INSTRUCTION MANUAL

Industrial Manipulators

360°

315°

360°
∞

Serial No.
----
DALMEC
Customer

POSIFIL - PF
®
 10

Original Instructions

MANUFACTURER

DALMEC S.p.A.
Via Gramsci, 2 - C.P. 104
38023 CLES (TN) - I
Tel: (0039) 0463-675111
Fax: (0039) 0463-421380 - 424450
dalmec@dalmec.it
www.dalmec.com

IDENTIFICATION DATA

Industrial Manipulator Posiplus

Type PPC
Serial No. ...
Construction year ...
Manual printed in Cles on ...
 Contents
1 RULES AND GENERAL WARNING
1.1 WARNINGS 8
1.2 INTRODUCTION 9
1.3 INFORMATION ABOUT THE MANUAL 9
1.4 USE OF ICONS 9
1.5 MEANING OF SYMBOLS 10
1.6 QUALIFICATION OF THE OPERATORS ASSIGNED TO THE MANIPULATOR 11
1.7 INDIVIDUAL PROTECTIVE DEVICES 12
1.8 SERVICE 12
1.9 SPARE PART ORDER 12
1.10 MAIN NORMATIVE REFERENCES 13

2 GENERAL DESCRIPTION AND TECHNICAL DATA

2.1 GENERAL DESCRIPTION OF THE MANIPULATOR 15
2.2 PERMITTED USE 15
2.3 OPERATING PRINCIPLE 15
2.4 STRUCTURAL CALCULATION - CERTIFICATIONS 15
2.5 EQUIPMENT ASSEMBLY DRAWING 16
2.6 TECHNICAL DATA 17
2.7 MARKING AND IDENTIFICATION 18
2.8 RESIDUAL EXHAUST 18
2.9 DEMOLITION OF THE MANIPULATOR 18

3 TRANSPORT AND INSTALLATION

3.1 PACKING 20
3.2 TRANSPORT 20
3.3 STORAGE 20
3.4 INSTALLATION 21
3.4.1 Fixing 21
3.4.2 Air connection 21
3.4.3 Rod reaction 21

4 ADJUSTMENT INSTRUCTIONS
4.1 PNEUMATIC ADJUSTMENTS 23
4.1.1 Supply pressure 23
4.1.2 No-load balancing 23
4.1.3 Load balancing 23
4.1.4 Preselector’s reference stops 24
4.2 MECHANICAL ADJUSTMENTS 25
4.2.1 Rotation stop 25
4.2.2 Joints brakes closing force 25
4.2.3 Handgrip adjustment 25

5 INSTRUCTION FOR USE

5.1 INSTRUCTIONS FOR USE 27
5.1.1 Permitted use of the Manipulator 27
5.1.2 Working cycle 27
5.1.3 Prohibited use 27
5.1.4 Controls diagram 28
5.1.5 Information on residual risks for the operator 28

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 5.1.6 Parking position 29

6 HAZARD ANALYSIS
6.1 RISK ASSESSMENT 31
6.1.1 Hazard analysis 31
6.1.2 List of the requirements, risks, rules and adopted solutions 33

7 SAFETY
7.1 SAFETY DEVICES 36
7.1.1 Non-return valve 36
7.1.2 Safety valve 36
7.1.3 Pneumatic reservoir 36
7.1.4 Closing device 37

8 MAINTENANCE AND TROUBLESHOOTING

8.1 ROUTINE MAINTENANCE 39
8.1.1 Information on residual risks for the maintenance operator 41
8.2 SCHEDULED MAINTENANCE 42
8.2.1 Cycle counter 43
8.3 SPECIAL MAINTENANCE 43
8.4 TROUBLESHOOTING 45
8.4.1 Pneumatic relay 46
8.5 CHECK REGISTERS 47

9 DIAGRAMS
9.1 PNEUMATIC DIAGRAM 52
9.2 LIST OF THE PNEUMATIC COMPONENTS 53

10 EC DECLARATION OF CONFORMITY

To avoid the incorrect and unpermitted use of the Manipulator, the instruction manual must always be
used and within the operator’s reach.

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1 RULES AND GENERAL WARNING

1
Rules and general warnings

This chapter describes the rules and the general warnings

for the correct use of the Manipulator, the qualifications
of the operators, the meaning of the symbols and general
information.
 1 RULES AND GENERAL WARNINGS

1.1 WARNINGS
● Do not use the Manipulator for the lifting or transport of persons and/or animals.
● The operator can use the Manipulator only after receiving precise instructions and a short training period.
● Do not lift loads heavier than the Manipulator max weight-capacity.
● Do not manipulate loads over persons.
● Manipulate only the products defined by contract.
● Only authorized people should stay within the working area of the Manipulator.
● When not in use bring the Manipulator to the parking position.
● Do not the use the Manipulator if it is damaged and report any wear and operating problem.
● Do not use the Manipulator if there are defects or irregularities relating to safety and working.
● Never disassemble, reassemble or dismantle your Manipulator without the supervision of Dalmec
authorized technicians.
● Make sure that the load is correctly positioned before releasing it.
● Use the Manipulator only as described in this manual.
● The operators must scrupulously follow what is reported in this manual and also adapt and observe the
general accident prevention rules enforced by the EC directives and by the legislation of the nation they
belong to.
● This manual must be complete and readable: every operator assigned to the use or maintenance of the
Manipulator has to know where the manual is kept and must have the possibility to consult it whenever
needed.
● It is severely forbidden to the customer/user or any third party to modify the Manipulator, its functions or
the present manual in any way.
● To prevent impacts and accidents, the working area must be defined and kept clear of obstacles.

