ALMAC MULTI-LOADER 2.5, Translation Of Original Instructions

Page 1: ...Translation of original instructions Prior to commissioning the machine carefully read this Use and Maintenance Manual Note table of contents at the end of the manual Edition Date 00 22 03 2017...

Page 2: ...OADER 2 5 Note Some of the photos and illustrations may not refer specifically to the version of the machine in your possession but provide indications concerning the purpose for which they have been...

Page 3: ...liability for direct or indirect damage to persons things or animals deriving from use of the machine in conditions differing from those envisaged ALMAC s r l reserves the right to make changes or imp...

Page 4: ...dentification data The machine named MULTI LOADER 2 5 is defined according to the current technical standards such as Identification plate In any case refer to the data on the identification plate for...

Page 5: ...ns Characteristic dimensions Machine length m 2 40 Maximum width Widened track m 1 64 Maximum width Narrow track m 1 46 Height of crawler mm 360 Width of crawler mm 250 Load platform minimum height Na...

Page 6: ...sure traslation bar 220 Oil tank capacity l 35 Climb angle 25 Maximum side slope of the terrain 14 Maximum longitudinal slope of the terrain 20 15 Maximum travelling speed km h 2 0 Overall weight kg 1...

Page 7: ...hine Electronic tilt control Engine specifications Electrical Dry weight 14 kg Installed power 3 kW Rpm 3000 Power supply 48 V Batteries series technical specifications Nominal Capacity Ah 180Ah Nomin...

Page 8: ...r l guarantees the equipment it manufactures and undertakes to replace free of charge and within the shortest possible time those parts that in its opinion possess manufacturing and or material defect...

Page 9: ...se of the machine and extraordinary maintenance are concerned this manual does not replace the expertise of the Technical Assistance sent by ALMAC S r l refer also to the Maintenance Chapter 1 9 1 Req...

Page 10: ...y the serial number of the machine given on the relative identification plate when requesting a new copy of the manual The manufacturer undertakes to provide a new copy Note When selling used equipmen...

Page 11: ...m capacity Attention Operation of the machine with operator on the loading platform is FORBIDDEN The machine MUST only be controlled from the ground via the console Attention It is FORBIDDEN to use th...

Page 12: ...m liability The manufacturer declines all liability in the following cases Use not indicated in this manual Improper use of the machine or its use by untrained personnel Use that fails to comply with...

Page 13: ...od conditions absence of changes induced by use of alcohol or drugs psychological equilibrium absence of depression or stress Operators who use the machine for professional purposes must undergo healt...

Page 14: ...2 Warnings The following sign plates are affixed to the machine Identification Instructions Command prohibition sign plates Caution Danger 2 2 1 Plates indicating instructions obligations dangers proh...

Page 15: ...inclination of the ground The maximum front inclination of the ground to stay safe is 25 There is no electronic control for this condition which is at the discretion of the operator Lateral inclinatio...

Page 16: ...substitute this Manual which is the only reference document containing complete information Comply with the indications on the sign plates Failure to comply with these indications may result in seriou...

Page 17: ...c panel or other live electrical devices Danger This symbol means that there is a danger of injury to the upper and lower limbs due to moving parts Do not insert your hands or feet into openings that...

Page 18: ...d free from any foreign objects or traces of oil mud or snow USE OF THE MACHINE WITH OPERATOR ON THE LOADING PLATFORM IS FORBIDDEN IT IS FORBIDDEN TO EXCEED THE MAXIMUM LOAD Do not use the controls or...

Page 19: ...mmands In this case make sure that the ramp gradient is within the gradeability indicated in the PERFORMANCE data and that the bearing capacity of the chutes suits the weight of the machine Note The m...

Page 20: ...using the relevant tubular elements Attention the maximum weight of the machine in the heaviest configuration is 1800 Kg Note Once the machine is positioned on the vehicle secure it by means of straps...

Page 21: ...PAGE 21 ALMAC s r l Warning the chassis must be completely lowered chassis wide Attention Do not excessively tighten the fixing straps to avoid damaging the structure...

Page 22: ...abnormally worn Always check to make sure that track tension is correct Check that the manual the plates and the stickers are on the machine 2 6 General safety instructions on use of the machine The i...

Page 23: ...ed Make sure movements are done on flat sturdy ground Make sure that there are no hollows or ridges in the floor and that there is enough room for the machine to pass through Make sure that there are...

Page 24: ...ou change direction in a situation where the track could move sideways owing to an obstruction the track could slip out of its housing Attention for inclined floors pay attention to the correct LEVELL...

