Athena 1090 EVO Translation Of Original Instructions
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Athena 1090 EVO Translation Of Original Instructions

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ATHENA 1090 EVO
Translation of original instructions
Prior to commissioning the machine read carefully this Use and
Maintenance Manual
Note: table of contents at the end of the manual
Edition
Date
01
15/03/2017

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Summary of Contents for Athena 1090 EVO

  • Page 1 ATHENA 1090 EVO Translation of original instructions Prior to commissioning the machine read carefully this Use and Maintenance Manual Note: table of contents at the end of the manual Edition Date 15/03/2017...

  • Page 2: General Information

    1.2 Details of Manual • Instruction manual for Elevating work platform • Version: Athena 1090 EVO 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 included.

  • Page 3: Manufacturer's Identification Data

    1.3 Ownership of the information This document contains confidential information. All rights reserved. This manual may be neither partially nor totally duplicated without the prior written authorization of ALMAC s.r.l. This document may only be used by the customer to whom the manual has been supplied along with the machine, and only for the purpose of use and maintenance of the machine to which the manual refers.
  • Page 4 1.5 MEWP identification data The machine named Athena 1090 EVO is defined according to the technical standards in force (ref. UNI EN 280:2015), as: Mobile Elevating Work Platform (MEWP), belonging to group B, type 3 (point 1.4-EN 280) Meanings: GROUP B: All types of mobile elevating work platforms other than "Group-A"...

  • Page 5: Identification Plate

    ASPAC GROUP ELEVATING WORK PLATFORM MANUFACTURER ALMAC s.r.l. SERIAL ALM-000340 Athena 1090-BL MODEL NUMBER UNLADEN WEIGHT YEAR OF 2900 2017 WITH TRACKS MANUFACTURE DATE OF TEST 250 kg RATED LOAD INC. 2 OCCUPANT & TOOLS MAX ALLOWABLE SIDE FORCE 40 daN...
  • Page 6 1.6 Performance Below are the configurations that the mobile elevating work platform can have during operation and transport. Dismantle only for special transport situations; before commissioning, the machine must be reconfigured by skilled and authorised personnel, according to the certified diagram, following the manufacturer's instructions...
  • Page 8 Characteristic dimensions Machine length 2.27 With work platform retracted Machine length 3.33 With work platform extended Length of work platform 1.80 With work platform retracted Length of work platform 2.92 With work platform extended Maximum width 1.64 Widened track Maximum width 1.46 Narrow track Height of crawler...
  • Page 9 Useful work distance in length Useful work distance in length 1540 Extension of work platform 1.12 Technical data Capacity of work platform Number of operators on work platform Lifting time (with 300Kg on the platform) Lowering time Hydraulic side-shift pressure Hydraulic lifting pressure Oil tank capacity Climb angle...
  • Page 10 Maximum transport height allowed (manual levelling and the adjustment of the travel speed is allowed)
  • Page 11 Maximum travel height allowed (manual levelling and the adjustment of the travel speed is not allowed) Standard equipment Optional equipment Electrical engine 230 V / 50 Proportional electrohydraulic controls Internal combustion engine (KUBOTA Z602) Sine wave inverter 1000W Automatic accelerator Cable remote control Radio control CANBUS display to manage working hours and...
  • Page 12 Harness anchorage points Doubled capacity on the lifting cylinder Electric starter on work platform Overload control Dynamic levelling system of the machine Electronic anti-shearing protection Electronic tilt control Proactive levelling system Engine specifications Z602-E3B TIER 4 Dry weight 60 kg Type of engine 4 TIMES LIQUID COOLING - DIESEL...

  • Page 13: Warranty

    • *UNI EN 349:2008 Minimum gaps to avoid crushing parts of the human – body • EN ISO 12100:2010 Safety of machinery -General principles for design - Risk assessment and reduction All parts available on the market and partly completed machinery installed on “...
  • Page 14 1.9 Assistance As far as the optimum use 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 Request for assistance and repairs To request ALMAC S.r.l.
  • Page 15 • installation of systems and equipment • cleaning • painting and paint removal The maximum allowed capacity for model ATHENA 1090 is 300 kg. Consider the following: • 2 (two) persons each weighing 80 kg • 140 kg of equipment An electronic control system prevents the work platform from lifting to any position when the load exceeds approx.
  • Page 16 Warning: NEVER exceed the machine's established maximum capacity. Warning: It is FORBIDDEN to transport large slabs or materials since this could increase wind resistance to a considerable extent and cause the machine to tip over. Warning: It is FORBIDDEN to apply horizontal loads to the platform when the machine is moving (e.g.
  • Page 17 1.11.2 Improper uses Any other use not specifically indicated in 1.11.1 Intended use. • The improper uses established for this MEWP include lifting and lowering persons to/from different storeys within space (typical use of elevators). • It is also forbidden to drive the platform to the ground using the mobile push-button panel with an operator on the work platform.

