Professional Documents
Culture Documents
11 - Mantirib.01 (Ing) - Tip Over Sensor
11 - Mantirib.01 (Ing) - Tip Over Sensor
INDUSTRIA METALMECCANICA
12020 S. Defendente di Cervasca (CN) - ITALY Tel. +39 0171 614111 - Fax +39 0171 614100
Web: www.merlo.com E-mail: info@merlo.com
CALIBRATION OF
TIP-OVER PREVENTION SYSTEM
ON MERLO TELEHANDLERS
MANTIRIB.01
INDICE
INDEX
INTRODUCTION.........................................................................................................................................................5
SAFETY AND GENERAL STANDARDS...........................................................................................................................5
PROCEDURE FOR CALIBRATION OF TIP-OVER PREVENTION SYSTEM ON PANORAMIC P25.6.......................................6
PROCEDURE FOR CALIBRATION OF TIP-OVER PREVENTION SYSTEM ON PANORAMIC CS............................................9
PROCEDURE FOR CALIBRATION OF TIP-OVER PREVENTION SYSTEM ON PANORAMIC HM........................................ 12
ADJUSTMENT OF MICROSWITCH................................................................................................................................................ 12
PROCEDURE FOR CALIBRATION OF TIP-OVER PREVENTION SYSTEM ON ALL PANORAMIC, TURBOFARMER OLD AND NEW..... 15
ADJUSTMENT OF MICROSWITCH................................................................................................................................................ 15
PROCEDURE FOR CALIBRATION OF TIP-OVER PREVENTION SYSTEM ON ROTO AND ROTO MCSS MODELS................ 17
ADJUSTMENT OF MICROSWITCH................................................................................................................................................ 17
PROCEDURE FOR CALIBRATION OF TIP-OVER PREVENTION SYSTEM ON ROTO 40.30 MCSS AND ROTO 60.24 MCSS
MODELS.................................................................................................................................................................. 21
MANTIRIB.01 3
OPERATING INSTRUCTIONS
INTRODUCTION
This manual provides instructions necessary for the correct implementation of maintenance procedures not covered
in the "USE AND MAINTENANCE INSTRUCTION MANUAL" accompanying the machine; accordingly, it is intended for
skilled persons possessing an extensive familiarity with the composition of the mechanical parts and with operation of
the hydraulic and electrical system of the machine on which work is being carried out. Remember that the application
of accident prevention procedures and regulations on health and safety in the workplace is the responsibility of the
repair workshop foreman, who must take all such measures as may be deemed necessary to avoid the occurrence of
accidents during maintenance operations (the "USE AND MAINTENANCE INSTRUCTION MANUAL" also contains advice
on this subject).
The symbol indicated alongside identifies the size of the wrench to be used for certain of the operations
described on the pages of this Manual.
The type of wrench will be indicated only if different to the standard tool.
CAUTION!!! Make certain there are no persons or animals standing or moving about within the opera-
ting radius of the telescopic boom during calibration of the tip-over prevention system.
With this in mind, a safety area should be marked off around the machine, creating at least 6 metres
clearance to the front and at least 4 metres to the rear.
In the case of ROTO models, mark off an area of at least 10 metres all around the machine.
CAUTION!!! It is forbidden to handle loads of any weight heavier than that indicated in the machine load
chart.
CAUTION!!! It is severely forbidden and extremely dangerous to modify any part of the machine in such a
way as will change its original structure; it is also forbidden to change hydraulic and electrical settings or
modify safety systems. If these rules are ignored, Merlo S.p.a. shall be relieved of all liability and entitled
to reject any claim under warranty.
CAUTION!!! Maintenance must be carried out by skilled and experienced personnel.
MANTIRIB.01 5
OPERATING INSTRUCTIONS
2. Place a weight of known value on the forks, in such a way that when added to weight of the fork carriage, the total
weight will be 1500 kg.
3. Extend the boom to the point at which the tip-over prevention system cuts in (all movements locked out, buzzer
sounding, warning indicator light showing in the display).