Page 25: ...PAGE 25 ALMAC s r l NO ICE NO SAND NO DUST OR SMOOTH SURFACES Attention during movement with ELECTRICAL POWER be careful of the connection cable in order to avoid dangerously crushing the cable itself...

Page 26: ...and on the side Activate the automatic levelling control Automatic levelling make sure that the system automatically keeps the frame horizontal Lift the loading platform without load to the maximum he...

Page 27: ...only if other operations are required e g if faults occur All MAINTENANCE work must be performed in compliance with the laws in force governing safety and protection of the environment THE MANUFACTUR...

Page 28: ...parts of the hydraulic circuit have been tightened correctly When compressed air is used for cleaning parts protect yourself by wearing safety goggles with side guards and limit the pressure to 2 atm...

Page 29: ...problems of electrical insulation of the machine can be highlighted with all the associated risks Low ambient temperature reduces battery capacity high temperature reduces lifespan Batteries series te...

Page 30: ...ies Wear plastic gloves an apron or overall to protect your clothes remove bracelets rings or other metal objects that could cause short involuntary circuits 2 13 2 Batteries status verification a The...

Page 31: ...f the machine via the battery switch b Remove the two planes A and B c Disconnect the GND battery negative pole see photo below taking care to keep the disconnected part well insulated protecting it a...

Page 32: ...the disconnected part well insulated protecting it adequately By way of example only achieve this with insulating tape or with plastic casing e Once all the operations have been performed up to point...

Page 33: ...ecting the poles as shown in the figure below having also in this case protected and isolated them 2 14 Battery status maintenance The machine stored without recharging of the batteries can remain for...

Page 34: ...nd maintenance before carrying out any operation with the battery Contact the manufacturer in case of difficulties or uncertainty Place the batteries and electrical appliances out of the reach of chil...

Page 35: ...the equipment This section describes the main components of the machine and their functions 1 Control push button panel console 2 Control console emergency button 3 Remote control compartment 4 Remot...

Page 36: ...PAGE 36 ALMAC s r l 7 Main hydraulic unit 8 Flashing light 9 Ground control panel emergency button 10 Electronic control unit ECU 11 Remote control unit 12 Remote control battery recharge compartment...

Page 37: ...emote control emergency cable connector 14 Battery disconnect switch 15 Emergency button right side 16 Emergency button left side 17 Hydraulic oil tank 18 Discharge filter 19 Intake filters in the tan...

Page 38: ...PAGE 38 ALMAC s r l 21 Visual hydraulic oil level 22 Booster for translation speed management 23 Electric motor AC 110V or 220V 24 Electric motor DC 48V 25 Batteries 26 Battery charger...

Page 39: ...PAGE 39 ALMAC s r l 27 Contactors group 28 Converter 220V 110V 12V 29 Frame angle sensor 30 Rod angle sensor 31 Chassis angle sensor 32 Bi levelling chassis 33 Attacchi rapidi...

Page 40: ...panel console that allows normal operation with the operator on the ground In the event of an emergency the push button panel can also be connected to the supplied cable by tightening the appropriate...

Page 41: ...PAGE 41 ALMAC s r l...

Page 42: ...ch on the electric motor press the button 1 located on the left side of the console The electric motor only works if the plug on the back of the machine has been connected to an external power source...

Page 43: ...status and battery of the radio control Refer to the radio control manual 8 Selector DYNAMIC LEVEL SELECTION DYNAMIC LEVELLING ON position Dynamic levelling activation during translation DYNAMIC LEVE...

Page 44: ...particular condition Use of radio remote control via cable radio bridge by pass 3 2 2 Ground control using the mobile push button panel The machine has been designed and built to be driven by an oper...

Page 45: ...r MACHINE ON OFF Left position 0 Machine turned off Right position 1 Machine turned on 4 Key selector RAPID COUPLINGS SELECTOR OPTIONAL Left position OFF The rapid hydraulic connections on the right s...

Page 46: ...e inspected and restored to their original conditions of safety and reliability DO NOT TAMPER WITH AND DO NOT CHANGE THE CALIBRATION OF ANY OF THE COMPONENTS OF THE ELECTRICAL AND HYDRAULIC SYSTEM The...

Page 47: ...hich constantly transmits the measured inclination to the electronic control unit The angle sensor is redundant thus composed of two distinct sensors and the Y axis of machine inclination longitudinal...