  • Page 18: Safety Information

    2 SAFETY INFORMATION 2.1 Notification of commissioning and routine inspections The work equipment indicated in Annex VII to Legislative decree D.Lgs 81/2008 and successive amendments must be subjected to REGISTRATION and ROUTINE INSPECTIONS by the competent authorities, i.e. INAIL, the National Institute for Insurance Against Industrial Accidents (former ISPESL, Higher Institute for Prevention in the Workplace), the Local Health Authority and other public and private bodies established by the criteria laid down in Ministerial decree DM...
  • Page 19 2.2 Fitness of the personnel The operators who use the machine must be properly trained, informed, instructed on how to use the machine in safe conditions and must possess a training certificate issued in accordance with the laws in force at the time of use*.
  • Page 20 2.3 Warnings The following sign plates are affixed to the machine: • Identification • Instructions • Command/prohibition sign plates • Caution • Danger 2.3.1 Plates indicating instructions, obligations, dangers, prohibitions and warnings DO NOT TRANSLATE AT HEIGHT ON WEAK, MUDDY, FROZEN, SLIPPERY GROUNDS OR CLOSE TO HOLES, MOATS, DRAINS OR DANGER...
  • Page 21 Maximum inclination of the ground: • Front 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 inclination of the ground: The maximum lateral inclination of the ground, keeping the frame as level as possible, to stay safe is 25°.
  • Page 24 Note: The plates are affixed to the machine for the purpose of helping the operator and/or warning him of the risks to which he may be exposed when he uses the machine. In no way does the information on the plates substitute this Manual, which is the only reference document containing complete information.
  • Page 25 2.3.2 Meanings of the sign pictograms Warning / Danger. This symbol means that you must take care or that danger is present. Failure to comply with this alert indication could cause damage to the machine, the operator or exposed persons. Warning.
  • Page 26 2.4 Provisions and prohibitions • Read this manual carefully before starting, using, servicing or performing other operations on the machine. • The MEWP must always be kept in perfect conditions by following the maintenance program described in the Maintenance Chapter. •...
  • Page 27 • USE OF THE PLATFORM ALWAYS REQUIRES 2 OPERATORS, ONE OF WHOM ON THE GROUND and able to perform the emergency operations described in this Manual. • The platform must not be used if there is insufficient light, since it is not fitted with its own lights.
  • Page 28 2) Lifting the platform using a CE certified beam (not included) and using hooks and steel steel ropes hooked to the holes marked with signs (see photo below). Warning: the maximum weight of Athena BL in the heaviest configuration is 2920Kg...
  • Page 29 Warning: The connecting rods of the chassis should be arranged as shown in the figure, that is with the frame fully lifted (chassis narrow) Warning: The railings must be folded Note: Once the machine has been loaded onto the vehicle, it must be fastened in place using belts;...
  • Page 30 2.6 Checks on the machine before each use • Visually check under and around the machine to make sure that there are no oil or fuel leaks. If leaks are discovered, follow the MAINTENANCE instructions. • Make sure that there is no hydraulic oil leaking from the hoses and from the other components (cylinders, distributors, fittings, etc.).
  • Page 31 • It is forbidden to work near high voltage overhead electric power lines. Moreover, the work platform must always be kept at a safety distance of at least 5 metres from cables. For voltages greater than 132KV, refer to the table below.
  • Page 32 2.8 Safety indications on the use of the travel function The instructions given below must be followed. • Make sure movements are done on flat, sturdy ground. To do this, use the spirit level located on the work platform. • Make sure that there are no hollows or ridges in the floor and that there is enough room for the machine to pass through.
  • Page 33 • If you change direction in a situation where the track could move sideways owing to an obstruction, the track could slip out of its housing. • Check to make sure that there are no bystanders near moving parts when the platform is lowered.
  • Page 34 NO ICE! NO SAND! NO DUST OR SMOOTH SURFACES! Warning: during movement with ELECTRICAL POWER, be careful of the connection cable in order to avoid dangerously crushing the cable itself!
  • Page 35 2.9 Mandatory safety indications to follow before lifting the work platform above the transport height The instructions given below must be followed. After having levelled it, lift the work platform only after making sure, both visually and by moving inside the work platform, that all 4 ends of the tracks rest on the ground.
  • Page 36 • Check the operation of the anti-shearing device; this can be done by lifting the platform to a height that involves an angle of the scissor frames greater than 12° with respect to the horizontal and make sure that the descent movement stops automatically at a scissor angle between 7°...
  • Page 37 that no functions are allowed. Release the mushroom-shaped button after this test. • Operate the warning buzzer and make sure it works. • Check the operation of the buzzer when the travel or work platform descent functions are used. • Make sure, with the machine travelling and the platform in the transport position (with travel selector on DM) that, when the Joysticks are released, the machine stops immediately.
  • Page 38 THE MANUFACTURER IS RELIEVED FROM ALL LIABILITY FOR ACCIDENTS OR FAULTS DUE TO FAILURE TO COMPLY WITH THE RECOMMENDATIONS AND SAFETY REGULATIONS. • Proceed with maintenance operations only after turning off the machine and deactivating the battery disconnect switch. • Before proceeding with the interventions, make sure the platform is completely blocked.
  • Page 39 The photo above shows how the locking system of the extensible structure must be positioned during maintenance work. By means of the "ground controls", it is possible to lift the work platform until it is possible to place the two locking brackets vertically and aligned with the pins below. Subsequently lower the work platform until the brackets are locked in the relative pins.
  • Page 40 2.13 Personal protective equipment (PPE) To operate the machine in complete safety, it is necessary to use appropriate personal protective equipment, which must be worn before climbing onto the work platform and used as indicated. Retaining system Safety helmet Safety shoes Protection Gloves Retaining system Before climbing onto the work platform, it is mandatory to wear suitable fall...
  • Page 41 Warning: This device is not to be considered a fall protection system, it is only used to prevent the fall. PERSONAL PROTECTION EQUIPMENT Hearing protection Body protection required Protective gloves required Safety shoes required required...

