Terex Robot 5000 Operator's Handbook Manual

Robot

5000 - 8000 - 15000

OPERATOR HANDBOOK

Code 57.0300.0200 - 4

th

Edition 07/2000

CAUTION: THOROUGHLY READ AND UNDERSTAND THIS MANUAL BEFORE OPERATING THE MACHINE

CAUTION: KEEP THIS MANUAL IN THE MACHINE AT ALL TIMES

English

Edition

Operator handbook ROBOT/GB.

transmitted in any form or by any means without prior written permission from ITALMACCHINE S.p.A.

In pursuing a policy of constant quality improvement, ITALMACCHINE S.p.A. reserves the right to

make changes at any time and without undertaking to give prior notice; therefore, also this publica-

tion may be subject to modifications.

Produced by:

Document 57.0300.0200 - 4

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DEALER’S OR ASSISTANCE CENTRE STAMP

ZONA INDUSTRIALE I-06019 UMBERTIDE (PG) - ITALIA

Telefono +39 075 941811 - Telefax +39 075 9415382

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INTRODUCTION ........................... Page 3

SYMBOLS.............................................. 4

Section A GENERAL INFORMATION

A-1 CONVENTIONAL REFERENCES ........... 6

A-1.1 Machine position ................................... 6

A-1.2 Labels and warning plates applied on

the machine ........................................... 7

A-1.3 Explanation of the symbols used on

the equipment ........................................ 8

A-2 MACHINE IDENTIFICATION .................. 9

A-2.1 Model and type of equipment ............... 9

A-2.2 Manufacturer ......................................... 9

A-2.3 Machine identification plate ................... 9

A-2.4 CE mark ................................................. 9

A-2.5 Identification plates of the main parts ... 9

A-3 ALLOWED USE ...................................... 10

A-3.1 Allowed use ........................................... 10

A-3.2 Improper use ......................................... 10

A-3.3 Application field of robot on

ITALMACCHINE handlers ...................... 10

A-4 GENERAL DESCRIPTION ...................... 11

A-4.1 List of the main components -

Robot 5000 and 8000 ............................ 11

A-4.2 List of the main components -

Robot 15000 .......................................... 12

A-5 TECHNICAL DATA AND

PERFORMANCE .................................... 13

A-5.1 Main dimensions Robot 5000 ............... 13

A-5.2 Main dimensions Robot 8000 ................ 14

A-5.3 Main dimensions Robot 15000 .............. 15

Section B SAFETY

B-1 GENERAL REMARKS ............................ 18

B-2 REQUISITES OF THE PERSONNEL

IN CHARGE ........................................... 18

B-2.1 Requisites of operator and ground staff 18

B-2.2 Requisites of the maintenance staff ...... 19

B-2.3 Working clothes ..................................... 19

B-2.4 Personal protective equipment .............. 19

B-3 SAFETY PRECAUTIONS ....................... 19

B-3.1 Working area.......................................... 19

B-3.2 Getting ready to work ............................ 20

B-3.3 During work or maintenance ................. 20

Section C OPERATING INSTRUCTIONS

C-1 COUPLING THE ROBOT TO THE

HANDLER .............................................. 22

C-2 STEPPING INTO THE ROBOT

PLATFORM ............................................ 23

C-2.1 Fastening the safety belts...................... 23

GENERAL INDEX

C-3 CONTROL PLACE ON THE

PLATFORM ............................................ 24

C-3.1 Controls ................................................. 24

C-3.2 Handler controls .................................... 25

C-3.3 Robot controls ....................................... 26

C-4 USING THE ROBOT .............................. 27

C-4.1 Switching the controls from handler to

platform ................................................. 27

C-4.2 Operating the controls from the

platform ................................................. 28

C-4.3 Stopping and storing the equipment ..... 28

C-4.4 Lowering in an emergency .................... 29

C-4.5 Using the robot for jobs under the level

surface (Models 5000 and 8000) ........... 30

C-4.6 Using the robot for jobs under the level

surface(model 15000) ............................ 31

C-4.7 Platform rotation

(models 5000 and 8000) ........................ 32

C-4.8 Platform rotation (model 15000) ............ 32

Section D MAINTENANCE