Texts, images, technical data and information contained in this manual are subject of intellectual property rights of Dalmec SpA. It is forbidden
to copy or reproduce it, even partly, except as is strictly necessary for the use and maintenance of the machine to which it is related to.
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 RULES AND GENERAL WARNINGS 1
1.2 INTRODUCTION
This instruction manual is part of the Manipulator, therefore it must be kept for eventual future references until
the dismantling of the Manipulator.
The user is requested to keep this manual near the Manipulator, in a dry place, sheltered from the sun’s rays.
The instruction manual conforms with 2006/42/EC directives, enclosure I, 1.7.4. Should the manual be damaged
or unreadable in any of its parts, please request Dalmec immediately for a replacement copy.
Dalmec suggests the reading of this instruction manual to the personnel assigned to the use and the maintenance
of the Manipulator as well as the personnel assigned to transport and assembly operations.
This document is a property of Dalmec and without its own written authorization it may not be imparted to third
party or reproduced.
All rights reserved.

1.3 INFORMATION ABOUT THE MANUAL

All pneumatic parts (valves, push-buttons, safety devices) mounted on the Manipulator are numbered in order
to make their identification easier. This numbering is reported in the pneumatic diagram.
The instruction manual is structured according to this numbering: the reference number reported in the manual
indicates a component illustrated in the pneumatic diagram.

1.4 USE OF ICONS

In this instruction manual icons symbolize and identify types of operation, qualification of the operators, dangers,
etc...
For example, if an operation, like maintenance, requires the intervention of an operator, an icon indicates the
necessary qualification to perform it.
Icons and their meaning are listed in the following paragraphs.

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 1 RULES AND GENERAL WARNINGS

1.5 MEANING OF SYMBOLS

These symbols are used throughout the instruction manual in order to visually indicate hazard warnings.

This symbol appears next to all safety instructions. The non-observance to all instructions
relating to safety may cause severe damages to the Manipulator and/or to the operator.

Contact with live parts can result in immediate death.

Protective covers marked with this sign may only be opened by specialists and/or instructed
persons. Before opening the feed voltage must be disconnected.

Suspended loads: do not stop or transit near suspended load.

Risk of hands crushing: do not approach mechanical parts, that are moving or may start moving.

Risk of feet crushing: do not approach mechanical parts, that are moving or may start moving.

Do not handle the load, standing in front of the terminal arm.

Parts of the Manipulator may come into collision with the operator.

Do not insert the gripping control without the load to be handled.

Magnetic field

Hot surfaces

This symbol appears next to all important informations relating to the use of the Manipulator in
an Atex (hazardous area) environment.

Texts, images, technical data and information contained in this manual are subject of intellectual property rights of Dalmec SpA. It is forbidden
to copy or reproduce it, even partly, except as is strictly necessary for the use and maintenance of the machine to which it is related to.
10
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 RULES AND GENERAL WARNINGS 1
1.6 QUALIFICATION OF THE OPERATORS ASSIGNED TO THE MANIPULATOR
The operator assigned to the use and maintenance of the Manipulator must have the specific professional
qualifications for each operation to be performed. The operator must be trained and informed of the tasks
assigned to him.
It follows a description of the professional qualifications of the operators assigned to the Manipulator.
The symbol next to the description show the qualification necessary to perform the operation described.

First level operator

QUALIFICATION Operator able to perform only simple tasks, as operating the Manipulator in normal conditions.
1

Second level operator

QUALIFICATION Operator able to perform the tasks assigned to the first level operator, as well as easy adjustments
and setting up of the Manipulator.
2

Maintenance technician

QUALIFICATION
Qualified technician able to perform the tasks assigned to the first and second level operators, who
is also able to operate on the mechanical and pneumatic parts in order to carry out adjustments,
3 trouble shooting, maintenance and repair.

Dalmec technician

QUALIFICATION Person qualified by Dalmec to carry out complex operations.

4

Persons under the influence of substances which may affect their reactivity, must not operate,
adjust or carry out maintenance operations on the Manipulator.

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 1 RULES AND GENERAL WARNINGS

1.7 INDIVIDUAL PROTECTIVE DEVICES

The operator and the technician must wear suitable working clothes and personal protective devices when
using and carrying out maintenance of Manipulator.

Personal protective devices:

Mandatory devices
- safety shoes against the risk of fall of loads (if the Manipulator operates in a potentially explosive atmosphere,
wear protective and antistatic shoes)

Optional devices
- safety gloves against the risk of abrasions or cutting one’s hand (if necessary);

- safety glasses and masks against splinters, dust, fumes or exhalations (if necessary);

- auricular protections (ear plugs or earphones), if the acoustic pressure level in the working area is over 85
dB(A);

- helmet against the risk of collision with parts of the Manipulator (if necessary).

Working clothes
The operators must not wear loose clothing and jewellery (rings, bracelets, etc..) which may be caught up into
the mechanism.
In case of long hair, suitable hairnets or caps must be worn to avoid being entangled.

1.8 SERVICE
In case of problems or situations, which requires the intervention of a qualified technician, please call our
Service Department.

1.9 SPARE PART ORDER

If spare parts have to be ordered, please call Dalmec Spare Parts Office or our Service Department indicating
the Manipulator’s serial number written on the identification plate.
Only Dalmec spare parts are to be fitted, although section 7.2 lists original suppliers name and order code of
pneumatic parts approved by Dalmec as an alternative.