  • Page 42: Description Of The Machine

    3 DESCRIPTION OF THE MACHINE 3.1 Structure of the equipment This section describes the main components of the machine and their functions. 3.1.1 Work platform assembly 3.1.2 Scissor assembly 3.1.2 Tank and chassis assembly...
  • Page 43 3.1.1 Work platform assembly 1. Control push-button panel 2. Control console emergency button (console) 3. Glove box 4. Extensible work platform 5. Spirit level 7. Device for the extension of the work 6. Socket on work platform platform 8. Device to access the work platform...
  • Page 44 3.1.2 Scissor assembly 9. Lifting cylinder 10. Lifting cylinder shut-off valve 11. Pressure transducer for load control 12. Scissor angle sensor...
  • Page 45 3.1.3 Tank assembly 13. Ladder to access the platform 14. Main hydraulic unit 15. Main differential panel 16. Ground control panel 17. Flashing light 18. Ground control panel emergency button...
  • Page 46 19. ECU electronic control unit 20. Battery disconnect switch 21. Emergency descent device 22. Hydraulic oil tank 23. Discharge filter 24. Intake filters (in the tank)
  • Page 47 25. Oil tank refill cap 26. Visual hydraulic oil level 27. Lifting cylinder double capacity 28. Booster for management of valve third travel speed 29. Combustion engine starter battery 30. Electrical engine...
  • Page 48 31. Inverter (if present) 32. Inverter differential panel (if present) 33. Frame angle sensor 34. "Proactive levelling" angle sensor Proactive levelling safety valves Proactive levelling limit “ ” “ ” switch...
  • Page 49 37. Combustion engine 38. Fuel tank 39. Bi-levelling chassis...
  • Page 50 3.2 Control stations 3.2.1 Mobile control push-button panel (console) The platform is equipped with a mobile control push-button panel (console) which allows for normal operation on the work platform. The console can be located in the dedicated metal support attached to the railing of the platform or removed and held by the operator.
  • Page 51 Warning: If the platform is transported on vehicles, always secure the support by means of the threaded knob. The push-button panel can also be disconnected from the spiral cable by unscrewing the ferrule indicated with A. Warning: Do not touch ferrule B; if ferrule B is turned, the wires inside the connector will be damaged.
  • Page 52 Warning: For all operations that required lifting the work platform above the transport height, the console and the operator must be inside the platform itself.
  • Page 53 Identification Function and Status Description of the function PLANARITY ALARM (with indicator light 3 on) Lateral inclination 0°<0.5° Longitudinal inclination 0° <0.5° FLASHING Lateral inclination >0.5° <3° (If the platform does not Longitudinal inclination >0.5° <3° exceed the maximum allowed transit height) Indicator light Lateral inclination >3°...

  • Page 54: Overload Alarm

    Identification Function and Status Description of the function OVERLOAD ALARM Load work platform between 0 and 360Kg (1.2 nominal load) Indicator light Load work platform greater than or equal to 360Kg (1.2 nominal load); the normal operation of the platform is prevented ENGINE ON / OFF To turn on the combustion engine, select ON.
  • Page 55 Identification Function and Status Description of the function power source. internal combustion engine operates at an accelerated rate WARNING BUZZER Button DRIVING MODE SELECTOR CENTRAL position Standard operation traction FORWARD/REVERSE enabled using 2 joysticks DC-S position Simultaneous movement Selector switch FORWARD/REVERSE of the tracks with the RH joystick only (11) ED-S position...
  • Page 56 Prior to carrying out the operation make sure the platform is brought into the transport position, that is completely lowered. Once the push-button panel has been removed from its housing on the work platform, have it firmly secured to the operator's body using a shoulder strap to avoid incorrect manoeuvres.
  • Page 57 3.2.3 Ground controls The platform features a control console located on the chassis at the back of the machine. These controls are useful for the operator on the ground for platform maintenance or for emergency situations (red mushroom button). The ground controls are protected against unauthorized use by a key that is used to activate the 3 way switch.

  • Page 58: Emergency Stop

    Identification Function and Status Description of the function Display of the hours of operation and machine status, with Display an indication of any alarms. PLATFORM UP / DOWN SELECTOR To control the upward movement of work platform, move 19 Selector switch selector UP To control the downward movement of the work platform, move the...

  • Page 59: Storage Compartment

    3.3 Storage compartment On the platform, under the control console, there is a compartment, which can be opened by hand. It contains: • This Use and Maintenance Manual • The spare parts catalogue • Wiring diagrams • Hydraulic diagrams • Declaration of conformity •...
  • Page 60 3.4 Platform operation safety devices Warning: Periodically verify that the safety devices are operating correctly. During work, the operator must be able to assess, recognize and avoid all dangers and must immediately inform the persons in charge of any faults in the safety devices so that they can be inspected and restored to their original conditions of safety and reliability DO NOT TAMPER WITH AND DO NOT CHANGE THE CALIBRATION OF ANY OF...
  • Page 61 3.4.2 Frame and height inclination redundant control device On the platform, there is an additional angle sensor which provides a 12V output signal if the frame is within the limit value of 3°. This sensor is connected in parallel to the limit switch that controls that the platform is at a height lower than the transport height (the 12V output signal is interrupted if the platform is lifted above the transport height).
  • Page 62 The limit switch and the relays are monitored by the control unit, which generates an alarm if a fault is detected. If the limit switch malfunctions, the Proactive levelling function is disabled. If the relays malfunction (bonding), the entire operation of the machine, except for the downward movement, is disabled.
  • Page 63 3.4.3 Work platform height control device On the upper frame of the scissors, directly under the work platform, there is a Can Bus angle sensor that constantly communicates the inclination measured to the electronic control unit. The angle sensor is redundant (thus consisting of two separate sensors) and the Y inclination axis of the scissor frame is monitored (longitudinal) The signals of the two sensors are constantly compared with each other to assess their consistency.