D-1 LUBRICANTS - HEALTH AND SAFETY

PRECAUTIONS ...................................... 34

D-2 MAINTENANCE INTERVENTIONS ........ 34

D-2.1 Greasing ................................................ 35

D-2.2 Types of grease ..................................... 36

D-2.3 Changing the sliding blocks of the

telescopic boom .................................... 36

D-2.4 Platform levelling adjusting

(only for models 5000 and 8000) ........... 37

D-2.5 Manual controls

(only for models 5000 and 8000) ........... 37

D-3 FAULTS AND TROUBLESHOOTING ..... 38

D-3.1 Faults - Causes - Solutions ................... 38

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INTRODUCTION

This handbook provides information for a safe and

correct use and maintenance of ITALMACCHINE robots.

STRICTLY COMPLY WITH THE INSTRUCTIONS

GIVEN IN THIS HANDBOOK!

READ AND UNDERSTAND THIS HANDBOOK

BEFORE STARTING, USING AND CARRYING

OUT ANY OPERATION WITH AND ON THE

MACHINE.

The robot is an equipment for civil and industrial use,

exclusively destined for ITALMACCHINE handlers fitted

with telescopic boom of the LIFT, TELELIFT and

GIROLIFT series.

The handbook consists of four sections:

Section A

GENERAL REMARKS

Section B

SAFETY

Section C

OPERATION INSTRUCTIONS

Section D

MAINTENANCE

Section A presents general concepts which are deci-

sive for the knowledge of the machine main parts. Ad-

ditionally, it contains all necessary data for a correct iden-

tification, it explains the technical features of the ma-

chine, etc.

Section B is especially addressed to both personnel,

who shall operate, repair and service the machine, and

-in case of companies with a wide fleet of machines- to

the safety responsible.

It describes the essential compulsory qualities of the

personnel in charge and provides important informa-

tion for the safety of persons and things.

Section C is mainly addressed to the operators who

shall operate and use the machine. This section shows

all control devices.

Additionally, it explains how to operate the machine -

i.e. engine starting, machine parking, machine storing.

Section D is especially addressed to the service respon-

sible and the operators who shall service the machine.

This section contains the maintenance schedule and

the relevant intervals. Specific chapters are dedicated

to the failure diagnostics, the tables and the reference

specifications to be used while maintaining the machine.

Sections are subdivided into chapters and paragraphs

that are numbered progressively.

Take care of this handbook and keep it in an

accessible place within the machine, even after

its reading, so that it will always be within

reach for consultation if in doubt.

If you are unsure about anything, please ad-

dress to the ITALMACCHINE Assistance Serv-

ice or to the local agent/dealer: addresses,

phone and fax numbers are printed in the cover

and in the title-page of this manual.

IMPORTANT

Before contacting the Technical Service, take note

of the machine model and serial number.

INTRODUCTION

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SYMBOLS

When using the equipment, operators could have to face

some situations requiring special care and particular

knowledge.

When these situations involve the safety of operators or

bystanders, the machine efficiency and proper utilisation,

the handbook highlights these specific instructions with

SPECIAL SYMBOLS.

There are three special (or safety) symbols in this manual,

always combined with keywords that class the situa-

tions according to their danger degree.

Symbols are always followed by a text explaining the

specific situation, the attention that must be paid to such

situation, the method and the behaviour that should be

adopted. If necessary, it highlights prohibitions or pro-

vides instructions to prevent risks.

Sometimes, texts can be followed by illustrations.

The special (or safety) symbols used in this manual ac-

cording to the seriousness of the hazard situation are:

DANGER

Draws the attention to situations that involve your

own as well as the others’ safety and that can result

in serious injury or death.

CAUTION

Draws the attention either to situations that involve

your own as well as the others’ safety and that can

result in minor or moderate injury or to situations

that may affect the working efficiency of the ma-

chine.