Texts, images, technical data and information contained in this manual are subject of intellectual property rights of Dalmec SpA. It is forbidden
to copy or reproduce it, even partly, except as is strictly necessary for the use and maintenance of the machine to which it is related to.
12
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 RULES AND GENERAL WARNINGS 1
1.10 MAIN NORMATIVE REFERENCES

Directive 2006/42/EC Machinery directive

Directive 2014/68/EU Pressure equipment

Standard EN ISO 12100:2010 Safety of machinery. General principles for design - Risk assessment and risk reduction

Standard EN 14238:2009 Cranes. Manually controlled load manipulating devices

Safety of machinery - Safety distances to prevent hazard zones being reached by upper and
Standard EN ISO 13857:2008
lower limbs

Standard EN ISO 13854:2020 Safety of machinery. Minimum gaps to avoid crushing of parts of the human body

Safety of machinery - Human physical performance - Part 3: Recommended force limits for
Standard EN 1005-3:2009
machinery operation

Standard EN ISO 4414:2012 Pneumatic fluid power. General rules and safety requirements for systems and their components

Safety of machinery. Guards. General requirements for the design and construction of fixed
Standard EN 14120:2015
and movable guards

Standard EN ISO 13850:2015 Safety of machinery. Emergency stop. Principles for design

Standard EN 574:2008 Safety of machinery. Two-hand control devices. Functional aspects. Principles for design

Standard EN 842:2009 Safety of machinery. Visual danger signals. General requirements, design and testing

Standard EN 1037:2008 Safety of machinery. Prevention of unexpected start-up

Safety of machinery - Ergonomic design principles - Part 2: Interactions between the design of
Standard EN 614-2:2009
machinery and work tasks

Standard ISO 8573-1:2010 Compressed air. Contaminants and purity classes

Standard EN ISO 13849-1: 2016 Safety of machinery. Safety-related parts of control systems. Part 1: General principles for design

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 2
General description and
technical data

This chapter illustrates the general description, the operating

principle, the main parts and the technical data of the
Manipulator.
 GENERAL DESCRIPTION AND TECHNICAL DATA 2
2.1 GENERAL DESCRIPTION OF THE MANIPULATOR
The Manipulator is a pneumatically actioned lifting equipment, that allows to have a level change of the load
being lifted. All the horizontal and vertical translations of the load in space, within the Manipulator action area,
are free and obtained by a direct action of the operator on the gripping tool or on the load.

2.2 PERMITTED USE

200Kg.
The Manipulator has been designed and manufactured to handle having a maximum weight of 80 Kg.
Only authorized personnel are allowed to stay within the working area of the Manipulator.
The Manipulator is not intended to operate in a potentially explosive atmosphere.

2.3 OPERATING PRINCIPLE

A pneumatic cylinder with a compressed-air feed, connected to a transmission system provides to lift the weight
applied. The cylinder force is controlled through two pneumatic circuits properly pre-set: the first one provides to
always maintain in a balanced condition the gripping and transmission system weight; the second one provides
to always maintain in a balanced condition the weight of the load.

2.4 STRUCTURAL CALCULATION - CERTIFICATIONS

The Manipulator structure has been designed for a theoretical resistance to fatigue and aging in the environmental
conditions reported in the technical data and observing the operating and maintenance instruction in this manual.
The structural dimensioning of the Manipulator is verified by our calculation software (Prod 11) and certified
by TÜV Nord which attests its compliance with current standards. Our production unit is EN ISO 9001- Quality
management systems - certified and our factories are EN ISO 14001 - Environmental management systems
- certified.

Texts, images, technical data and information contained in this manual are subject of intellectual property rights of Dalmec SpA. It is forbidden
to copy or reproduce it, even partly, except as is strictly necessary for the use and maintenance of the machine to which it is related to. 15
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 2 GENERAL DESCRIPTION AND TECHNICAL DATA

2.5 EQUIPMENT ASSEMBLY DRAWING

The main parts of the Manipulator and their respective names are shown in the following figure.

Mounting flange Mounting flange brake Main arm Pulley

Intermediate
Pneumatic box axis brake

Terminal arm

Compressed-air Rope
connection

Column

Tooling

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 GENERAL DESCRIPTION AND TECHNICAL DATA 2
2.6 TECHNICAL DATA

Mechanical specifications
Max weight-capacity 200 kg
Manipulator mass 330 kg
Max radius 3000 mm
Usable radius 3000 mm
Vertical lift 1900 mm
Max overall dimensions 2850 mm
Min overall dimensions 2480 mm
Rotation on the mounting flange axis ∞360°
Rotation on the intermediate axis 315°
Rotation on the tooling axis ∞360°

Pneumatic specifications
Supply fluid Filtered (40 µm), oil-free (with max 1mg/m³ of oil)
and dry compressed air (dew point +3 ºC).
In conformity with the air quality degree 5,4,3 of the
classification ISO 8573-1.
Supply pressure 0,8 Mpa
Consumption “at rest” 5 Nl/min
Max consumption per working cycle 60 Nl
Ejector consumption
Pneumatic motor consumption

Electric specifications
Supply -
Power -
Protection -
Explosion-proof -

Aerial noise and vibration

A-weighted emission sound pressure level 73 dB(A)
Measurement made on a similar Manipulator with the
sound level meter at a distance of 1mt from the
Manipulator and at 1.60 mt from the ground.

The hand-arm vibration on the handgrip is less than 2.5 m/s2.

Operating environmental conditions

Use the Manipulator in covered areas protected from atmospheric hazards, with the following
environmental conditions.
Temperature +0 ÷ +40°C
Relative humidity max 95%
Altitude max 1500 m/asl
Atmosphere Clean air, without abnormal quantities of dust, acid,
corrosive gas, salt etc.