  • Page 64: Load Limiting Device

    3.4.4 Load limiting device The machine is equipped with a work platform that, once extended, has a surface area greater than 1 m². For this reason, on the cylinder there are two pressure transducers which, with the angle sensors of the frame and of the scissors, make up a system able to detect whether the load on the work platform exceeds the nominal load by 20%.
  • Page 65 3.5 Hydraulic system safety devices 3.5.1 Hydraulic pressure limiting devices The hydraulic system of the platform features special general maximum pressure valves (1-2) in order to limit the pressures relating to the operation of the machine, preserving the integrity of the various components. These valves need no adjustments since they are calibrated by ALMAC S.r.l.
  • Page 66 1. Maximum system pressure valve : set to 210 bar 2. Maximum system pressure valve : set to 210 bar 3. Maximum lifting pressure valve : set to 160 bar Warning: modifications to the positions of the maximum pressure valves without authorization from ALMAC S.r.l.
  • Page 67 3.5.3 Hydraulic failure safety devices The hydraulic system of the lifting circuit, in the event that there is an accidental fault in the hydraulic piping that feeds the lifting cylinder of the work platform, features a one-way valve, normally closed (1), electrically DRIVEN and connected directly to the cylinder, which prevents the uncontrolled descent of the work platform from any height, thus avoiding dangerous situations.
  • Page 68 Proceed as described below to restore the machine to normal operating conditions: 1. Repair the damaged hydraulic hose and/or connections 2. Fill and bleed the hydraulic circuit 3. Lift the platform to its maximum height If the hydraulic hoses that supply the track chassis levelling cylinders malfunction and suddenly change the track and the inclination, dedicated BALANCING VALVES prevent the track from moving suddenly (ref.Section 5.10.2 EN280).
  • Page 69 If one of the balancing valves malfunctions (fault not provided for in UNI EN 280:2015), there are 4 normally closed valves placed on each of the dangerous movements of the cylinders of the chassis. These valves are fed (kept open) only if the chassis is inclined in the two axes by an angle lower than 3°, or if the platform is below the transport height.
  • Page 70 3.6 Blackout safety devices 3.6.1 230V external power source On the work platform there is a power socket to supply the power tools required during work. For 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).
  • Page 71 3.6.2 220V inverter (optional) If the machine is equipped with a 220V inverter to power the outlet on the work platform, the following safety devices will also be present: 1) Insulation control device between the cables that go from the inverter to the outlet on the work platform and the machine frame (Sentinel) 2) Trip coil (triggered in the event of an alarm from the sentinel) 3) Circuit breaker...
  • Page 72 3.6.3 12V system Near the access ladder is the "battery isolator" (3) which physically disconnects the 12v electric line coming from the battery supplying the various users. It is recommended to operate this device at the end of the work day, to prevent draining the batteries.
  • Page 73 3.7 Platform operation devices which are not part of the safety system On both connecting rod assemblies (right and left) connecting the tracked chassis and the central frame, there are two Can Bus angle sensors. The angle sensors are redundant (thus consisting of two separate sensors) and monitor the X inclination axis of the respective connecting rod.
  • Page 74 4 Instructions for use 4.1 Preliminary operations 4.1.1 Suitability of the soil To assess whether the ground is fit to bear the machine, it is extremely important to ensure that the ground surface does not allow the machine to slip once it has been stopped for work.
  • Page 75 DO NOT TRANSLATE AT HEIGHT ON WEAK, MUDDY, FROZEN, SLIPPERY GROUNDS OR CLOSE TO HOLES, MOATS, DRAINS OR DANGER CRACKS THAT OPEN UP TO EMPTY SPACES. Note: Do not use the MEWP if you are doubtful about the fitness of the ground surface.
  • Page 76 4.1.2 Action of the wind It is forbidden to use the machine if the wind speed exceeds 12.5 m/s. The following chart describes the consequences of different wind speeds (Beaufort scale). Scale of the Italian Hydrographic Service Beaufort International Scale Effects Corresponding speed N°...
  • Page 77 Danger: The platform must never be used when wind speed corresponds to a value greater than 6 of the Beaufort scale. Work must be performed with the utmost warning with wind speeds between 4 and 6 of the scale. 4.1.3 Access to the work platform The work platform must only be accessed with the platform completely LOWERED.
  • Page 79 Warning: IT IS FORBIDDEN to block the gate in such a way as to keep access to the platform open. 4.1.3.1 Easy-Access system to facilitate access to the work platform A system that allows the operator to place the machine in such a way that it is easier to climb up the ladder to access the work platform.
  • Page 81 Warning: while descending from the working position, pay warning to possible obstacles beneath the work platform to prevent the platform from overturning or being damaged!
  • Page 82 4.1.5 Checking the fuel level Before turning on the engine and/or starting a work shift, it is advisable to check the fuel level. The fuel level is visible in the ground control area (1). There is also a reserve sensor (2). If the fuel level is too low, the machine will emit an acoustic signal, the FUEL alarm will appear on the display and after 15 seconds the engine will turn off to avoid emptying the fuel system completely.
  • Page 83 4.1.6 Checking the oil level in the engine Check the engine oil level before starting it, or when more than 5 minutes have gone by after stopping it. Pull out the oil level indicator, clean it by wiping it and reinsert it. Pull the oil level indicator out again and check.
  • Page 84 • Unlock the fastenings of the RH railing of the expandable work platform • Fold the railing according to the figure • Unlock the fastenings of the LH railing of the expandable work platform • Fold the railing according to the figure •...
  • Page 85 gates with a height below 2 • Should it be required to transport the machine, it is necessary close expandable part up to the "T" lock. Unlocking the railing fastenings To unlock the railing fastenings, it is necessary to: 1) Turn the safety catch (A) of the locking pin (B) and then pull it from its seat 2) Remove the safety screw (C) 3) Once you have extracted all fastenings of the railings, is possible to fold it according to the instructions in the previous pages...
  • Page 86 Before stepping on the platform, it is absolutely mandatory to put all the railings back in the vertical position and secure them as shown in the figure. 4.2 Machine operation 4.2.1 Starting the internal combustion engine To start the internal combustion engine and the hydraulic pumps, use the ignition key on the ground controls.