IMPORTANT

Draws the attention to any important technical in-

formation or practical advice that allows for a more

efficient and economic use of the machine with due

respect to the safety and to the environment.

WHEN READING THIS MANUAL, PAY THE

GREATEST ATTENTION TO THESE SPECIAL

SYMBOLS AND THE EXPLANATION OF THE

SITUATIONS THEY EMPHASIZE.

SYMBOLS

A

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Section A

GENERAL INFORMATION

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NAVICELLA PORTAPERSONE / MAN PLATFORM

MODELLO

TYPE

N° SERIE

SERIAL N°

MASSA

WEIGHT

PORTATA NOM.

PAY LOAD

Kg

ANNO

YEAR

A-1 CONVENTIONAL REFERENCES

 A-1.1 Machine position

Conventionally the machine should be considered po-

sitioned as shown in figure A1.

This convention is necessary to make any reference of

this handbook to different machine parts (front, rear, etc.)

clear and unmistakable.

Any exception to this rule will always be specified.

Fig. A1

LEFT SIDE

RIGHT SIDE

REAR SIDE

FRONT

SIDE

(handler

coupling point)

CONVENTIONAL REFERENCES

A

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 A-1.2 Labels and warning plates applied on

the machine

This paragraph shows the labels and warning plates

normally applied on the machine.

IMPORTANT

The familiarisation with these labels is never a waste

of time.

Make sure they are easy to read. For this purpose,

clean them and replace those which become unread-

able (either graphic or text).

Clean labels with a soft cloth, water and soap. Never

use solvents, petrol, etc.

When a label is applied on a part going to be re-

placed, make sure that the new part is already la-

belled as required or apply a new label.

MAX. PAYLOAD 200 kg

OR 2 PERSONS

IMPORTANT

The work platform may be operated only when sta-

bilisers are lowered.

The lift capacity refers to the entire working range

of the LIFT, TELELIFT and GIROLIFT handlers which

the platform can be coupled to.

Description:

aluminium label with red inscription “Maximum lift ca-

pacity: 200 kg or 2 persons".

Meaning:

represents the working limits of the equipment. The

maximum payload refers to the “operators’ weight +

equipment and/or materials" and cannot exceed the

lift capacity indicated.

Location:

inside the platform, on the inner side member (see fig.

A1).

CONVENTIONAL REFERENCES

A

Fig. A2

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 A-1.3 Explanation of the different symbols

applied on the machine

This paragraph illustrates the symbols that are normally

applied on the main control devices and instruments of

a standard machine. Although they are mainly (ISO)

standardised symbols that are now part of the common

life, we consider useful to explain them once again.

IMPORTANT

Spend the necessary time to become familiar with

these symbols and to learn their meaning.

Handler lifting

Handler lowering

Handler boom extension

Handler boom retraction

Handler turret rotation

Power ON

Power OFF

Robot boom lifting

Robot boom lowering

Robot boom extension

Robot boom retraction

Symbol Meaning

2

nd

robot boom lifting

2

nd

robot boom lowering

1

st

robot boom lifting

1

st

robot boom lowering

Robot boom retraction

Robot boom extension

Boom with platform clockwise rotation

Boom with platform counter-

clockwise rotation

Machine clockwise rotation for

works under level surface

Machine counter-clockwise rotation

for works under level surface

Symbol Meaning

CONVENTIONAL REFERENCES

A

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A-2 MACHINE IDENTIFICATION

IMPORTANT

Check that the operator handbook refers to the de-

livered machine.

When asking for information or technical assistance,

always specify model, type and serial number of the

machine.

 A-2.1 Model and type of equipment

 Robot 5000 with platform

 Robot 8000 with platform

 Robot 15000 with platform

 A-2.2 Manufacturer

ITALMACCHINE SpA

Zona Industriale - I-06019 UMBERTIDE (PG) - ITALY

Enrolled in the register of companies at the Court of

Perugia under the n°4823

C.C.I.A.A. n°102886

Fiscal Code/V.A.T. no. 00249210543

 A-2.3 Machine identification plate

The machine identification plate is applied within the

platform (Fig. A1).

