iteco IT 10151 Manual

IT
IT 10151
IT 12151
10151
12151
MUM_IT151_GB_R01 10/2008
OPERATING AND
MAINTENANCE HANDBOOK

7
3900
270
48/320 C5
IT10151
7
4400
270
48/320 C5
IT12151
Here below you can nd the picture regarding the metal plate aached on the machine and concer-
ning identication data; it is advised to full in the serial number of the corresponding model in order
to bind this manual to the specic machine.

IMPORTANT
A suitable working safety is very important in order to avoid serious
injuries for the operator himself and for the others persons, therefore
it is compulsory to carefully read and well-understand this handbook
to know the exact and essential instructions for the use of the machine
and the maintenance operations.
This handbook has to be considered as an integral part of the machine
and it should always remain on the platform.
Only qualied and skilled operators could use this machine.
ITECO S.p.a.
46020 PEGOGNAGA (MN) ITALIA
Via S. Francesco D’Assisi, 8
Tel. [phone]
Fax [phone]
E-mail: [email protected] - www.itecolift.it

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IT10151 - IT12151
OPERATING AND MAINTENANCE HANDBOOK
Table of contents
Foreseen conditions of use.......................................................................................... 8
Aer-sale service ......................................................................................................... 10
Spare-part service........................................................................................................ 10
Structure of the handbook ........................................................................................ 10
General recommendations - safety rules................................................................ 11
Safety systems .................................................................................................. 11
Adhesive labels and plates ............................................................................. 11
Operator’s requirements ................................................................................. 12
The operator shall: ........................................................................................... 12
Not allowable operations ................................................................................ 14
To minimize hazards ....................................................................................... 16
Description of the machine....................................................................................... 18
Main components ............................................................................................ 19
Identication ..................................................................................................... 20
Description ........................................................................................................ 21
Standard equipement ...................................................................................... 24
Optional ............................................................................................................. 24
Technical features ............................................................................................. 25
Overall dimensions .......................................................................................... 26
Rating plates and adhesive labels .................................................................. 27
Operating principles ...................................................................................... 28
Hydraulic circuit ...................................................................................... 28
Electric circuit ........................................................................................... 28
Electronic circuit ...................................................................................... 29
Safety systems .................................................................................................. 30
Microswitches ........................................................................................... 30
SQ3 Microswitch ...................................................................................... 31
Anti-shearing device ............................................................................... 32
Baery connection plug ......................................................................... 32
Emergency stop push buon ................................................................. 33
Flatness indicator ..................................................................................... 33
Load limiting device ................................................................................ 34
Safety belt anchorage points .................................................................. 34
Use of the machine...................................................................................................... 35
Checking before use ........................................................................................ 35
Visual checking ........................................................................................ 35

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OPERATING AND MAINTENANCE HANDBOOK
Operating check ....................................................................................... 36
Controls and Action ......................................................................................... 38
Control panels .................................................................................................. 39
Ground control panel .........................................................................................39
Platform control panel ........................................................................................40
Operations from ground ......................................................................... 41
Starting and enabling ground controls ............................................................41
Platform liing/lowering ...................................................................................42
Starting and enabling platform controls ..........................................................42
Emergency stop device ......................................................................................43
Overload pilot ligth ...........................................................................................44
Baery charge indicator - Hour counter ..........................................................44
Diagnostic.............................................................................................................44
Operations from platform ...................................................................... 45
Traction .................................................................................................................46
Steering .................................................................................................................49
Platform liing/lowering ...................................................................................50
Emergency stop ...................................................................................................51
Platform extension ..............................................................................................52
Railing overturning.............................................................................................53
Machine stopping .................................................................................... 55
Emergencies .............................................................................................. 56
Overload ...............................................................................................................56
Machine unstable ................................................................................................57
General diagnostic ..............................................................................................57
Diagnostic display ..............................................................................................57
Emergency lowering ...........................................................................................58
Baery recharge ....................................................................................... 59
Before the charge .................................................................................................60
Charge start ..........................................................................................................60
Charge end ................................................................................................ 61
Baery disposal ........................................................................................ 62
Liing and transportation ...................................................................... 62
Storage ....................................................................................................... 62
Emergency towing ..............................................................................................63
Disposal and scrapping........................................................................... 64
220V Line ........................................................................................................... 65
Rotating beacons .............................................................................................. 65
Optional ........................................................................................................................ 66
110V line ............................................................................................................ 66
Baery charger kit 110V .................................................................................. 66