Texts, images, technical data and information contained in this manual are subject of intellectual property rights of Dalmec SpA. It is forbidden
to copy or reproduce it, even partly, except as is strictly necessary for the use and maintenance of the machine to which it is related to. 17
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 2 GENERAL DESCRIPTION AND TECHNICAL DATA

2.7 MARKING AND IDENTIFICATION

Each Manipulator is identified with a metallic plate mounted on the pneumatic box indicating the information
about the CE mark.

Tampering, removal, absence of the identification plates makes any maintenance operation difficult.

Identification plate specifications

Identification plate
Material Aluminium
Dimensions 120 x 120 mm
Thickness 0,8 mm
Manipolatori Industriali Fixing way Rivets
Dalmec S.p.A.
Via A. Gramsci, 2 38023 CLES (Trento) - Italy
Telefono 0463/675111 - Telefax 0463/421380

Tipo Portata max Kg

Matricola N° Anno di costruzione

Pressione Voltaggio

Tampering, removal, absence of the identification plates makes any maintenance operation difficult.

2.8 RESIDUAL EXHAUST

The Manipulator emits air in the environment with the same characteristics of the compressed-air used to supply
it and periodically also water condensate (see par. 8.1).

2.9 DEMOLITION OF THE MANIPULATOR

If the Manipulator is no longer used, it is reccomended to make it inoperative.
The materials used to manufacture the Manipulator are mainly ferrous. Besides there are also aluminium or
alluminium alloys, which contain no more than 7.5% of magnesium, plastic and rubber materials.
The thickness of the paint of the Manipulator does not exceed the 0.2mm.
During the demolition of the Manipulator it is recommended to separate the above mentioned materials and to
dispose of them according to the applicable regulations in force.

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 3
Transport and installation

Some information about the packing, the transport and the

installation of the Manipulator are indicated in this chapter.
 QUALIFICATION

3 TRANSPORT AND INSTALLATION

3
Maintenance
technician

3.1 PACKING
The Manipulator is packed in a wooden crate, designed to hold and protect the Manipulator during transport.
Non painted metal surfaces are covered with protective grease.

A plate positioned visibly on the packing indicates the net/gross weight and the instruction for the handling of
the package.

GROSS WEIGHT KG. NET WEIGHT KG.

BEFORE HANDLING THE CRATE FIND THE

POSITION WITH MAX. STABILITY.
THE CENTER OF GRAVITY OF THE LOAD IS
NOT IN THE MIDDLE OF THE CRATE.

USE LIFT TRUCKS SUITABLE FOR HANDLING

THE ABOVE INDICATED WEIGHT HAVING
ADEQUATE OPENING AND LENGHT OF THE
FORKS THAT MUST STICK OUT AT LEAST 20
CM BEYOND THE CRATE.

STORE THE CRATE IN A CLEAN, DRY,

PROTECTED SITE.

UNPACKING AND INSTALLATION OPERATIONS

SHOULD BE DONE ONLY WITH THE SUPERVISION
AND FOLLOWING THE INSTRUCTIONS OF A
DALMEC TECHNICIAN (SEE BELOW).

3.2 TRANSPORT
Handle the crate only with a lift truck suitable for handling the weight indicated on the plate, with adequate
opening and length of the forks, which must remain at least 20 cm beyond the crate.

BEFORE HANDLING THE CRATE FIND THE POSITION WITH MAX STABILITY.
THE CENTRE OF GRAVITY OF THE LOAD IS NOT IN THE MIDDLE OF THE CRATE.

3.3 STORAGE
Store the packed Manipulator in a clean, dry, dust-free protected place.

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QUALIFICATION
4
Dalmec
technician
TRANSPORT AND INSTALLATION 3
3.4 INSTALLATION

Sm. 20x45°
3.4.1 Fixing
The Manipulator is supplied with base-plate as shown in the picture.
Four bolts for holes Ø25 should be used to fix the base-plate to the floor.

N°4 holes ø 25

475
400
3.4.2 Air connection
The compressed-air connection, as shown in the figure, is positioned: 400

- on the top of the column; 475

- or on the filter of the booster, if supplied;

- or on the top of the fork.

The connection is made with a 3/8” GAS fitting.

The Manipulator should be fed with filtered
(40 micron), dry and oil-free air with
Compressed-air
pressure and capacity as indicated in the supply on the top of
technical data. the fork

These instructions should be followed Compressed-air supply

before carrying out the connection: on the booster

- exhaust the air supply tube before

connecting it to the Manipulator
- adjust the regulator-filter group to
the correct pressure (see adjustment
instructions)
Compressed-air supply
- when finished check that there is no on the top of the
column
loss in the circuit, which may result in R
malfunction of the Manipulator.

3.4.3 Rod reaction

Rod reaction (R), due to the Manipulator mass and to the charge applied to it, is 6000N on each rod.

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 4 ADJUSTMENT INSTRUCTIONS

4
Adjustment instructions

The adjustments of the Manipulator are described in this

chapter.
 QUALIFICATION
2
Qualified
operator
ADJUSTMENT INSTRUCTIONS 4
During test and inspection, your Manipulator has been finely adjusted.
However, if necessary, we list the main adjustments to be done on your Manipulator for its correct operating.

4.1 PNEUMATIC ADJUSTMENTS

4.1.1 Supply pressure
- Pull the knob of the regulator (No. 9) to release it
and slowly turn it until the pressure gauge (No. 10) Supply pressure
Release
regulator
indicates 0.7 MPa. Push the knob to lock it. Lock

NB The Manipulator supply pressure must be dry, filtered

and oil-free.

Silencer
4.1.2 No-load balancing
Gauge
- Turn the button (No. 24) to disengage the brakes of

Pneumatic box
the Manipulator
- Pull the knob of the regulator (No. 8) to release it and
slowly turn it until the tooling remains balanced. Push Relay

the knob to lock it.