The identification plate (Fig. A3) contains model, serial

number, weight, payload and year of manufacture.

NAVICELLA PORTAPERSONE / MAN PLATFORM

MODELLO

TYPE

N° SERIE

SERIAL N°

MASSA

WEIGHT

PORTATA NOM.

PAY LOAD

Kg

ANNO

YEAR

 A-2.4 CE mark

The CE mark is applied directly on the identification plate

of the machine.

 A-2.5 Identification plates of the main parts

The plates of the main components, which are not di-

rectly manufactured by ITALMACCHINE (engines,

pumps etc.), are located where originally applied by the

manufacturers.

MACHINE IDENTIFICATION

A

Fig. A3

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A-3 ALLOWED USE

 A-3.1 Allowed use

The robot has been designed and manufactured to be

used as man-platform coupled to telescopic boom

equipped handlers of the LIFT, TELELIFT and GIROLIFT

series to increase their application field.

Any other use is considered contrary to what established

and, therefore, improper.

The compliance with and the strict respect of the use,

maintenance and repair instructions of the Manufacturer

represent an essential part of the allowed use.

The use, maintenance and repair of the work platform

shall be carried out by skilled personnel having the nec-

essary knowledge of its special features and the safety

precautions to be taken.

It is also essential to comply with the national safety at

work legislation, the provisions concerning the safety

and health of workers at work, and the road traffic regu-

lations.

The Manufacturer disclaims any responsibility for dam-

age to persons or things arising from arbitrary modifica-

tions of the machine.

TELELIFT 3013 ••

GIROLIFT 3514 ••

GIROLIFT 5022 •••

Robot Robot Robot

For machines 5000 8000 15000

with platform with platform with platform

 A-3.2 Improper use

Improper use means a utilisation of the robot following

working criteria which do not comply with the instruc-

tions of this manual, and which, in general, may result in

risks for both operator and bystanders.

DANGER

We list below some of the most frequent and hazard-

ous situations of improper use:

- Carrying protruding loads on the work platform

- Not strictly complying with the operation and

maintenance instructions of this handbook

-Working beyond the operation limits of the robot

(see application field, par. A-3.3)

-Working beyond the operation limits of the plat-

form

-Working without stabilisers

-Working with stabilisers resting on unstable or

yielding grounds

-Working on steep slopes or working with a non-

levelled machine due to an inefficient action of

the stabilisers

- Fit mobile guards to the robot platform that may

increase the wind action and jeopardise the stabil-

ity of the machine

- Using the robot for purposes other than those

recommended

- Using telescopic handlers not approved or not

manufactured by Italmacchine

 A-3.3 Application field of robot on ITALMACCHINE handlers

ALLOWED USE

A

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A-4 GENERAL DESCRIPTION

 A-4.1 List of the main components - Robot 5000 and 8000

1 - Platform

2 - Handler control board

3 - Platform control board

4 - Platform sway cylinder

5 - Sway compensating cylinder

6 - Boom rotation column

7 - Boom extensible section (only Robot 8000)

8 - Boom fixed section

9 - Robot boom motion cylinder

10 - Electrical control branch box

11 - Electric cable reel

12 - Boom rotation cylinder

13 - Handler coupling frame

123

4

78

5

910

11 12

13

6

GENERAL DESCRIPTION

A

Fig. A4

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 A-4.2 List of the main components - Robot 15000

1 -2

nd

boom

2 -2

nd

boom linkage

3 - Telescopic boom

4 - Platform linkage

5 - Platform sway cylinder

6 - Platform

7 -1

st

boom

8 -2

nd

boom cylinder

9 -1

st

boom cylinder

10 - Boom supporting column

11 - Mobile frame

12 - Support with platform rotation fulcrum

13 - Slewring

14 - Rotation locking bolts

15 - Fixed frame with GIROLIFT couplings

12

13

78

5

9

6

43

12

10

11

14

15

GENERAL DESCRIPTION

A

Fig. A5

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A-5 TECHNICAL DATA AND PERFORMANCE