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OPERATING AND MAINTENANCE HANDBOOK
Maintenance................................................................................................................. 67
Machine cleaning ............................................................................................. 67
Maintenance devices ....................................................................................... 68
Safety rest .................................................................................................. 68
Baery connection plug ......................................................................... 69
Maintenance summary table .......................................................................... 70
Check oil level .................................................................................................. 71
Electrolyte level check ..................................................................................... 72
Check of baery charge ................................................................................... 72
Check of screw tightening .............................................................................. 73
Grease the mechanisms .................................................................................. 75
Safety check ...................................................................................................... 75
Red emergency stop push buon .......................................................... 75
SQ1 Microswitch ...................................................................................... 75
Safety speed .........................................................................................................75
Inclination ............................................................................................................76
Load limiting device ................................................................................ 78
Antishearing operations......................................................................... 78
Baery inspection and cleaning ..................................................................... 79
Emergency lowering control ......................................................................... 79
Check of engine brushes ................................................................................. 80
Check brakes on ramp ..................................................................................... 80
Braking spaces .......................................................................................... 80
Structure check ................................................................................................. 81
Check of hydraulic tubes ................................................................................ 82
Checking performance .................................................................................... 83
Safety speed .............................................................................................. 83
Steering speed .......................................................................................... 83
Check register ................................................................................................... 85

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IT10151 - IT12151
OPERATING AND MAINTENANCE HANDBOOK
This edition contains the use and maintenance of the self-propelled
aerial platforms IT10151 - IT12151.
The dierence between the two described models is in the machine
frame and therefore in the height :
IT10151 manufactured with 5 scissors, reaches a height of 9,90 m.
IT12151 manufactured with 6 scissors, reaches a height of 11,80 m.
Designed and manufactured to be hydraulically operated and with
proportional controls.
The platform manufacturer is :
ITECO S.p.a.
46020 PEGOGNAGA (MN) ITALIA
Via S. Francesco D’Assisi, 8
Tel. [phone]
Fax [phone]
E-mail: [email protected] - www.itecolift.it

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IT10151 - IT12151
D
C
B
A
OPERATING AND MAINTENANCE HANDBOOK
Foreseen conditions of use
The self-propelled aerial platform here described could be used to li
persons, materials and equipment accordingly with the foreseen tech-
nical data described in the suitable sheet, on solid and strong grounds
and aer a Qualied Operator has checked that he is working under
safety conditions.
It is equipped with:
• base or truck (A)
• liing structure or scissors (B)
• operating structure or platform (C)
• platform extension (D)
The possible movements are the following:
•Liing and lowering of the platform;
•Forward and backward traction of the machine;
• Steering;
•Manually-operated longitudinal travelling of the mobile platform.
The foreseen control workplaces for the operator are two : one in pla-
tform for the normal operations and one at ground used also under
emergency situations.
Using one operator place doesn’t allow the other place to come into
operation.
The movements are controlled by the platform control workplace.
The platform lowering and liing could be carried out also by the
ground control panel.
The traction movement could be carried out simultaneously with the
steering.
The backward and forward traction of the machine has carried out in-
dependently the platform height which could be also entirely lied.
The platform lowering/liin and machine traction are carried out inde-
pendently the platform extension which could be entirely extracted.

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IT10151 - IT12151
OPERATING AND MAINTENANCE HANDBOOK
The machine could be used:
•with temperatures between -10/+40°C;
The machine can be used outdoors with wind speed less than 12,5
m/s
It is possible face the maximum slope with :
•Machine entirely closed.
•The operator solely on board.
•Selecting the slow speed.
•On even ramp without transversal inclinations.
The machine has equipped with overturning railings to minimise when
the machine is completely closed, the maximum height thus allowing
the passage through openings of reduced height.