Supply pressure
gauge
4.1.3 Load balancing
- Turn the button (No. 24) to disengage the brakes of
the Manipulator
- Turn the regulator knob (No. 19) counterclockwise
Release
No-load balancing
until it stops, or until the pressure gauge (No. 20) pressure regulator Lock
indicates 0 MPa
- Hook the load making sure that the closing device is
correctly positioned
- Push the buttons (No. 17) to insert the load balancing
- Slowly turn the regulator knob (No. 19) clockwise until the load remains balanced.
NB Should the load weight change, the load balancing adjustment must be repeated for every variation of
weight.

() The numbering refers to the component reported in the pneumatic diagram (see par. 9.1)
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 QUALIFICATION

4 ADJUSTMENT INSTRUCTIONS
2
Qualified
operator

4.1.4 Preselector’s reference stops

- Loosen the fixing screws using a 3 mm setscrew
Position indicator
wrench
- Turn the preselector knob counterclockwise until it Reference B
Reference A
stops
- Grip the lower weight load
- Turn the preselector knob clockwise until the load
remains balanced
- Place the reference stop (A) close to the position
indicator (left)
- Position the load on its support point and release it
- Grip the heaviest load
- Turn the preselector knob clockwise until the load
remains balanced
- Place the reference stop (B) close to the position Fixing screws

indicator (right)
- Tighten the fixing screws.

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QUALIFICATION
3
Maintenance
technician ADJUSTMENT INSTRUCTIONS 4
4.2 MECHANICAL ADJUSTMENTS
4.2.1 Rotation stop
On the brake disk there are 12 equidistant holes. The following rotations are obtained by removing or inserting
the stops into the holes:

No. of Rotation on the Rotation on the Brake disk

Attention
rotation stops mounting flange axis intermediate axis

Make sure that

there are no tubes
0 ∞360° 315° or cables that may
twist around the
Manipulator
min 0° - 60°
1 350°
to max 0° - 285°
min. 0° - 60° min 0° - 60° Brake disk
2 Rotation stop
to max. 0°- 330° to max 0° - 255°

Adjustment holes

NB: Other holes can be done on the brake disk to obtain

rotation angles different from the ones listed above.

4.2.2 Joints brakes closing force

Brake unit
- Supply the Manipulator. Covering dowel

- Using a 3/16’’ hex. key unscrew the covering dowel

positioned on the back of the brake unit.
- Using a 6 mm spanner unscrew the adjustment screw
to bring the brake linings/pad near the brake disc or
screw it to distance them. Adjustment screw

- The correct distance between disc and pads is from 1

to 1,5 mm.
- Reposition the covering dowel in its seat.

4.2.3 Handgrip adjustment

- Loosen the inclination adjustment lever to change the
position of the control handgrip.

Inclination adjustment lever

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 5 INSTRUCTION FOR USE

5
Instruction for use

This chapter describes the correct use of the Manipulator and

the residual risks for the operator.
QUALIFICATION
1
Operator INSTRUCTIONS FOR USE 5
5.1 INSTRUCTIONS FOR USE
Operator to carry out visual inspection for anomalous air leaks of the Manipulator before every shift.

5.1.1 Permitted use of the Manipulator

The Manipulator has been designed and manufactured to handle having a maximum weight of 80 Kg.
Only authorized personnel are allowed to stay within the working area of the Manipulator.
The Manipulator is not intended to operate in a potentially explosive atmosphere.

5.1.2 Working cycle

- Turn the button (No. 24) to disengage the brakes of the Manipulator
NB Should the load weight change, repeat the load balancing adjustment (see par. 4.1.3)
NB Do not insert the load balancing without having hooked the load
- Hook the load making sure that the closing device is correctly positioned
- Push the buttons (No. 17) to insert the load balancing
- Handle the load
- Position the load on its support point.
Before releasing the load, make sure it has been positioned on its support point in a correct and stable
way. If the load has not been properly placed, it may fall to the ground.
- Push the buttons (No. 22) to disconnect the load balancing
- Unhook the load
- Push the button (No. 24) to brake the Manipulator if you stop using it
- At the end of the work, bring the Manipulator to the parking position (see par. 5.1.6).

5.1.3 Prohibited use

- Do not leave the Manipulator with the load during gripping.
- It is forbidden to use the Manipulator for the lifting or transport of persons and/or animals.
- Do not lift loads heavier than the Manipulator max weight-capacity.
- Do not handle products other than those indicated in the paragraph Permitted use of the Manipulator.
- Do not handle loads over persons.
- Do not use the Manipulator if there are defects or irregularities relating to safety and working.
- In case of anomalies, damages, injury or block, bring the Manipulator to the parking position (see par.
5.1.6) and do not use it until the resolution of the problem.

() The numbering refers to the component reported in the pneumatic diagram (see par. 9.1)
27
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 QUALIFICATION

5 INSTRUCTIONS FOR USE

1
Operator

5.1.4 Controls diagram

The drawing below shows the gripping tooling and the position of the control devices. The numbering
indicated refers to the number of the device reported in the pneumatic diagram (see par. 9.1).

Brake lever (No. 24) Load balancing pressure

regulator (No. 19)

Load balancing pressure

gauge (No. 20)

Load balancing
insertion button (n° 17)

Load balancing
disconnection button (n° 22)

5.1.5 Information on residual risks for the operator

The following hazards are present for the operator within the working area of the Manipulator:

Rischi residui

L'operatore non deve mai lasciare il Manipolatore con il carico in Possibile caduta del
Arresto normale
presa ed il dispositivo di arresto inserito. carico

Rischi dovuti alla L'operatore deve sempre posizionare il manufatto sul punto di
caduta o alla deposito in modo corretto e stabile prima di effettuare il rilascio. Un Possibile
proiezione di posizionamento scorretto può provocare la caduta a terra del schiacciamento
oggetti manufatto.