 A-5.1 Main dimensions Robot 5000

α

A

B

D

F

E C

G

α

H

L

N

M

h

a

x

b

Technical data with robot set to normal configuration

A Max. reach ................................... mm 4155

B Min. reach.................................... mm --

C Max. height .................................. mm 4500

D Reach at max. height .................. mm 1710

E Max. working depth .................... mm 1300

F Reach at max. working depth .... mm 3130

G Boom extension .......................... mm --

Technical data with reversed robot for jobs under

the level surface

H Reach at max. height .................. mm 3130

L Max. height .................................. mm 290

M Reach at max. depth................... mm 1710

N Max. depth .................................. mm 5520

General characteristics

axb Platform dimensions ................ mm

820x1200

h Platform height............................ mm 1100

• Operators on board ................... max 2

• Max. lifting capacity

(with operators on board) ..................... kg 200

α Boom rotation ................................... 360°

• Telescopic boom .............................. no

• Frame rotation for jobs under

level surface ...................................... manual

• Robot weight ................................. kg 810

• Platform weight ............................. kg 40

TECHNICAL DATA AND PERFORMANCE

A

Fig. A6

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α

A

B

D

F

E C

G

α

H

L

N

M

h

a

x

b

 A-5.2 Main dimensions Robot 8000

Caratteristiche con robot in posizione normale

A Max. reach ................................... mm 7405

B Min. reach .................................... mm 5805

C Max. height .................................. mm 7600

D Reach at max. height .................. mm 2690

E Max. working depth .................... mm 3600

F Reach at max. working depth .... mm 5430

G Boom extension .......................... mm 1600

Technical data with reversed robot for jobs under

the level surface

H Reach at max. height .................. mm 5430

L Max. height .................................. mm 2260

M Reach at max. depth................... mm 2690

N Max. working depth .................... mm 8950

General characteristics

axb Platform dimensions ................ mm

820x1200

h Platform height............................ mm 1100

• Operators on board ................... max 2

• Max. lifting capacity

(with operators on board) ..................... kg 200

α Boom rotation ................................... 360°

• Telescopic boom .............................. yes

• Frame rotation for jobs under level

surface ............................................... manual

• Robot weight ................................. kg 970

• Platform weight ............................. kg 40

TECHNICAL DATA AND PERFORMANCE

A

Fig. A7

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α

E

F

B

D

A

C

H H

M

L

N

R

G

P

 A-5.3 Main dimensions Robot 15000

V Z

U

T

S

TECHNICAL DATA AND PERFORMANCE

A

Fig. A8

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Technical data with robot set to normal configuration

A Max. reach ................................... mm 8980

B Height at max. reach ................... mm 5640

C Reach at max. depth................... mm 3270

D Depth from rotation fulcrum ....... mm 390

E Reach at max. height .................. mm 1310

F Max. height .................................. mm 11930

G Boom extension .......................... mm 2100

Technical data with reversed robot for jobs under

the level surface

H Max. reach ................................... mm 8980

L Depth at max. reach ................... mm 6780

M Reach at max. depth................... mm 1310

N Max. depth .................................. mm 13070

P Reach at max. height .................. mm 3270

R Max. height .................................. mm 750

Technical data with robot set to road circulation

configuration

S Rotation axis to lifter hinge pin

distance ....................................... mm 600

T Rotation axis to lifter hinge pin

height ........................................... mm 150

U Height at platform ....................... mm 3310

V Maximum overhang .................... mm 1570

Z Overall dimensions on boom ...... mm 4000

General characteristics

axb Platform dimensions ................ mm

800x1490

h Platform height............................ mm 1100

• Operators on board ................... max 2

• Max. lifting capacity

(with operators on board) ..................... kg 200

α Boom rotation ................................... 360°

• Telescopic boom .............................. yes

• Frame rotation for jobs under

level surface ...................................... hydraulic

• Robot weight (c/w platform) ......... kg 1500

TECHNICAL DATA AND PERFORMANCE

A

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