Page 48: ...components These valves do not require adjustments as they are calibrated directly by ALMAC S r l At the testing phase The diagram below illustrates the integrated power pack and the position of the p...

Page 49: ...pass These solenoid valves indicated with 1 2 3 are part of the safety system of the machine and must never be operated manually ATTENTION If the valve 3 is not fully inserted by pressing and turning...

Page 50: ...ariation of the roadway and the inclination appropriate BALANCING VALVES prevent sudden movement of the chassis Proceed as described below to restore the machine to normal operating conditions 1 Repai...

Page 51: ...r safety reasons a device is installed so as to cut out the electricity supply in case of over voltage and differential circuit breaker dispersions 1 To access the device it is necessary to unscrew th...

Page 52: ...48V power line coming from the battery and supplies the various users and the 12V line of electronic power supply and utilities It is recommended to operate this device at the end of the work day to p...

Page 53: ...sensors are constantly compared with the X values of the sensors attached to the frame By measuring their difference it is possible to determine the relative position of the connecting rod with respe...

Page 54: ...ther There are no acceptable values for one factor that can exclude the risk of slipping if the other factor is extremely unfavourable Ground that is almost flat may not be fit if its surface is icy O...

Page 55: ...s to position 1 The key switch functions are RIGHT POSITION 1 machine on energised electrical system LEFT POSITION SX 0 machine off de energised electrical system To turn on the machine proceed as fol...

Page 56: ...ent at start up Joystick contact or movement selector jammed Once ignition is completed it is therefore possible to start the motor Operate selector no 2 for motor selection o High position AC 110V or...

Page 57: ...ds to drive the platform forwards Move the lever backwards to drive in reverse You can work with one track at a time depending on the movement required at that particular moment The platform is fitted...

Page 58: ...on ATTENTION If you must drive up a slope do not change direction when the ground changes from flat to sloping If this is absolutely necessary perform the manoeuvre gradually It is forbidden to climb...

Page 59: ...59 ALMAC s r l 4 2 2 1 Standard travel mode With the selector 6 on the central position DRIVE MODALITY it is possible to carry out all the translation movements with independent tracks see paragraph 4...

Page 60: ...g the manoeuvre In fact the activated function controls in addition to the selected track also the movement of the other track but at a lower speed This allows for controlled steering When this functi...

Page 61: ...her increase in speed reducing the traction capacity To use this function in the best way it is advisable to control both Joysticks in the desired direction first and then move selector 6 from DM to D...

Page 62: ...low the machine to operate within the maximum inclination permitted thus always keeping the loading platform horizontal with respect to the ground within a range of 0 5 both longitudinally longitudina...

Page 63: ...console The system will bring the frame back to an inclination of less than 0 5 compared to the horizontal 4 2 3 2 Manual levelling LH lateral levelling RH lateral levelling Longitudinal levelling By...

Page 64: ...y levelled To activate this mode it is necessary to turn the selector 8 of the push button panel to the DYNAMIC LEVELING ON position and the selector 6 to the DRIVE MODALITY or ED S position Attention...

Page 65: ...ghts of the loading platform During translation or automatic levelling the machine will move and keep the selected configuration HIGH Maintain maximum height of the platform from the ground MED Mainta...

Page 66: ...ity of 2500 kg ATTENTION The load must always be fixed to the machine frame by means of safety straps to be fixed to the holes present along the entire perimeter of the frame ATTENTION When levelling...

Page 67: ...PAGE 67 ALMAC s r l A number of examples follow...

Page 68: ...PAGE 68 ALMAC s r l...

Page 69: ...PAGE 69 ALMAC s r l...

Page 70: ...y also shows any errors and or alarms that may occur E operating hours with 220Vac electric motor e operating hours with 48Vdc electric motor In the upper part the charge status of the 48V battery is...

Page 71: ...eviously alarms caused by malfunctions that appear intermittently the service symbol will appear on the display The control unit can store up to 16 alarms which are shown by pressing the right button...

Page 72: ...signal from the frame angle sensor 2 32 No signal from the chassis angle sensor 2 10 No signal from the console 50 Right connecting rod angle sensor redundancy error 80 Left connecting rod angle senso...

Page 73: ...2 they offer the availability to use any tool with hydraulic supply To activate the operation it is necessary to move the AUX selector 1 towards the right ON in this way the quick couplings are activ...

Page 74: ...t prevents the machine from moving unless hydraulic pressure is exercised to disengage it Deactivation of the machine must take place in these ways Stop the machine in the manner described above Posit...