Rischi dovuti alla

movimentazione Non movimentare manufatti diversi da quelli indicati nell' Uso Possibile caduta del
di manufatti non consentito del Manipolatore carico
conformi

L'operatore deve accertarsi che l'area di lavoro sia priva di ostacoli

Movimento
Controllo dei che possano interferire con la normale conduzione del
incontrollato
movimenti Manipolatore. A lavoro ultimato portare la macchina in posizione di
dell'attrezzo di presa
fine lavoro.

Movimenti di
carichi durante la La movimentazione deve essere eseguita con calma.
movimentazione

() The numbering refers to the component reported in the pneumatic diagram (see par. 9.1)
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QUALIFICATION
1
Operator INSTRUCTIONS FOR USE 5
5.1.6 Parking position
As illustrated in the figure, the Manipulator is in the parking
position, when:

- no load is hooked
- the vertical excursion is at the lower end
- arms are bent at minimum radius
- the articulation brake system is engaged.

● To avoid damaging your Manipulator or other nearby

machinery or personnel, always bring the Manipulator to
the parking position when it is not in use.

() The numbering refers to the component reported in the pneumatic diagram (see par. 9.1)
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 6 HAZARD ANALYSIS

6
Hazard analysis

In this chapter, in conformity with the annex I of the Machinery

Directive 2006/42/EC, all the possible hazards categories
have been examined.
 ANALYSIS 6
6.1 RISK ASSESSMENT
6.1.1 Hazard analysis
In conformity with the annex I of the Machinery Directive 2006/42/EC, all the possible hazards categories have
been examined as follows:
● Mechanical hazards
● Electrical hazards
● Thermal hazards
● Hazards generated by noise
● Hazards generated by vibrations
● Hazards generated by materials and substances
● Hazards generated by neglecting ergonomic principles
● Hazards associated with environment in which the machine is used
● Hazards generated by the absence (temporary) and/or by the wrong positioning of the measure/instruments
regarding the safety
● Other hazards.

The intended use and any reasonably foreseeable misuse thereof have been evaluated, the hazards that can
be generated by the machinery and the associated hazardous situations have been identified according to the
UNI EN ISO 12100 standard.
For the risks assessment it has been used the 4x4 matrix R = P x I described below.
It has been assessed for each risk the Probability (P) of occurrence of possible damages.
The table below shows the criteria and the value assigned to factor (P).

Occurence probability scale

P Probability Evaluation criterion

- other similar facts have occurred

4 Almost certain
- its occurrence is practically certain
- other similar facts have occurred
3 Likely
- its occurrence would give rise to modest surprise
- its occurrence would require uncommon and unlikely circumstances
2 Possible - there have been very few similar facts
- you would be surprised if this happened
- its occurrence would require the concomitance of several unlikely events.
1 Unlikely - no similar facts have ever occurred
- you would be surprised if this happened

It has been assessed for each risk the severity of the impact (I) caused by the occurrence of the evaluated event.
The table below shows the criteria and the value assigned to factor (I).

Impact severity scale

I Impact Evaluation criterion

- accident / deadly disease

4 Extremely serious
- multiple fatal accident
3 Serious - injuries / serious illnesses (fractures, amputations, severe debilitations)
- incident that does not cause injuries and / or diseases
2 Medium
- minor injuries / illnesses (abrasions, small cuts)

1 Slight - slight damage

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 6 ANALYSIS

The risk (R) entity has been quantified using the formula R = P x I
The table below shows the different combinations between the impact and
the probability of occurence (risk assessment)

Risk assessment

Probability

1 2 3 4

1 1 2 3 4 Low

Impact severity 2 2 4 6 8 Medium

3 3 6 9 12 High

4 4 8 12 16 Very high

Prevention and protection.

The assessed risk (R) identifies the priority scale of the actions to be planned to reduce the risk

Timing

R Actions planning

R>8 - necessary corrective actions to be planned urgently

4≤R≤8 - necessary corrective and / or improvement actions to be planned in the short term
2≤R≤3 - necessary corrective and / or improvement actions to be planned in the medium term
R=1 - any measures to be considered during the review of the assessment

Safety-related parts of control systems - Determination of Required Performance Level (PLr)

Risk graph to determine PLr required for the safety function according to the standard UNI EN ISO 13849-1.

Risk parameters:
Low risk

S Severity of injury
S1 slight (normally reversible injury)
S2 serious (normally irreversible injury or death)

F Frequency and/or exposure to hazard

START F1 seldom-to-less-often and/or exposure time is
short
F2 frequent-to-continuous and/or exposure time is
long

P Possibility of avoiding hazard or limiting harm

P1 possible under specific conditions
High risk
P2 scarcely possible

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 ANALYSIS 6
6.1.2 List of the requirements, risks, rules and adopted solutions
From the analysis of the hazards that are present, the following applicable safety requirements have been found,
listed and codified according to the numeration indicated in the Machinery Directive, the residual risks and the adopted
solutions to reduce the remaining hazards. Furthermore, the PLr has been indicated according to the UNI EN ISO
13849-1 standard and the pictograms placed on the manipulator and in the instruction manual regarding the identified
residual risk.
Valutazione del rischio Valutazione del rischio residuo Pittogrammi
EN ISO 12100 EN ISO 12100 EN13849-1
Cod. Zona-Oper. Req/Rischio Effetto P G R
Soluzioni adottate P G R S F P PLr
Manuale Manipolatore

Tecnico Progettazione
1.1.5 montaggio della macchina Possibile 2 4 8 E’ stato predisposto un apposito imballo con indicato come 1 2 2 - - - N/A
Installazione ai fini della ribaltamento sollevare, con quale mezzo e la massa da sollevare.
movimentazione

Sicurezza ed
Operatore affidabilità dei I sistemi di comando montati sul manipolatore sono
1.2.1
3 3 9 conformi alla norma ISO 13849-1: 2008 Categoria 1 PL c. I 1 2 2 S1 F2 P1 b
Area di lavoro sistemi di
comando comandi si trovano sull’estremità del braccio terminale.