4. Retract the boom completely, then extend again to a distance of 2250 mm from the forwardmost point on the
front tyre.
6 MANTIRIB.01
OPERATING INSTRUCTIONS
6. Addressing the hub with the tip-over prevention device still in place, loosen the nut (A) located beneath the epi-
cyclic unit, and then back off the set screw (B). Adjust the loading on the springs by way of the bolt (C).
7. If the movements were already locked out at the extended position described in step "4", unscrew the bolt (C)
until the buzzer no longer sounds, then retighten to the point at which the buzzer is heard again.
If lockout had not yet occurred at the extended position in question, tighten the bolt (C) until the buzzer is heard.
NOTE!!! In either case, once the buzzer is heard, tighten the bolt (C) further by one ¼ turn.
8. Reposition the set screw (B) and tighten the lock nut (A).
9. Retract the boom completely, then extend a second
time.
Mark the point, on the second boom section, at which
movements were locked out; this mark should be no
more than 100 mm beyond the mark (1) made pre-
viously (see point "5").
MANTIRIB.01 7
OPERATING INSTRUCTIONS
10. Once lockout has occurred, turn the red key to the
bypass position.
14. Remove the weight from the forks and elevate the boom.
15. Reattach the connector detached previously (step 1), and detach the other connector.
16. Repeat the procedure described from step "2" to step "12” for the other sensor.
8 MANTIRIB.01
OPERATING INSTRUCTIONS
CAUTION!!! Before proceeding with calibration, ensure complete familiarity with the safety measures
listed under "SAFETY AND GENERAL STANDARDS" on page 4.
3. Connect the "Framatone" connector, with the jumper fitted, to the connector detached previously.
IMPORTANT!!! From this point onwards, keeping to the instructions that follow, the steps described in-
dicate how to calibrate the tip-over prevention microswitch wired to the connector that REMAINS IN
PLACE.
MANTIRIB.01 9
OPERATING INSTRUCTIONS
5. Extend the boom to the point of reaching the reference letter indicated on the load chart.
10 MANTIRIB.01
OPERATING INSTRUCTIONS
7. Climb into the cab and, using the joystick, retract the boom and restore the machine to stable conditions.
8. Extend the telescoping boom again; check that ma-
chine movements are locked out effectively at the di-
stance indicated on the load chart.
Mark the point of lockout on the second boom sec-
tion.
9. Turn the safety bypass key to the right and hold, then
extend the boom to the point at which the machine
begins tipping over.
11. Retract the boom and remove the weight from the forks.
MANTIRIB.01 11
OPERATING INSTRUCTIONS
3. Connect the "Framatone" connector, with the jumper fitted, to the connector detached previously.
IMPORTANT!!! From this point onwards, keeping to the instructions that follow, the steps described in-
dicate how to calibrate the tip-over prevention microswitch of the connector that REMAINS IN PLACE.
ADJUSTMENT OF MICROSWITCH
4. Raise the rear axle off the ground, utilizing the lifting points provided on the chassis.
Make the adjustment to the microswitch, on the
wheel hub, associated with the connector that was
not detached at step "2".
5. Loosen the lock nut (A).
Adjust the set screw (B), turning clockwise to screw
down or anticlockwise to back off, until the buzzer is
heard.
If the buzzer sounds on turning the set screw clockwi-
se, screw down further by one ½ turn.
If the buzzer sounds on turning the set screw anticloc-
kwise, back off further by one ½ turn.
12 MANTIRIB.01
OPERATING INSTRUCTIONS
1. Loosen the set screw (C) and the socket screw (D) retaining the cap bracket; remove the bracket, then the cap.
MANTIRIB.01 13
OPERATING INSTRUCTIONS
4. Checks:
a. If the buzzer sounds, tighten the lock nut (E) aga-
inst the adjuster nut and proceed to step "5".
6. Run a number of test cycles to ensure correct operation of the tip-over prevention device (for example, with a load
of 4000 kg on the forks, the device should cut in at letter (E) on the telescoping boom).