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OPERATING AND MAINTENANCE HANDBOOK
Aer-sale service
For interventions, repairs and revisions, address to workshops which
have available qualied personnel as well as the suitable equipment.
The ITECO Technical Aer-Sale Assistance is available to give explana-
tions and give assistance with skilled persons.
Spare-part service
A good and lasting working guarantee has assured by only use original
spare parts; make reference to the “SPARE PART CATALOGUE”.
Always state the data described on the identication plate placed on
the truck if you need spare parts or assistance.
Structure of the handbook
• Standard recommendations - safety rules
• Technical features and dimensions of the machine
• Use of the machine
• Maintenance
This instruction handbook must be carefully preserved by the
user for the whole machine life, even if the machine is lent, rent or
sold.
The gures described in this handbook DON’T exactly reproduce
the model described but these are used for a beer and easier un-
derstanding of the text.

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IT10151 - IT12151
OPERATING AND MAINTENANCE HANDBOOK
General recommendations - safety rules
The aim of this handbook is to help the operator to well know the
platform for an eective use under maximum safety conditions; it is
for this reason that it is very important to read and well understand
this handbook.
Safety systems
The safety systems foreseen for the machine are inevitably subjected
to wear and to be put out of tune. Check them periodically and keep
them in an ecient way. When the operative and safety conditions
are checked, do not base on their working solely.
These safety devices, being installed on the machine, don’t relieve the
Operator from the responsibility to use the machine adequately and
carefully .
Remove, modify or tamper important self-propelled aerial platform
instruments is strictly forbidden in order to assure its safety and sta-
bility.
Particular aention must be paid to the baeries which also carry
out a stabilising function. Check that their weight equals, or exceeds,
that given in the table of machine specications before making any
replacements.
Any tampering of the main instruments and safety devices of the
aerial self-propelled platform could cause the immediate lapse of the
guarantee terms.
Adhesive labels and plates
Possible dangers and prescriptions concerning the machine are de-
scribed on labels and plates ; therefore it is important that these are
well readable and in good conditions.

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OPERATING AND MAINTENANCE HANDBOOK
Operator’s requirements
The operator shall:
• Read and well understand all the documentation enclosed to the
machine, be properly trained and instructed in the correct use of
the machine and know the safety rules and devices.
•Be of age
•Be physically in good conditions and not make use of dope, alcohol
or drugs that could aect the aention, the reaction, the sight and
the hearing.
• Make always use of an assistant in areas where the sight has ob-
structed.
• Use suitable accident prevention equipment accordingly with the
working conditions and the local rules in force.
• During the working keep all the parts of the body inside the railings
and both feet have to be rmly rest on the oor surface
• Give a great importance to the safety and refuse to work when you
state to not work under safe conditions.
•Always work under highest safe conditions, tidiness and cleaning.
•Make a daily check before using the machine and also to controls and
safety devices and make sure they are in perfect working order.
•Check the working area is free from persons, animals or obstacles
before making any movement of the machine.
• Check that the ground where the machine has to operate is free
from potholes, bumps, drops, uneven levels, obstructions, debris,
obstacles and coverings which could hide possible potholes or others
dangers.
•Well-know the allowable maximum capacity.
•Clean from oil and grease the ladder, the oor surface of the platform
and the handrails.
•Once the work has been nished and when the machine remains
unaended, switch the machine o and take the key o to avoid that
unauthorized persons can use it.

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IT10151 - IT12151
OPERATING AND MAINTENANCE HANDBOOK
• Commuting the controls on the platform, always take the key o
to avoid an unauthorized use from the operating place on ground
while personnel is present on the platform. The safety manager must
hold a spare key enabling to use the operating place on ground as
emergency place when the machine is in use. In case of trouble it is
always possibile lower the machine operating on the devices placed
in the right box.