Page 75: ...mstances or situations in which all machine movements must be stopped the operator can IMMEDIATELY STOP all the machine functions by pressing the MUSHROOM SHAPED button on the push button or the emerg...

Page 76: ...trol If the radio control console does not work correctly it is possible to use the cable supplied 1 to connect it to the machine using the connector 2 5 2 Transporting the machine in an emergency To...

Page 77: ...rformed directly from the hydraulic block To perform the movements it is necessary to release by turning anti clockwise the safety valve 3 and screw by turning clockwise the valves 1 and 2 provided wi...

Page 78: ...ual and functional checks as specified X X Discharge filter cartridge replacement X X Suction filters replacement X X Check the hydraulic oil level X X Change the hydraulic oil X Track reduction gear...

Page 79: ...ne movements necessary for checks maintenance Note Use of spurious spare parts or parts that have not been approved by the manufacturer voids the warranty and relieves ALMAC S r l from all liability N...

Page 80: ...he system automatically keeps the frame horizontal Position the machine with the frame inclined to the horizontal by a value greater than 0 5 on the longitudinal Operate the automatic levelling contro...

Page 81: ...se the Max torque Resistance class in accordance with DIN ISO 898 8 8 Yielding point Rp 0 2 N mm 640 for M16 660 for M16 Metric thread ISO Cross section of the powered zone Cross section of the thread...

Page 82: ...ure and of the tracked chassis In particular check if there is any rust in the structure State of the rubber tracks Oil leaking Pins and stop devices 6 2 3 Damage to tubes and cables Visually check at...

Page 83: ...y on the tank 6 2 5 Hydraulic reservoir oil change The hydraulic oil in the tank must be changed with the frequency indicated in the general chart 1 Collect the used oil in a suitable vessel and dispo...

Page 84: ...0 bar to the pressure outlets supplied 4 and 5 Checking the general maximum pressure valves of the system 1 and 3 The pressure gauges relating to these valves are those connected to the outlets 4 and...

Page 85: ...PECIALIST PERSONNEL according to the monitoring procedure described above Using the appropriate tools unscrew the lock nut 1 and tighten or loosen the adjuster screw 2 until the indicated pressure lev...

Page 86: ...ter replacement Replace the discharge filters of the hydraulic circuit at the frequencies indicated in the general chart The hydraulic oil tank features No 2 intake filters inside the tank 1 1 dischar...

Page 87: ...ne to its normal operating conditions 6 Seal the lid with sealing paste 7 Fill the hydraulic oil reservoir with oil and check the level 6 2 7 2 Replacing the discharge filter To replace the discharge...

Page 88: ...cloth or place a vessel underneath so that the oil drains into it ONLY USE GENUINE SPARE PARTS when replacing the filters Contact the ALMAC technical assistance service Do not reuse used oil Do not di...

Page 89: ...e Comply with the following instructions THE INSTALLATION IS PERFORMED BY THE MACHINE CONSTRUCTOR IN ACCORDANCE WITH THE INSTRUCTIONS AGREED WITH THE SUPPLIER S TECHNICAL SUPPORT CAREFULLY READ THE IN...

Page 90: ...ean the terminals and connectors if necessary Recharge the system every 3 4 weeks if the vehicle is left stationary for long periods without disconnecting the electrical system cables If you disconnec...

Page 91: ...ccasionally Attention Continuously using only one 20A charger will damage the batteries The Lead Crystal batteries can be recharged only with the battery chargers on board the machine in case of a dif...

Page 92: ...TTERY BEYOND THE MAXIMUM VOLTAGE INDICATED Check the external status of the terminals and casing for any signs of damage or abnormal wear which may have occurred during service If in any doubt about t...

Page 93: ...e greater than 0 5 on the longitudinal Operate the automatic levelling control and make sure that the system automatically keeps the frame horizontal Position the machine with the frame inclined to th...

Page 94: ...m automatically keeps the frame horizontal Position the machine with the frame inclined to the horizontal at the maximum angle both on the longitudinal and on the side Operate the automatic levelling...

Page 95: ...ug in the ladder to an electric power supply that conforms to the following specifications Voltage 230 v 10 Frequency 50 Hz Grounding line working and equipped with a differential circuit breaker Use...

Page 96: ...able check the tightness of the flanged valves on the cylinders To perform this check it is necessary to 1 Position the machine as shown in the figure chassis fully raised 2 Position 2500 Kg as shown...

Page 97: ...st be of approximately 2 cm If the track sags and becomes too noisy as it moves it must be tightened as described below 1 Remove the guards 1 2 For correct track tension use a tensioning kit 2 not inc...