  • Page 87 The key-switch functions are: • (CENTRAL): Machine off - electrical system not powered • (RH POSITION): The whole electrical system of the platform starts, including the mobile push-button panel in the work platform. The ground controls are excluded. • (LH POSITION): The whole electrical system of the platform starts. The ground controls are automatically enabled and the push-button panel in the work platform is disabled.
  • Page 88 4.2.2 Starting the current source During operation with the INTERNAL COMBUSTION ENGINE, it is possible to turn the selector (6) to the OUT 220V position. In this way, it will be possible to use the 220V power in the outlet on the work platform (only for machines with inverter).
  • Page 89 • Use an extension power cord with an appropriate section depending on its length Warning: the connection to a network that does not meet the requirements of the electrical engine may cause serious damage to some of the components of the machine.
  • Page 90 Each lever controls the respective track (right lever right track, left lever left → → track). Move the lever forwards 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.
  • Page 91 Rotation on itself towards the left (counter-rotation) Travel is enabled or disabled depending on the status of the travel approval light located on the control panel. It provides the following information: • On: travel allowed up to a maximum height of 4.5 m platform floor, proactive levelling active •...
  • Page 92 It is forbidden to travel above the transport height in the following conditions: • Wet ground • Snowy and/or icy ground • Dry asphalt but covered with sand, gravel or other aggregates Warning: slipping hazard! 4.2.4.1 Standard travel mode With selector 8 on the central position DRIVE MODALITY , it is possible to “...
  • Page 93 Adjusting the speed: This is possible using selector 9 on the console that controls the internal combustion engine accelerator. Turtle: engine idling Hare: engine at accelerated rate (If the electrical engine is selected, there is no speed variation) 4.2.4.2 Easy-Drive System (ED-S) Moving the selector 8 on the push-button panel to the "ED-S"...
  • Page 94 4.2.4.3 Direct-Control System (DC-S) By moving the selector on the push-button panel to the "DC-S" position, you can use only the right Joystick (11) to move in the driving direction, maintaining a straight trajectory without having to correct the direction with the other joystick.
  • Page 95 To use this function in the best way, it is advisable to control both Joysticks in the desired direction first) with selector 9 on hare) and then move selector 8 from DM to DC-S. At this point it is possible to release the left joystick and to keep holding only the right one.
  • Page 96 4.2.5 Levelling the platform The platform is equipped with an automatic levelling system with hydraulic cylinders to allow for the work platform to operate within the maximum inclination allowed, thus allowing to keep the work platform always horizontal with respect to the ground within a range of ± 0.5°, both longitudinally (longitudinal cylinder) and laterally (connecting rod cylinders).
  • Page 97 4.2.5.1 Levelling in the transport configuration (with the upward movement of the work platform) With the work platform completely lowered, it is possible to activate the automatic levelling by keeping selected the work platform upward control. The system will bring the frame back to an inclination of less than 0.5° compared to the horizontal.
  • Page 98 RH lateral levelling Longitudinal levelling By activating any movement, the platform will stop automatically once it reaches the horizontal. If the inclination of the platform remains within ± 0.5° both laterally and longitudinally, it is possible to lift the work platform. Warning: manual levelling is less accurate than automatic levelling 4.2.5.3 Dynamic Levelling during travel Note: dynamic levelling can be activated only with the platform completely...
  • Page 99 Warning: If selector 8 is positioned on DC-S, the function is not active. 4.2.5.4 Proactive Levelling Note: the Proactive Levelling is active only up to the maximum travel height allowed, which on this model is 4.5 mt platform floor (6.5 mt work). This system allows to correct the levelling of the machine when it is at a height, if after travelling on not perfectly flat ground, the platform is no longer aligned with the ground itself.
  • Page 100 Preliminary notes: The system is active only when the platform floor is higher than 2mt The system is active only within 3° of inclination The system is active only if the work platform is below the maximum travel height of 4.5 mt platform floor (scissor frame angle with respect to frame 23°) If indicator light 1 is off, it means that the inclination is less than 0.5°...
  • Page 101 Operating principle: During travel at a height if an inclination of 0.5° is exceeded, light 1 will start to flash; if 1° is exceeded, travel will stop. • It is necessary to release the joysticks • When the joysticks are reactivated, the platform will be levelled again. The levelling can be performed also by commanding the upward movement of the work platform.
  • Page 102 Configuration summary table Height of work Frame Travel Levelling Platform up inclination platform Allowed Allowed at Lower that the Manual Allowed after transport height maximum speed Dynamic levelling levelling Automatic levelling Higher than the transport height but lower that Allowed but only Proactive levelling Allowed after >0.5°<1°...
  • Page 103 4.2.6 Lifting/descent of the work platform The work platform can be lifted by means of the dedicated selector on the control push-button panel. The lifting and descent speed are controlled by the electronic control unit (ECU). The platform descent can also be performed with the combustion engine off but the electrical panel ON.
  • Page 104 4.3 Messages and alarms on the hour counter The hour counter, placed next to the ladder, allows to display the machine status. This display also shows any errors and/or alarms that may occur. If there are no alarms present, the display will show the hours of work with the electrical engine and with the internal combustion engine: d = hours of operation with diesel engine E = hours of operation with electrical engine...
  • Page 105 If there are no alarms at the moment but there were alarms previously (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 of the hour counter.
  • Page 106 The table below shows the list of alarm/error codes. CODE DESCRIPTION FUEL fuel level (only Kubota engine) (Warning: This alarm is not stored) Starter battery voltage lower than 9V Starter battery voltage higher than 16V EPROM memory internal error CAN network communication error Frame angle sensor redundancy error Scissor angle sensor redundancy error Pressure transducer redundancy error...
  • Page 107 4.4 Stopping the machine 4.4.1 Normal stop During normal platform use, releasing the TRANSLATION joysticks (10 and 11) stops the movement. Each track installed has a braking system that prevents the machine from moving unless hydraulic pressure is exercised to disengage it. Releasing the platform UP or DOWN (15) lever, under normal working conditions, stops the relative movement.
  • Page 108 4.4.2 Emergency stop In abnormal circumstances, 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 emergency button place on the GROUND CONTROLS (see figures below).

