important to try to drive as parallel as possible in relation to the fuselage.
Proceed to wash the fuselage by raising the telescope extension arm to an elevation above the
area previously washed.
Select wash position "under" and arm selector switch to "upper".
This wash position is called “Under-upper” Figure 1
FIGURE 1 FIGURE 2
When you have reached the window area, lower the lower arm to approx. 45 deg and
raise the upper arm to a horizontal position by:
Pull the centre joy-stick lever backwards.
Push the left joystick forward.
Adjust the brush package so that the sensor arms are parallel to the washing area—rotate
the centre joystick to the left or right.
Select wash position switch to "over" and arm selector switch to "lower".
Switch back to "auto" mode and continue to wash.
This wash position is called “Over-Lower” Figure 2

Having finished the window area, proceed to wash the top of the fuselage as follows:
Start by lowering the lower arm
Then raise the upper arm to an elevation over the area just washed.
Adjust the brush package so that the sensor arms are parallel to the washing area. For this
movement, rotate the centre joystick left or right.
Raise the lower arm again until the sensor arms are approx.30cm from the fuselage.
Keep the wash position switch in "over" and change the arm selector switch to "upper".
Switch back to "auto" mode and continue to wash.
This wash position is called “Over-Upper” Figure 3
The principal wash procedure for the rear section is the same as on the front section.
Over-upper
FIGURE 3
When washing the top of the fuselage, make sure you know where any antennas are
located. You must lift the brush over any obstacle higher than 3cm.

Having finished the front fuselage, carry on by washing the top of the wing.
1. Raise the upper arm approx. 1 metre over the fuselage
2. Reverse the machine approx. 3 metres

3. Then go forward and full right until you are in a position parallel to the leading edge
of the wing.

4. Lower the upper as well as the lower arm until the brushes are approx. 30cm above the
top of the wing. Switch back to automatic mode and start washing towards the wing tip.
Turn back towards the wing root again and this time, steer a little closer to the leading edge
so that the brush washes the mid-section of the wing.
Before making a final sweep towards the wing tip, switch back to manual mode, raise the
upper arm and then the lower arm so that the brushes will reach as far back towards the flap
section as possible.
NOTE: Keep your eye on the top surface of the lower arm since it will be very close to the
leading edge on the final sweep.

Over-upper
The flap section on the top of the wing cannot be reached from the leading edge. It is
therefore necessary to drive around the wing tip and wash this section from the trailing
edge.
Proceed as follows:
When you have finished washing from the leading edge, switch over to manual mode, lift the
upper arm approx. 60cm, make a U-turn around the wing tip and position the machine
approx. 3 metres in from the wing tip (where the flap section starts). Switch back to auto
mode and wash the flap section.

Under-upper
Having completed the top surface of the wing, it is time to wash the underside of the wing.
Proceed like this:
Position the machine approx. 3 metres outside the wing tip. Lower the lower arm to the
bottom position. Push the left joy-stick lever forward.
Turn the lower arm back to parking position (parallel to the machine). Rotate the left joystick
to the left.
Lower the upper arm to about 1.5 metres above the Dino engine cover.
Then turn the brush package around 180 degree so that the sensor arms are facing upwards.
Rotate the centre joystick left or right. Finally lower the upper arm to its bottom position.
Wash in the direction of the wing with the front end of the machine facing the fuselage.
Start washing from the wing tip and wash as far as possible towards the fuselage. Select
under wash with upper arm.

Service and maintenance
Daily maintenance
Since the Nordic Dino machines will be constantly drenched in a mixture of water/detergent
during washing operations, it is essential to follow a strict maintenance schedule. Make sure
that the operators responsible for the day-to-day operation of the machine makes notes in a
logbook.
The wireless PCM system should only be serviced or repaired by Aviator Robotics AB.
To obtain service both of sender device and receiver device must be sent to Aviator Robotics
AB.
Any attempt to service or repairs the wireless PCM system dealt with in this service
information by anyone else will invalidate any warranty and could result in serious injury and
malfunction.
Visual check regarding oil leaks, damage etc. Check for hydraulic leaks from cylinders,
hoses, hose-fittings, pipes, valves and for fuel leaks in the diesel fuel system hoses, pipes,
clamps and filters. Tighten or replace if necessary.
Functional check on all sensing bars. Activate the control system. Check all sensing bars for
proper function. If a sensing bar does not function properly, check for damage on the
sensing bar or hoses/fittings. If not try to increase the sensitivity on the press wave relay…
(see separate service letter section for instructions). If this does not help, suspect a faulty
relay. Replace if necessary. (see separate service letter section for instructions).
Check the following on the Dino before starting up.