8. Elevate the boom and reinstate the connector detached during step "2" (see page 11).
14 MANTIRIB.01
OPERATING INSTRUCTIONS
3. Connect the "Framatone" connector, with the jumper fitted, to the connector detached previously.
IMPORTANT!!! From this point onwards, keeping to the instructions that follow, the steps described in-
dicate how to calibrate the tip-over prevention microswitch of the connector that REMAINS IN PLACE.
ADJUSTMENT OF MICROSWITCH
4. Raise the rear axle off the ground, utilizing the lifting
points provided on the chassis.
Make the adjustment to the microswitch, on the
wheel hub, associated with the connector that was
not detached at step "2".
5. Loosen the lock nut (A). Adjust the set screw (B),
turning clockwise to screw down or anticlockwise to
back off, until the buzzer is heard.
If the buzzer sounds on turning the set screw clockwi-
se, screw down further by one ¼ turn.
If the buzzer sounds on turning the set screw anticloc-
kwise, back off further by one ¼ turn.
6. Retighten the lock nut (A)
MANTIRIB.01 15
OPERATING INSTRUCTIONS
2. Checks:
a. If the buzzer sounds, proceed to point "3".
5. Elevate the boom and reinstate the connector detached during step "2" (see page 14).
16 MANTIRIB.01
OPERATING INSTRUCTIONS
PROCEDURE FOR CALIBRATION OF TIP-OVER PREVENTION SYSTEM ON ROTO AND ROTO MCSS MODELS
ADJUSTMENT OF MICROSWITCH
CAUTION!!! Before proceeding with calibration, ensure complete familiarity with the safety measures
listed under "SAFETY AND GENERAL STANDARDS" on page 4.
IMPORTANT!!! To carry out the full calibration procedure on machines with no UPD screen in the cab,
the company strongly recommends the use of the "DIAGNOSTICS KIT FOR MERLO TELEHANDLERS" (part
number 077996), which can be ordered from the MERLO S.p.A. parts store.
2c. On hearing the "click" (and seeing the change of status on the screen), continue turning the set screw (B) in
the same direction, one ¼ turn further.
3. Retighten the lock nut (A).
MANTIRIB.01 17
OPERATING INSTRUCTIONS
2. Slew the turret through 45° approx, into alignment with one of the four wheel hubs.
3. Apply a weight to the forks, corresponding to the
weight indicated on the load chart of the machine;
extend the telescopic boom, keeping it parallel to the
ground;
advance the weight to the distance indicated on the
load chart.
4. When extending the boom, check that movements are locked out (as in the example given above) at a pull-out
distance of 13.5 metres. Check also that the traffic light indicator located inside the cab changes from green to
amber when lockout occurs, and thereafter from amber to red.
Should the traffic light change directly from green to red, this means that the sensitivity of the mechanical respon-
se generated by the system needs to be adjusted:
- loosen the lock nut (E)
- turn the setscrew (F) to the point at which the
traffic light indicator changes from green to am-
ber,and thereafter from amber to red, which cor-
responds to the lockout of all movements indu-
ced by the MERlin software.
- tighten the lock nut (E) against the adjuster nut.
18 MANTIRIB.01
OPERATING INSTRUCTIONS
5. Check at what point the microswitch should effectively cut in under the red traffic light condition (software-activa-
ted lockout of movements induced by MERlin system).
IMPORTANT!!! This operation is carried out using the UPD screen in the cab, or in the case of machines
with no UPD screen, using the "DIAGNOSTICS KIT FOR MERLO TELEHANDLERS" (part number 077996),
which can be ordered from the MERLO S.p.A. parts store.
Procedure:
5a. in the cab, turn the safety bypass key to the right
and hold.
MANTIRIB.01 19
OPERATING INSTRUCTIONS
NOTE!!! Repeat the "TIP-OVER PREVENTION ADJUSTMENT" procedure from step "1" to step "5" for each
of the four positions illustrated below.
6. Slew the turret left, to a position at 90° relative to the longitudinal axis of the machine.
7. Extend the telescopic boom to the point at which loc-
kout occurs.