I dispositivi di comando sono ben visibili e facilmente

1.2.2
Operatore Dispositivi di 1 2 2 identificabili. L’operatore è in grado di assicurarsi 1 1 1 - - - N/A
Area di lavoro comando dell’assenza di persone nell’area di lavoro del
Manipolatore.

2 3 6 La macchina è dotata di freni per bloccare le articolazioni, 1 2 2 - - - N/A

1.2.4 Arresto pilotati da un apposito comando.

Possibile La macchina è dotata di freni per bloccare le articolazioni.

1.2.4.1 Arresto normale caduta del 3 3 9 Come indicato nel manuale non si deve abbandonare il 1 2 2 - - - N/A
carico manipolatore con il carico in presa ed il dispositivo di
arresto inserito.

La macchina è stata dotata di una riserva d’aria che

Guasto del Possibile permette di portare a termine l’operazione in corso. A
Operatore circuito di 3 3 9 riserva d’aria esaurita il Manipolatore si posiziona 1 2 2 - - - N/A
1.2.6
Area di lavoro schiacciame
alimentazione di nto lentamente a fine corsa inferiore. Il cinematismo di presa
energia non consente il rilascio del pezzo perchè di tipo
irreversibile.

Operatore Rischio di Con la macchina sono stati forniti i dati relativi ai carichi per
1.3.1 perdita di 3 3 9 1 2 2 - - - N/A
Area di lavoro un corretto dimensionamento dei tiranti.
stabilità

Operatore Rischi dovuti Possibile Il rischio di caduta di oggetti è legato all’operazione di

1.3.3 Area di alla caduta o schiacciame 3 2 6 presa e rilascio del carico. Per l’operazione di rilascio, 1 2 2 - - - N/A
presa/rilascio alla proiezione nto l’operatore deve accertarsi che il carico sia stato
di oggetti appoggiato sul punto di rilascio in modo corretto e stabile.

Rischi dovuti
Operatore alla Possibile Il Manipolatore è stato progettato e dimensionato per la
1.3.3a movimentazione caduta del 3 3 9 2 1 2 - - - N/A
Area di lavoro movimentazione di manufatti specifici e concordati.
di manufatti non carico
conformi

Operatore Rischi dovuti a Gli spigoli dove possibile sono stati arrotondati se
1.3.4 superfici, spigoli 1 3 3 necessario le parti potenzialmente a contatto con 1 1 1 - - - N/A
Area di lavoro
e angoli l’operatore sono stare rivestite con materiale soffice.

Rischi dovuti
Operatore agli elementi I comandi costringono l’operatore a mantenere le mani
1.3.7 2 2 4 sull’impugnature. Dove possibile gli elementi mobili sono 1 2 2 - - - N/A
Area di lavoro mobili (arti
superiori) provvisti di ripari o dispositivi di protezione.

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 6 ANALYSIS

Valutazione del rischio Valutazione del rischio residuo Pittogrammi

EN ISO 12100 EN ISO 12100 EN13849-1
Cod. Zona-Oper. Req/Rischio Effetto P G R
Soluzioni adottate P G R S F P PLr
Manuale Manipolatore

Rischi dovuti
Operatore agli elementi Il normale utilizzo del manipolatore impone all'operatore di
1.3.7a 2 2 4 porsi frontalmente all'attrezzo di presa. Gli arti inferiori non 1 2 2 - - - N/A
Area di lavoro mobili (arti
entrano in contatto con elementi in movimento.
inferiori)

Possibile I sistemi di fissaggio sono adeguati al tipo di riparo e alla

1.4.2.1 Ripari fissi schiacciame 3 3 9 mancanza di movimenti incontrollati (1.3.9). Garantiscono 1 2 2 - - - N/A
nto l’interferenza minima durante le attività di funzionamento
dei cinematismi e la visibilità necessaria all’operatore.

Non esiste rischio di caduta nella normale conduzione della

macchina. Per effettuare le operazioni di
Rischio di regolazione/manutenzione su parti non raggiungibili da
1.5.15
scivolamento, 3 3 9 terra, è fatto obbligo di utilizzare attrezzature di 2 1 2 - - - N/A
inciampo o sollevamento che rispondano alle normative vigenti sulla
caduta sicurezza nel luogo di installazione. E’ assolutamente
vietato appoggiare dispositivi di sollevamento (es. scale)
alla macchina.

Tecnico Manutenzione Gli interventi di manutenzione della macchina devono

1.6.1 3 2 6 essere effettuati da personale qualificato, osservando le 2 1 2 - - - N/A
manutenzione della macchina indicazioni del manuale istruzioni.

Accesso ai posti Per effettuare le operazioni di regolazione/manutenzione su

di lavoro e ai parti non raggiungibili da terra, è fatto obbligo utilizzare
1.6.2
Tecnico punti Possibile 3 2 6 attrezzature di sollevamento che rispondano alle normative 2 1 2 - - - N/A
manutenzione d'intervento caduta vigenti sulla sicurezza nel luogo di installazione. E’
utilizzati per la assolutamente vietato appoggiare dispositivi di
manutenzione sollevamento (es. scale) alla macchina.