  • Page 109: Emergency Procedures

    5 Emergency procedures 5.1 Emergency manual descent Following a failure in the electrical system or hydraulic circuit, the platform DESCENT manoeuvre can be performed from any height by means of the emergency control at ground level. In this case, the operator on the ground (remember that at least one operator must be present at ground level to ensure the platform is used in safe conditions) must pull the hydraulic valve control installed on the lifting cylinder.
  • Page 110 5.2 Transporting the machine in an emergency To move or transport the platform using external equipment, refer to paragraph 5.3 Emergency movements from hydraulic block Warning: this operation must be performed only by qualified technicians trained by Almac Srl If the control unit is not working but it is possible to turn on the internal combustion engine or the electrical engine, then it will be possible to perform then movements of the machine directly from the hydraulic block.

  • Page 111: Maintenance

    6 Maintenance 6.1 General maintenance The main maintenance interventions and the frequencies with which they must be carried out are given in the chart below. 6.1.1 Ordinary maintenance schedule table The checks and maintenance operations must be performed as indicated in the table below...
  • Page 112 ORDINARY MAINTENANCE SCHEDULE TABLE 10 50 100 250 500 1500 Visual and functional checks as specified Discharge filter cartridge replacement Suction filters replacement Check and, if necessary, grease the runners and nylon wheels Check the hydraulic oil level Change the hydraulic oil Track reduction gear oil level inspection Replace oil in the track reduction gear Check the oil level in the engine...
  • Page 113 Warning: All maintenance operations must be performed as indicated in Chapter 2 Safety information. In particular, maintenance must only be carried out after the emergency push-button has been pressed, the engine turned off and using individual protective equipment and the extendible structure locking system. Warning: Disconnect the machine from all power sources Warning: It is mandatory to perform all MEWP movements required for inspections/maintenance using the ground controls and without operators on the...
  • Page 114 6.1.2 Checks before each use Prior to commissioning and before each use the machine must undergo the visual and functional checks given below. The instructions given below must be followed. VISUAL CHECK CHECK OPERATION • • Visually check under and around the With platform transport...
  • Page 115 fully charged; a simple way to check is lifting the platform to a height that involves an turning on the internal combustion angle of the scissor frames of 23° with respect engine, which must turn on easily. to the horizontal (maximum height of transit •...
  • Page 116 • Make sure that the platform extension can move freely and that the pedal blocks it safely • Make sure that the folding railings are correctly positioned and secured...

  • Page 117: Maintenance: Details

    6.2 Maintenance: Details The following points deal with the most significant specific cases 6.2.1 Checking and tightening screws, bolts, plug ring nuts The operation of the following components must be checked. If necessary, the parts must be tightened with the appropriate tools as indicated in the charts on the following pages.
  • Page 118 6.2.2 Visual and structural inspection Visually check the following points according to the schedule indicated in the general chart. Immediately inform a maintenance technician if faults are discovered. • Integrity of the railings of the work platform • Condition of ladder •...
  • Page 119 6.2.4 Greasing the runners Grease these parts at the frequency indicated in the general chart and EACH TIME that the following operations are performed: • Washing the machine • After a long period of inactivity • After use in particularly harsh conditions, e.g. damp or dusty places, marine environments, etc.
  • Page 120 6.2.5 Greasing the nylon wheels of the platform extension Grease these parts with the frequency indicated in the general chart and as specified for the runners. The surfaces to be greased are those in contact with the wheels, both in the fixed part of the platform and in the extension (see figures below): Remove all dirt from the parts before greasing.
  • Page 121 6.2.6 Checking the hydraulic tank oil level and topping up if necessary The hydraulic oil level is checked by means of a level indicator located directly on the tank. The correct oil level must be checked with the machine in the configuration indicated in the following pictures.
  • Page 122 In this configuration, the oil level must be as shown in the figure below. A = 60mm...
  • Page 123 6.2.7 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 dispose of it in the proper way. 2. Empty then tank by means of the dedicated cap placed under the tank (1), or use a manual (2) or electric (3) pump making use of the filler cap placed on top of the tank (4).
  • Page 124 6.2.8 Checking the operation of the maximum pressure valves With the frequency indicated in the general chart, check the operation of the maximum pressure valves of the distributor. To test them, connect two pressure gauges with a full scale of 250 bar to the pressure outlets supplied (4 and 5).
  • Page 125 Checking the maximum pressure valves relating to lifting (2) The pressure gauge relating to this valve is the one connected to outlet 4. Start the internal combustion engine. Press the platform "up" button (15) until it reaches the limit and hold it down.