That there is sufficient oil and coolant in the engine and oil in the hydraulic tank
That there is sufficient fuel in the diesel tank. (see special info regarding bio-diesel fuels in
the Kubota operational manual).
That there is sufficient detergent in the main and spray tanks.
Functional check on sensor arms and emergency switches. Start up the Dino machine and
activate the control system. Run through all the automatic washing functions. Test the
functions of all three sensor arms including the emergency switch, Spray switches with
plenty of lube spray. If you do not get the proper response from the sensor arms or switches,
check the wiring. Look for damage to cables, excessive corrosion on connectors. If nothing
else helps the potentiometer is most likely faulty. Check function and calibration.

After using the machine
Wash the machine with the brush using the same detergent as on the aircraft.
Rinse the machine off using hot water.
Dry the portable control module off, first with a damp tissue and then with a dry tissue.

Periodic Maintenance
To maintain the functionality we recommend making periodic maintenance every week and
regularly after 50 hours usage and monthly inspections.
Every week
Grease the entire machine if using grease other than the recommended product, otherwise,
every month (refer to supplied list of greasing points)
Spray the following places with a suitable lube spray:
1. Hydraulic cylinders
2. Push pistons and eye mounting bearings
3. Sensor arm housing
4. Bearing for brush unit rotation
5. Linkage for brush bend
6. Link bearing on the brush package.
7. Front wheel bearings
8. Hydraulic valves on the upper arm
9. Mast lock unit mounting bearings.
Every month
Check the wiring, modules and connectors for humidity and corrosion.
Wireless portable control module
Control system in the main electrical control panel.
All chassis, arm, and brush unit electrical connection boxes
Note: Regarding maintenance of engines, please use the submitted engine manual from the
manufacturer.

Periodic maintenance: Every 100 hours or every 2 months
Functional check of:

Upper arm
Operate the joystick, up-down. Make sure that the arm moves smoothly and silently. Test
the auto function by selecting:
1. Under/upper
2. Over/upper
Operate all three sensor arms and test all sensing bars to make sure you get a proper
response.
Adjust speeds if necessary (see adjustment section for the proper procedure).
Lower arm
Operate the joystick up-down. Make sure the arm moves smoothly and silently.
Test the auto function by selecting first:

1. Under/Lower (speed is normally not set since this function is not used)
2. Over/Lower
Operate all three sensors to ensure that you have proper arm response. Adjust
speeds if necessary. (see adjustment section for the proper procedure)
Telescope arm/Middle arm

1. Operate the joystick extend/retract (or up-down on WB/XWB). Make sure arm moves
smoothly and silently. Test auto function by selecting” under/lee and then” over/tele.
2. (or under/middle followed by over/middle on WB/XWB). Operate all sensor arms and
sensing bars to make sure you get the proper response. Adjust speeds if necessary. (see
adjustment section for the proper procedure).
Mast rotation left/right.

Rotate the joystick left-right. Make sure the mast functions properly. If needed, adjust. (see
adjustment section for the proper procedure).
Brush bend/rotation
Operate the joystick up-down and left-right. Make sure arm moves smoothly and silently.
Test auto function by selecting 1=” under-upper” and then 2=” over-upper”. Operate all
three sensor arms to make sure you get a proper arm response. Adjust speed if necessary.
(see adjustment section for the proper procedure).

Brush tilt/rotation
1. Operate the joystick left-right. Make sure the brush unit moves smoothly and silently.
Adjust speed if necessary. (see adjustment section for the proper procedure).
Steering front/rear
1. Operate steering in” normal” as well as” crab steering” mode. Make sure you get proper
joy-stick response in both steering modes.
Speed: Oper-Man-Trans
1. Note: Sometimes after making speed adjustments, we have noted that steering centre
position settings change. You can easily re-adjust by using the two switches on the main
electrical control panel. (see adjustment section for the proper procedure).
Sensor arms
1. Check condition of the three sensor arms.
2. NOTE: The condition of the sensor arms is very critical for the function of the control
system so if you suspect that a sensor arm is damaged or about to break, change it right
away.
Touch sensing bars:

1. Check all sensing bars for proper function. Check all sensing bars for possible damage and
repair or change if necessary.
2. NOTE: The sensing bars, especially the two on the brush package are very important
safety feature on the Dino machines and it is essential that all sensor bars function properly
at all times.
Detergent and spray pumps:

1. Run both pumps and make sure they work properly. If no detergent comes thru the spray
nozzles, take the nozzles apart and clean.
Emergency stops:
1. Check the function of each emergency stops. The emergency stop on the machine takes
a lot of beating and can sometimes be the cause for disturbances to the control system.
Electrical equipment:
Main Electrical Control Panel (MECP):
1. Look for water or traces of water. If you have an indication that you have water leaking
into the main electrical control panel, try to determine where the leak might come from.
2. Check rubber seals around the panel door.
3. Check rubber seals around cables going into the main electrical control panel.