Page 98: ...ABLE The grease normally used by the manufacturer is PAKELO Grease C 10 40 PAKELO BEARING EP GREASE NLGI2 BP GREASE LTX2 CASTROL LM2 SPEEROL APT2 SHELL ALVANIA GR R 2 ESSO BEACON 2 SMALL VALVES LITHIU...

Page 99: ...s forbidden to open the reducer for any operation not provided for by scheduled maintenance The manufacturer shall not be held responsible for any operations not included in scheduled maintenance that...

Page 100: ...AC s r l 4 Loosen the tensioning valve 2 5 Remove the tensioning valve only when it is no longer under pressure 6 Using the nut supplied point A 7 Move the front wheel back by pressing on the track wi...

Page 101: ...idler wheel 3 To install the new track proceed as indicated in the previous points but in reverse order 4 The track is correctly tensioned by using the tensioning kit pumping grease until the pressur...

Page 102: ...maintenance and checks table 1 Move until the gear motor is in the condition in which the FILL cap is at the top and perpendicular to the DRAIN cap 2 To drain the oil a Unscrew the FILL cap b Unscrew...

Page 103: ...d to make it must be recovered for recycling purposes where possible Note ALMAC S r l declines all liability for damage to persons animals or things deriving from reuse of parts of the equipment for f...

Page 104: ...r parts of it because the combustion products of plastic materials and paints could develop harmful polluting gases 7 3 Battery disposal Battery recycling is mandatory European Directive 2006 66 EC an...

Page 105: ...PAGE 105 ALMAC s r l 8 ATTACHMENTS 8 1 Declaration of conformity FAC SIMILE...

Page 106: ...s Register is to record events concerning the life of the machine in detail Mandatory routine inspections INAIL ASL authorised bodies Maintenance and obligatory inspections to check the integrity and...

Page 107: ...PAGE 107 ALMAC s r l MANDATORY ROUTINE INSPECTIONS Date Observations Seal Signature...

Page 108: ...ecessary but should be made at least once a year when other operations are performed Type of inspection Description Visual and structural inspection Check the integrity of the anchors supports carpent...

Page 109: ...registration is not necessary but should be made at least once a year when other operations are performed Type of inspection Description Hydraulic tank oil level inspection Date Observations Signatur...

Page 110: ...r 8th year 9th year 10th year NOTE frequency of the operation as indicated in the table in Chapter 6 Type of inspection Description Check the operation of the maximum pressure valve Date Observations...

Page 111: ...year 8th year 9th year 10th year NOTE frequency of the operation as indicated in the table in Chapter 6 Type of inspection Description Lead Crystal battery status verification Date Observations Signa...

Page 112: ...th year 9th year 10th year NOTE frequency of the operation as indicated in the table in Chapter 6 Type of inspection Description Check the operation of the differential switch of the 230V outlet Date...

Page 113: ...the operation as indicated in the table in Chapter 6 Daily registration is not necessary but should be made at least once a year when other operations are performed Type of inspection Description Tra...

Page 114: ...ecessary but should be made at least once a year when other operations are performed Type of inspection Description Parking brake Make sure that parking brake functions correctly when machine stops Da...

Page 115: ...escription of fault Solution Spare parts used Description Code qty Serious faults Date Description of fault Solution Spare parts used Description Code qty Serious faults Date Description of fault Solu...

Page 116: ...acteristics and that variations if any have been recorded in the register Seller s business name Seller Purchaser Copy to be spent to ALMAC S R L on the machine properties serial no year of manufactur...

Page 117: ...PAGE 117 ALMAC s r l 8 4 Hydraulic diagram See attachment 8 5 Wiring diagram See attachment...

Page 118: ..._______________ 11 1 11 1 Intended use __________________________________________________________ 11 1 11 2 Improper uses_________________________________________________________ 12 1 11 3 Cases that...

Page 119: ...e limiting devices ________________________________________ 48 3 4 2 Hydraulic block safety devices_____________________________________________ 49 3 5 BLACKOUT SAFETY DEVICES ________________________...

Page 120: ...use ___________________________________________________ 80 6 2 MAINTENANCE DETAILS_________________________________________________________ 81 6 2 1 Checking and tightening screws bolts plug ring nut...

Page 121: ...___________________ 103 7 2 DECOMMISSIONING AND DEMOLITION _______________________________________________ 103 7 3 BATTERY DISPOSAL ___________________________________________________________ 104 8 AT...