  • Page 126: Explosive Atmospheres

    working life, limit any problems that may arise and reduce the running costs of the machine. Comply with the following instructions: • Charge the battery in ventilated areas. • Keep open flames well away from the battery since explosive gases may form.
  • Page 127 Recharge the battery only in ventilated areas. With the main switch QS1 (battery disconnect switch) turned to the ON position, connect the positive pole of the battery charger to the 150A fuse or to the dedicated connector placed under the ladder; connect the negative pole of the battery charger frame.
  • Page 128 2 = Converter 230V AC/ 12V DC Connect the plug 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 •...
  • Page 129 6.2.10 Hydraulic filter replacement Replace the discharge filters of the hydraulic circuit at the frequencies indicated in the general chart. The hydraulic oil tank features: 2 or 4 suction filters inside the tank (1) 1 discharge filter in the top part of the tank (2). 6.2.10.1 Suction filters replacement...
  • Page 130 To replace the discharge filters located inside the hydraulic tank, proceed as follows: 1) Arrange the machine with the extending structure lifted and block it with the special mechanical locks for maintenance. Now turn it off and deactivate the electric panel 2) Empty the hydraulic oil reservoir 3) Unscrew the blocking screws (3) on the hydraulic tank lid and remove it from its housing...
  • Page 131 Warning: during operations some oil could spill. Remove spilt oil with a 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.
  • Page 132 6.2.11 Checking the operation of the frame angle sensor With the frequency indicated in the general chart, check the frame angle sensor. • With the platform in the transport configuration, place the machine with the frame tilted with respect to the horizontal by a value greater than 0.5°...
  • Page 133 6.2.12 Checking the operation of the scissor angle sensor With the frequency indicated in the general chart, check the scissor angle sensor. • Lift the platform to a height greater than the transport height, check that the manual levelling functions are not allowed. •...
  • Page 134 6.2.13 Checking the operation of the Proactive levelling redundant angle sensor With the frequency indicated in the general chart, check the redundant angle sensor of the Proactive Levelling system. • With the platform in the transport configuration, place the machine with the frame tilted with respect to the horizontal by a value slightly greater than 3°...
  • Page 135 6.2.14 Checking the differential circuit breaker With the frequency indicated in the general chart, check the differential circuit breaker Connect the plug in the ladder to an electric power supply that conforms to the following specifications: • Voltage: 230 v ± 10% •...
  • Page 136 6.2.15 Electrical insulation monitoring device operation test With the frequency indicated in the general chart, check the operation of the device that monitors the electrical insulation of the 220V power supply of the inverter (only if present). The test must be performed with the internal combustion engine on, selector 6 on the console must be in the "OUT 220 V"...
  • Page 137 6.2.16 Manual emergency device operation test Test the operation of the manual EMERGENCY DESCENT device at the inspection frequency indicated in the general chart. Near the access ladder, indicated with special stickers, there is a control lever which, when pulled, allows the platform to lower in any condition, i.e.: •...
  • Page 138 6.2.17 Checking the operation of the Proactive levelling safety valves “ ” With the frequency indicated in the general chart, check the additional levelling locking valves. Remove the connectors from the solenoid valves and try to perform manual levelling operations with the machine in the transport position. All the movements must be prevented and the maximum pressure relief valves of the hydraulic block will be activated.
  • Page 139 6.2.18 Checking the seal of the cylinder balancing valves Warning: this operation must be performed only by qualified technicians trained by Almac Srl With the frequency indicated in the general chart (as for the Proactive levelling safety valves), check the seal of the flanged valves on the cylinders. To perform this check, it is necessary to: 1) Position the machine as indicated in the figure (chassis completely raised and platform extended)
  • Page 140 7) Perform the procedure with the remote controller (running time 90 minutes) 8) Make sure that the machine remains in the position where it was left and that there were no movements due to oil leaking from the valves (because of a malfunction or impurities trapped in the cursor). Warning: if the test has a negative outcome, do not use the machine and contact a qualified technician trained by Almac Srl...
  • Page 141 6.2.19 Procedure with remote controller for checking the seal of the cylinder balancing valves Warning: this operation must be performed only by qualified technicians trained by Almac Srl...
  • Page 142 Push the emergency push button on controller; Select commands on chassis (22); Release the emergency push button on Console; The lamps 1‐2‐3‐4 come on, when only the red lamps 1‐4 are steady press two times selector 14 forward and after two times selector 12 forward The procedure that open the valves SV 4-5-6-7 begin, the valves are energized for 90 minutes, an a count down will be shown on the hour meter (from 90 to 0)
  • Page 143 6.2.20 Maintenance of the engine Below are general instructions for the correct maintenance of the engine. In any case, always consult the use and maintenance manual of the engine.
  • Page 153 6.2.21 Track inspection and tensioning Check track tension at the inspection frequency indicated in the general chart. Pull the track slightly upwards in correspondence with the centre line; the deformation must 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 proper track tension use a tensioning kit (2) - not included - and pump...
  • Page 154 6.2.22 Checking the tracks for wear Check the wear and condition of the tracks, replacing them when the tread is equal to or less than 10 mm. The tracks must be changed even before they reach this limit if they are cuts or tears are noted.
  • Page 155 6.2.23 Replacing the tracks WARNING: it is 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 have caused damage to property and/or harmed people.
  • Page 156 6- Using the nut supplied (point A) 7- Move the front wheel back by pressing on the track with your foot...
  • Page 157 WARNING: BE CAREFUL WHEN THE TRACK FALLS TO THE GROUND 8- Lift the track at the lower centre line 9- Pull the track out , prying between the track itself and the idler wheel 10- To install the new track, proceed as indicated in the previous points, but in reverse order 11- The track is correctly tensioned by using the tensioning kit, pumping grease until the pressure indicated on the technical data sheet has been...