If any of these seals are damaged, repair or change ASAP. Remove and check all connectors
for corrosion. Clean and spray with 2-26 (or equal product) if necessary.
Control system:
Remove and check all the connectors. Make sure there are no traces of corrosion on any of
the connector pins. Clean and spray with CRC 2-26 or equal electronic spray if necessary.
Main switch panel:

Make sure there are no traces of corrosion. Clean and spray with CRC 2-26 or equal
electronic spray if necessary.

Wireless portable control module:
Check the wireless PCM for water or traces thereof. If you have an indication that you may
have water leaking into the PCM try to determine where the leak might be coming from
.
1. Check the rubber covers around the base of the joysticks. If any of these are damaged,
repair or change ASAP.
2. Check the rubber covers over the toggle switches. If any of these are damaged, repair or
change ASAP.
Stand-by moving system (SMS):
Test all functions.

Electrical connection boxes on chassis, arms, and brush unit:
Open the electrical connection boxes, check for corrosion.
Microswitches on the brush sensor housings
The microswitches often get jammed in the off position by dried-up detergent/water
mixture. This will prevent the control system from functioning properly. Clean up the switch
and spray using a suitable lube spray.
Steering, arm and brush unit sensors

Check for damage and signs of water or corrosion at cable connections. If necessary, clean
and spray using a suitable electronic spray.
Cables and connectors on the CANBUS hydraulic valves

Make sure there are no traces of corrosion. Clean and spray using a suitable electronic spray
if necessary.
Electric wiring
Check all CANBUS wiring and connectors for damage and corrosion—replace if
necessary. Also check condition of chassis earth straps and replace if damaged or worn.
Safety precautions for working with batteries:

Risk for explosion when working with hydrogen gas.
It is totally forbidden to smoke or have a naked flame around the battery.
Avoid short circuit and sparks.
Avoid corrosive acid.
Use safety gloves and density glasses.
Battery
Before servicing, disconnect negative battery cable from the battery terminal.
Make a visual check and clean if necessary.
Terminal and connectors make sure they are in good condition. Check for:
Corrosion
Dirt
Check battery fluid level, if necessary, fill the cells with distilled water
Charge the battery
Hydraulic system:
Check following parts for leaks:
Hydraulic tank
Pump suction hose
Hoses, pipes and fittings
Valves
Hydraulic motors
Cylinders
Transfer valves
Pressure and return filters
Stand-by moving system
Make sure there are no leaks and check oil level.
Diesel system
Check following parts for leaks
:
Check diesel tank
Connections
Tap
Hoses and hose-clips
Filter
Fuel pump
If there are any leaks, tighten or change hose-clip or replace hose.
NOTE: Complete structural inspection of chassis, arms and brush unit

Periodic maintenance: Every 400 hours or every 8 months
Engine:
Change the oil
Change the air filter elements
Check the 24V alternator drive belt tension
Check the exhaust system for leaks
Check the 24V starter motor
Water/detergent system:
Clean and rinse out the tank
Check:
Taps
Pumps
Hoses and pipes
Non-return valves and hose-clips
Nozzles and filters
Brushes
If necessary, fill up the tanks
Check all the chassis covers for damage.
Every 200 hours:

Change the hydraulic oil
Change the hydraulic oil filters
Every 400 hours:
Hydraulics:
Change the pressure and return filter elements
Brush drive and brush unit rotation gearboxes:

Check tension of the chain, adjust if necessary.
Fill up with grease if required.
Grease brush unit rotation gearbox
For daily maintenance use anti-corrosion spray CRC 3-36
Engine oil SAE 15W-40 diesel engine oil

Hydraulic oil ISO HVI 15 (cold climates), HVI 46 (hot climates)
Electric spray CRC 2-26
Grease Kernite: K-NATE grease
Kernite: K-NATE grease in 400g cartridge

Mechanical adjustments
Adjustment of microswitch: Brush sensors 1
Press the sensor arm into the brush. When the sensor arm is approx. 30 mm from the brush
centre a "clicking sound" should be heard from the microswitch. If not, loosen the nut on
the microswitch arm and adjust the arm forward or backwards depending on if the "click"
comes early or late...
“Loosen the nut on the

microswitch arm and adjust the
arm forward or backward”.
Adjustment of sensor arms 2

Make sure that the sensor arms are in the rest position (against the stop pin).
Shape the sensor arm until it is approx. 40 mm from the brushes.
CAUTION: During the adjustment, keep the brushes rotating

Service logbook
DATE Hour meter Hour meter TIME SIGN REMARK

START STOP
Remarks
1.
2.
3.
4.
5.
If you need more

space, use the
reverse side.