8. Turn the safety bypass key to the right and hold (see
step "5a" on page 18).
11. Still keeping the safety bypass key turned toward the right, continue extending the boom until the machine finally
begins tipping over sideways.
12. Make certain that the distance between the mark (a) made at step "10", and the point (b) where the carriage to-
uches the ground, is not less than 1 metre.
13. If this is not the case, then turn the set screws (F) of both the microswitches clockwise (see step "4" on page 17),
so as to compress the springs and advance the point at which the microswitches cut in (see step "9"). Thereafter,
repeat the procedure from step "7" to step "12", to run a further check.
14. Slew the turret right, to a position at 90° relative to the longitudinal axis of the machine, and repeat the procedure
described thus far from step "7" to step "12" to test the operation of the front and rear microswitches on the left
hand side of the machine.
20 MANTIRIB.01
OPERATING INSTRUCTIONS
PROCEDURE FOR CALIBRATION OF TIP-OVER PREVENTION SYSTEM ON ROTO 40.30 MCSS AND ROTO
60.24 MCSS MODELS
CAUTION!!! Before proceeding with calibration, ensure complete familiarity with the safety measures
listed under "SAFETY AND GENERAL STANDARDS" on page 4.
CAUTION!!! To ensure correct adjustment of the tip-over prevention system, the geometrical system of
the machine must also be set up correctly. If this is not the case, proceed first with calibration of the
geometrical system.
CAUTION!!! There may be more than one load chart displayed in the cab, given that the values on the
chart will change with different types of tyre fitted to the machine and/or different machine status (on
stabilizers or on wheels). Accordingly, take care when selecting which chart to refer to.
1. Stand the machine on its wheels, and align the wheels with the chassis.
2. Slew the turret through 45° approx, into alignment with one of the four wheel hubs.
3. Apply a weight to the forks, corresponding to the
weight indicated on the load chart of the machine;
extend the telescopic boom, keeping it parallel to the
ground;
advance the weight to the distance indicated on the
load chart.
4. When extending the boom, check that movements are locked out (as in the example given above) at a pull-out
length of 13.5 metres. Check also that the traffic light indicator located inside the cab changes from green to am-
ber when lockout occurs, and thereafter from amber to red.
Should the traffic light change directly from green to red, this means that the sensitivity of the mechanical respon-
se generated by the system needs to be adjusted:
MANTIRIB.01 21
OPERATING INSTRUCTIONS
5. Retract the boom, then extend a second time: check that the traffic light indicator changes correctly from green to
amber, then from amber to red.
6. Turn the safety bypass key to the right, and hold;
extend the telescopic boom to the point at which the tip-over prevention microswitch is tripped, and halt the te-
lescoping movement of the boom;
check on the relative UPD diagnostics page (see illustration below) that the microswitch has been tripped; retract
the boom.
NOTE!!! Repeat the procedure from step "1" to step "6" for each of the four positions illustrated below.
22 MANTIRIB.01
OPERATING INSTRUCTIONS
7. Slew the turret left, to a position at 90° relative to the longitudinal axis of the machine.
8. Extend the telescopic boom to the point at which loc-
kout occurs.
9. Turn the safety bypass key to the right and hold (see
step "6" on page 21).
12. Still keeping the safety bypass key turned toward the right, continue extending the boom until the machine finally
begins tipping over sideways.
13. Make certain that the distance between the mark (a) made at step "11", and the point (b) where the carriage to-
uches the ground, is not less than 1 metre.
14. If this is not the case, then turn the cover adjuster nuts (B) of both the microswitches clockwise (see step "4a" on
page 21), so as to compress the springs and advance the point at which the microswitches cut in (see step "10").
Thereafter, repeat the procedure from step "8" to step "13", to run a further check.
15. Slew the turret right, to a position at 90° relative to the longitudinal axis of the machine, and repeat the procedure
described thus far from step "8" to step "13" to test the operation of the front and rear microswitches on the left
hand side of the machine.
MANTIRIB.01 23