  • Page 158: Machine Life

    3- Once it has been emptied a. Replace the DRAIN cap b. Using a syringe, add oil through the FILL cap, until the oil comes out of the LEVEL cap 4- Screw the LEVEL cap back on 5- Screw the FILL cap back on USE Shell SPIRAX S3 AX 80W/90 OIL 7 Demolition 7.1 Machine life...
  • Page 159 Note: ALMAC S.r.l. declines all liability for damage to persons, animals or things deriving from reuse of parts of the equipment for functions or assembly situations differing from the original ones. Danger: Machine decommissioning and demolition must be carried out only by properly trained and equipped personnel.
  • Page 160 7.3 Battery disposal Battery recycling mandatory (European Directive 2006/66/EC) recommended. • Cells and batteries, even if fully discharged, may still contain a considerable amount of energy. It is therefore necessary to always protect the terminals to prevent short circuits. • Dispose of the batteries in compliance with local laws and regulations (contact your nearest dealer).
  • Page 161 8 ATTACHMENTS 8.1 Declaration of conformity...
  • Page 162 8.2 Report register Report register The Report register is issued to the platform user with reference to: ➢ technical standard UNI EN280:2015 ➢ Legislative Decree D.Lgs 17/2010 Implementation of Machinery – Directive 2006/42/EC The purpose of this Register is to record events concerning the life of the machine;...
  • Page 163 MANDATORY ROUTINE INSPECTIONS Date Observations Seal/Signature...
  • Page 164 Type of inspection Description Checking and tightening screws, bolts, plug ring nuts Date Observations Signature 1st year 2nd year 3rd year 4th year 5th year 6th year 7th year 8th year 9th year 10th year NOTE: frequency of 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.
  • Page 165 Type of inspection Description Damage to tubes and cables Date Observations Signature 1st year 2nd year 3rd year 4th year 5th year 6th year 7th year 8th year 9th year 10th year NOTE: frequency of the operation as indicated in the table in Chapter 6. Monthly registration is not necessary, but should be made at least once a year when other operations are performed.
  • Page 166 Type of inspection Description Hydraulic tank oil level inspection Date Observations Signature 1st year 2nd year 3rd year 4th year 5th year 6th year 7th year 8th year 9th year 10th year NOTE: frequency of 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.
  • Page 167 Type of inspection Description Check operation maximum pressure valve Date Observations Signature 1st year 2nd year 3rd year 4th year 5th year 6th year 7th year 8th year 9th year 10th year NOTE: frequency of the operation as indicated in the table in Chapter 6. Type of inspection Description Hydraulic filter replacement...
  • Page 168 Type of inspection Description Check the operation of the angle sensors Date Observations Signature 1st year 2nd year 3rd year 4th year 5th year 6th year 7th year 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 Proactive levelling...
  • Page 169 Type of inspection Description Check the operation of the differential switch of the 230V outlet Date Observations Signature 1st year 2nd year 3rd year 4th year 5th year 6th year 7th year 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 electrical insulation...
  • Page 170 Type of inspection Description Manual emergency device operation test Date Observations Signature 1st year 2nd year 3rd year 4th year 5th year 6th year 7th year 8th year 9th year 10th year NOTE: frequency of the operation as indicated in the table in Chapter 6. Type of inspection Description Engine oil inspection...
  • Page 171 Type of inspection Description Engine oil change Date Observations Signature 1st year 2nd year 3rd year 4th year 5th year 6th year 7th year 8th year 9th year 10th year NOTE: frequency of the operation as indicated in the table in Chapter 6. Type of inspection Description Track inspection and tensioning...
  • Page 172 Type of inspection Description Track inspection and replacement Date Observations Signature 1st year 2nd year 3rd year 4th year 5th year 6th year 7th year 8th year 9th year 10th year NOTE: frequency of the operation as indicated in the table in Chapter 6. Type of inspection Description Track reduction gear oil level inspection...
  • Page 173 Type of inspection Description Make sure that parking brake functions Parking brake correctly when machine stops Date Observations Signature 1st year 2nd year 3rd year 4th year 5th year 6th year 7th year 8th year 9th year 10th year NOTE: frequency of the operation as indicated in the table in Chapter 6. Registration every six months is not necessary, but should be made at least once a year when other operations are performed.
  • Page 174 Type of inspection Description Make sure that parking brake functions Check the levelling cylinder balancing valves correctly when machine stops Date Observations Signature 1st year 2nd year 3rd year 4th year 5th year 6th year 7th year 8th year 9th year 10th year NOTE: frequency of the operation as indicated in the table in Chapter 6.
  • Page 175 Serious faults Date Description of fault Solution Spare parts used Description Code Serious faults Date Description of fault Solution Spare parts used Description Code Serious faults Date Description of fault Solution Spare parts used Description Code...
  • Page 176 8.3 Property transfers Copy to be kept ownership of the MEWP: serial no. year of manufacture was transferred to: It is hereby certified that, as of the date above, the technical, dimensional and functional characteristics of the aforementioned platform conformed to the original characteristics and that variations, if any, have been recorded in the register.
  • Page 177 8.4 Hydraulic diagram See attachment 8.5 Wiring diagram See attachment...
  • Page 178 9 INDEX GENERAL INFORMATION __________________________________________________________ 2 OCUMENTS SUPPLIED WITH EACH MACHINE ____________________________________________ 2 ETAILS OF ANUAL ____________________________________________________________ 2 RECIPIENTS OF THIS MANUAL ______________________________________________________ 2 WNERSHIP OF THE INFORMATION __________________________________________________ 3 ANUFACTURER S IDENTIFICATION DATA ______________________________________________ 3 MEWP IDENTIFICATION DATA ______________________________________________________ 4 ERFORMANCE ________________________________________________________________ 6 CE D...
  • Page 179 2.11 RECAUTIONS WHEN WORK TERMINATES OR IS INTERRUPTED _______________________________ 37 2.12 AFETY REGULATIONS DURING MAINTENANCE __________________________________________ 37 2.13 (PPE) ___________________________________________ 40 ERSONAL PROTECTIVE EQUIPMENT DESCRIPTION OF THE MACHINE ___________________________________________________ 42 TRUCTURE OF THE EQUIPMENT ___________________________________________________ 42 3.1.1 Work platform assembly __________________________________________________ 43 3.1.2 Scissor assembly _________________________________________________________ 44 3.1.3...
  • Page 180 4.1.5 Checking the fuel level ___________________________________________________ 82 4.1.6 Checking the oil level in the engine ________________________________________ 83 4.1.7 Folding the railings ______________________________________________________ 83 ACHINE OPERATION ___________________________________________________________ 86 4.2.1 Starting the internal combustion engine ____________________________________ 86 4.2.2 Starting the current source _______________________________________________ 88 4.2.3 Starting the electrical engine _____________________________________________ 88 4.2.4...
  • Page 181 6.2.1 Checking and tightening screws, bolts, plug ring nuts _______________________ 117 6.2.2 Visual and structural inspection __________________________________________ 118 6.2.3 Damage to tubes and cables ______________________________________________ 118 6.2.4 Greasing the runners ____________________________________________________ 119 6.2.5 Greasing the nylon wheels of the platform extension _______________________ 120 6.2.6 Checking the hydraulic tank oil level and topping up if necessary _____________ 121 6.2.7...
  • Page 182 ATTERY DISPOSAL ___________________________________________________________ 160 ATTACHMENTS ______________________________________________________________ 161 ECLARATION OF CONFORMITY ___________________________________________________ 161 EPORT REGISTER ____________________________________________________________ 162 ROPERTY TRANSFERS _________________________________________________________ 176 YDRAULIC DIAGRAM __________________________________________________________ 177 IRING DIAGRAM _____________________________________________________________ 177 INDEX ________________________________________________________________________ 178...

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