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IT10151 - IT12151
OPERATING AND MAINTENANCE HANDBOOK
Not allowable operations
It is strictly forbidden:
• Use the machine on slippery, frozen, muddy, uneven ground and with
holes, which has a slope higher than the allowed limit; make sure the
ground suitably support the maximum load per each tyre.
•Use the machine near free ames or source of heat.
•Use the machine in environments with explosive atmosphere.
•Carry out works near high-voltage transmission lines at a distance
lower than 5 meters.
•Modify the machine and use it in a dierent way from what it has
been described in the instruction handbook.
•Modify or remove the safety devices.
•Work in case of strong strom, with or without rain, or with wind
with speed higher than 12,5 m/s.
•Fasten the machine to adjacent structures.
•Do not lean out of the safety perimetric railings of the platform.
• Use the machine as a crane.
• Use the machine without an adequate environmental lighting to
work or to move under safety conditions.
•Load the machine with an higher weight compared to the nominal
range.
• Carry more people than indicated.

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OPERATING AND MAINTENANCE HANDBOOK
• Increase the maximum available working height by puing ladders
or scaolds on the platform.
•Run on public roads.
•Move the machine with the opened box.
• Use the machine making sure the gate to be admied to the platform
is not closed.
• Use an horizontal force above 400N.
•Throw some objects and tools from the top to down and viceversa.
•Use the machine if the working area is not free from obstacles which
could cause dangerous conditions.
•Use the handrails as admiance means to get on or get down from
the platform.
•Get on or get down from the platform when it is in the liing posi-
tion.
•Operate or li the platform when it has placed on the truck loading
platform or other vehicle.
•Charge the baeries near sparkles of free ames.
• Li the platform making sure there are not any obstacles above
it.
•Work with a machine operating under bad working conditions.
•Enter in contact with xed or mobile objects.
•Place materials on the handrails.
• Equip the machine with elements (ex. panels) which increase the
wind exposure.

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IT10151 - IT12151
OPERATING AND MAINTENANCE HANDBOOK
To minimize hazards
Follow the here below instructions:
Precautions for the travelling with the lied platform
•Check the ground is rm and even.
• Do not use the machine on slippery, icy, muddy ground and with
holes, which has a slope higher than the allowed limit.
•Check that the ground where the machine has to operate is free from
holes, bumps, drops, uneven level, obstructions, debris, obstacles
and coverings which could hide possible potholes or others dan-
gers.
•Comply with the maximum load and the allowable number of per-
sons.
•Distribute the loads and place them if possible in the middle of the
platform.
•Make sure the ground resists to the force and load of tyres.
•Avoid the machine knocks against xed or mobile obstacles.
•Do not use the machine with materials suspended to the handrails
or to the scissors li.
• Give the best aention during movements with mobile travelling
platform.
• During movements, liing and lowering of the platform, check that
there are not obstructions around, over and under the machine.
•Carry out the movements only if the working area visibility is com-
plete.
•Do not work with wind having a speed higher than 12,5 m/s.
•Do not equip the machine with elements (ex. panels) which increase
the wind exposure.

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IT10151 - IT12151
OPERATING AND MAINTENANCE HANDBOOK
Electric hazards
•To assure the earth-leakage of the electrostatic charges, the back parti-
tion of the machine is equipped with a conductive strip.
Always check the wear of this strip and there is the earth contact.
•As the machine is not electrically insulated, the operator has to pay
a particular aention to avoid any contact with probably energized
parts.
• As already mentioned in the section “Not allowable operations”,
do not carry out works near high-voltage transmission lines at a
distance lower than 5 meters.
•Do not work in case of strong strom, with or without rain.
Explosion or burn hazards
•Do not use the machine near open ames or heat sources.
•Charge baeries in ventilated environment, far from heat sources
or explosive uids.
•Do not use the machine if there are oil leakage.

Description of the machine

19
IT10151 - IT12151
2
3
1
5
11
7
4
8
7
6
10
9
OPERATING AND MAINTENANCE HANDBOOK
Main components
1 - Truck
2 - Drive wheels
3 - Liing strucure:
IT10151 5 scissors 2 liing cylinders
IT12151 6 scissors 2 liing cylinders
4 - Fixed platform
5- Control box
6- Platform extension
7 - Baeries
8 - Ground control panel
9 -Electrical pumps
10 - Idler wheels
11 - Railings

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IT10151 - IT12151
7
3900
270
48/320 C5
IT10151
7
4400
270
48/320 C5
IT12151
OPERATING AND MAINTENANCE HANDBOOK
The data refer to the standard version.
Identication
A metallic plate xed to the truck contains all data necessary to iden-
tify the machine