Troubleshooting
Troubleshooting-1
The troubleshooting guide covers a number of possible problems and describes the
appropriate fault-finding sequence. The guide is divided into the following sections.
Control system
Power unit
Starter
Battery charging
Hydraulic system
As an aid to the troubleshooting guide, electrical and hydraulic schematics are provided in
the ‘Appendix’ section. The fault finding and repair procedures presume a certain knowledge
of electrical and hydraulic systems and should therefore be undertaken only by competent
personnel.
Control system
Symptom Action
1. No function at all. 1.1 Check the hydraulic system pressure.

1.2 Ensure the chassis and PCM emergency stops
are disengaged.
1.3 Check that the PCM rechargeable battery is
fully charged.
1.4 Ensure the PCM wireless communication
switch is activated.
1.5 Ensure the PCM control system timer switch is
activated.
1.6 Check the BRUSH UNIT/MAST ROTATION
proximity sensors.
2. The unit does not respond as expected 2.1 Possible fault with CANBUS system (contact
Aviator Robotics AB).
3. Steering inoperative/faulty. 3.1 Check the hydraulic system pressure.

3.2 Check CANBUS cables/connectors & output
from PCM drive/steer joystick.
3.3 Check valve current in steering system.

4. Propulsion system faulty. 4.1 Check for hydraulic system pressure.
activated.
from PCM drive/steer joystick.
4.4 Check valve current in drive system.
5. Upper arm/brush unit faulty. 5.1 Check for hydraulic system pressure.
activated.
from upper arm/brush unit joystick.
5.4 Check valve current in upper arm/brush unit
system.
Control system (cont’d)
6. Lower arm, left/right, middle arm/telescope 6.1 Check for hydraulic system pressure.
not functioning. 6.2 Check the PCM wireless communication
switch is activated.
6.3 Check the PCM control system timer switch is
activated.
from the lower/middle arm telescope joystick.
6.5 Check the valve current in the lower
arm/telescope system using the valve monitor.
7. The blue ‘SAFETY OVERRIDE’ switch will not go 7.1 Check the emergency stop controls.
out when pressed. 7.2 Check the PCM is activated.
7.3 Check the pneumatic sensing system.
8. Brush unit rotation, brush bend, brush rotation 8.1 Check for hydraulic system pressure.
not functioning. 8.2 Check the PCM control system timer switch is
activated.
from the upper arm/brush unit joystick.
8.4 Check the valve current in the upper
arm/brush unit system using the valve monitor.
Power unit

Symptom Action
9. Engine cannot be started or stops during 9.1 Check the engine fuel system & fuses.
operation. 9.2 Refer to the KUBOTA engine manual.
9.3 Fault with the engine CANBUS control module.
9.4 Check mast rotation and brush unit rotation
proximity switches.
10. Engine will not crank over. 10.1 Check for 24VDC at the starter motor.
10.2 Check the earth connection to the starter
motor.
10.3 Check the starter relay function.
10.4 Check the battery voltage on each battery
under load. With the starter engaged the voltage
on each battery should not fall below 11 V DC. For
more information, refer to the wiring diagram.
10.5 Fault with the engine CANBUS control
module.
Charging
Symptom Action
11. If charge indicator lamp fails to go out. 11.1 Check the condition/tension of the alternator
belt.
11.2 Check for satisfactory connection between
alternator and control system.
11.3 If previous items are in order, suspect faulty
alternator. For further information, refer to the
wiring diagram.
Hydraulic system
A single system failing to function properly indicates a faulty component in that system. Use
the hydraulic diagram for fault finding. When working with the hydraulic system it is
particularly important to observe the necessary standards of cleanliness, since even the
smallest particles of dust or dirt can damage the valves and other components. Always place
protective covers over inlets and hose ends when disassembling, and do not remove the
covers from new components until they are to be fitted.
Symptom Action

12.1 Check the oil level in the hydraulic tank.
12. Unusual noises from the hydraulic pump. 12.2 Check the pump suction pipe or
kinking/deformation of hydraulic hoses. In the
absence of such faults, it may be assumed that the
hydraulic pump is faulty and should be replaced.
13. No hydraulic system pressure. 13.1 Check the control system has been activated.
13.2 Check the PCM emergency stop actuator is
reset.
13.3 Check the PCM control system timer switch
has been activated.
13.4 Check the PCM rechargeable battery voltage.
13.5 Check the brush sensor micro switches are in
their ‘home’ position.
13.6 There is a fault with the CANBUS control
system.

Appendix
In the appendix section you will find the electrical, hydraulic schematics and spare parts. You
will also find a selection of service letters.
Contact
We know that things can happen and therefore we are available for you to make sure that
your Nordic Dino robot works perfectly.
For administrative questions, spare parts and order please contact:

maria.brunstedt@aviator.eu + 46 708683329.
For technical enquiries please contact: steve.tilleard@aviator.eu or + 44 7960 32701
Aviator Robotics AB
Fågelsångsvägen 7B
18642 VALLENTUNA
SWEDEN

Contact
For administrative questions, spare parts and order please contact:
Ms Maria Brunstedt, maria.brunstedt@aviator.eu or +46 70 868 33 29
For technical enquiries please contact:

Mr Steven Tilleard, steve.tilleard@aviator.eu or + 44 7960 32701
Aviator Robotics AB
Fågelsångsvägen 7B
18642 VALLENTUNA
SWEDEN


User Manual Nordic Dino NB WB XWB

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Operation, Service and Spare Parts

Nordic Dino NB, WB, XWB

NORDIC DINO NB, WB, XWB 1

NORDIC DINO NB, WB, XWB 2

WARNING: This robot should only be operated by trained personnel

WARNING: Keep clear of moving parts. Risk of injury.

NORDIC DINO NB, WB, XWB 3

NORDIC DINO NB, WB, XWB 4

WARNING: Keep your feet clear - risk of injury.

Before starting, check the following:

Before the machine is started, check the following:

NORDIC DINO NB, WB, XWB 5

Always wear a safety harness when operating access platforms.

Mix the detergent according to the manufacturer’s recommendation.

Use water at a maximum of 38-degree C.

NORDIC DINO NB, WB, XWB 6

Let the detergent soak.

Rub the surface with a soft brush.

Start from the bottom and work upwards.

On smaller surfaces, use cloths or swabs.

Make sure the brakes are properly covered

WARNING: DO NOT clean the tyres with the aircraft detergent.

WARNING: Avoid the Airflow sensor.

This is a critical airflow sensor - all aircraft are equipped

NORDIC DINO NB, WB, XWB 7

NORDIC DINO NB, WB, XWB 8

A Kubota diesel engine, mounted in a sound insulated compartment, powering a hydraulic

Hydraulically driven pumps for detergent and polish.

Hinged aluminium covers on gas springs in an attractive durable surface.

Power unit (Diesel option):

Power unit (Electric option):

NORDIC DINO NB, WB, XWB 9

Electronically controlled load sensing hydraulic system:

NORDIC DINO NB, WB, XWB 10

NORDIC DINO NB, WB, XWB 11

WARNING: The pneumatic sensing bars, brush sensor micro

NORDIC DINO NB, WB, XWB 12

1 Spray tank pump toggle switch

11 PCM power ON pushbutton switch with battery condition-red LED

NORDIC DINO NB, WB, XWB 13

Wireless Portable Control Module (PCM) Control 2.

NORDIC DINO NB, WB, XWB 14

NORDIC DINO NB, WB, XWB 15

The removable/rechargeable battery is located in the base of the PCM.

A spare rechargeable battery is

NORDIC DINO NB, WB, XWB 16

NORDIC DINO NB, WB, XWB 17

NORDIC DINO NB, WB, XWB 18

NORDIC DINO NB, WB, XWB 19

I. The sensor arm limit switch circuit.

NORDIC DINO NB, WB, XWB 20

NORDIC DINO NB, WB, XWB 21

NORDIC DINO NB, WB, XWB 22

NORDIC DINO NB, WB, XWB 23

Calibration of shaft encoders:

A. The front and rear steering must be in the STRAIGHT-AHEAD position.

NORDIC DINO NB, WB, XWB 24

NORDIC DINO NB, WB, XWB 25

NORDIC DINO NB, WB, XWB 26

IMPORTANT: This is for temporary use ONLY.

NORDIC DINO NB, WB, XWB 27

Operation: Emergency procedures; Manual operation of some hydraulic valves 3