Isolamento delle
1.6.3
Tecnico fonti di 2 2 4 Predisporre a monte della macchina una valvola 1 2 2 - - - N/A
manutenzione alimentazione di d’intercettazione per isolarla dall’alimentazione di energia.
energia

Pulitura delle Portare la macchina in posizione di fine lavoro, come

1.6.5 parti interne 2 2 4 1 2 2 - - - N/A
della macchina descritto nel Manuale Istruzioni. Staccare l’alimentazione.

2.1.1
Considerazioni 3 3 9 La macchina non è destinata a operare in ambienti per 1 2 2 - - - N/A
generali alimentari, cosmetici o farmaceutici.

Rischi dovuti Con la macchina sono state fornite istruzioni per un corretto
4.1.2.1 alla mancanza 3 4 1
2 uso, trasporto e ancoraggio. La macchina è dotata inoltre di 1 2 2 - - - N/A
di stabilità freni di stazionamento o catena antideriva.

Movimento I movimenti sono ottenuti mediante comando mantenuto

Operatore Controllo dei incontrollato dall’operatore. Sull'attrezzo di presa del Manipolatore è
4.1.2.6 2 2 4 stato posta un'avvertenza per la deriva provocata 1 2 2 S1 F2 P1 b
Area di lavoro movimenti dell'attrezzo
di presa dall'inserzione del bilanciamento a carico o in caso di
inserzione per sovrabilanciamento.

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 7 SAFETY

7
Safety

This chapter describes the most important safety devices

mounted on the Manipulator, how they work and how to be
checked.
 QUALIFICATION

7 SAFETY
3
Maintenance
technician

7.1 SAFETY DEVICES

List of the safety devices, how they operate and how to check them. Check inspections intervals are listed at
par. 8.2.
The control systems mounted on the manipulator comply
with the standard ISO 13849-1 Category 1 PL c.

7.1.1 Non-return valve

Should the supply of compressed-air fail, the non-
return valve prevents the reservoir from emptying.

● Check
Bring the Manipulator to the parking position
- Disconnect the compressed-air supply Non-return valve Compressed-air
supply
- Check that there is no loss on the return valve
Symbol of the non-return valve

7.1.2 Safety valve

This device considerably slows down the speed of
Safety valve
vertical drift of the tooling with or without load.
It avoids dangerous conditions should the operator
give the wrong command, for example: giving the
gripping command before having hooked the load, or
giving the release command before having positioned
the load on a firm surface

● Check
- Moving the gripping tool up and down very quickly,
you should notice a decreasing speed of the Symbol of the safety valve

movement.

7.1.3 Pneumatic reservoir

It is an air reserve that allows the operator to position
the load safely, in case of sudden compressed-air
supply interruption.

● Check
No check is needed Reservoir

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QUALIFICATION
3
Maintenance
technician SAFETY 7
7.1.4 Closing device
This device on the hook prevents the accidental release of the
Closing device
load or the applied tooling.

u Check
Check if the device returns to the closing position

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 8 MAINTENANCE AND TROUBLESHOOTING

Maintenence and
8
troubleshooting

This chapter describes the actions of routine, scheduled and

special maintenance and also a careful troubleshooting of the
most important malfunctions.
QUALIFICATION
3
Maintenance
technician
MAINTENANCE AND TROUBLESHOOTING 8
8.1 ROUTINE MAINTENANCE

Before carrying out maintenance operations, bring the manipulator to the parking position, disconnect the
pneumatic and electrical supply from the manipulator, unless otherwise indicated.

Check the Manipulator bolts and screw

- With a torque wrench check the bolts and screws of the Manipulator, of the gripping tooling and of the
suspension system: trolley - tracks - motorization (if present), verifying that the value of the tightening
torque corresponds to the one listed below:

Bearing bolts

Brake unit

Screws

Check that the ring nut (A) is tightly fastened

Resistance class 8.8 in conformity with UNI-3740

Nominal Tightening Nominal Tightening

diameter torque in Nm diameter torque in Nm

M6 10 M18 290

M8 25 M20 410

M10 50 M22 560

M12 85 M24 710

M14 140 M27 1050

Screws
M16 210 M30 1420

M14 100
For bearing bolts only
M16 130

█ If the Manipulator is fixed to the floor by fasteners, refer to the tightening torque recommended by the
manufacturer

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 QUALIFICATION

8 MAINTENANCE AND TROUBLESHOOTING

3
Maintenance
technician

Remove the condensate from the reservoir

- Bring the Manipulator to the parking position
Exhaust valve Reservoir
- Disconnect the air supply line
- Place a small container under the exhaust valve
- Turn the exhaust valve knob counterclockwise to
remove the condensate from the reservoir
- When finished, turn the knob clockwise to close the
exhaust valve
- Connect the supply line.

Cleaning of the silencers

- Clean the silencer on the pneumatic cylinder, on the
relay and/or on the tooling by blowing in compressed-
air.

Check the brake system

- Check the wear condition of the pads mounted on the Silencer
brake units and replace them if necessary.
To replace the pads, proceed as follows:
- Bring the Manipulator to the parking position
- Release the brakes of the Manipulator
- Do not disconnect the compressed air supply from
Brake unit
the brakes on the joints of the Manipulator
Brake pads

Joints brake unit

- Insert the screwdriver into the hole, disconnect and
tap the pneumatic connection
- Unscrew the brake unit from the Manipulator
- Unscrew the pads and replace them (see drawing)
- Screw the brake unit back onto the Manipulator

Up/down brake unit

- Unscrew the brake unit from the Manipulator
- Insert a screwdriver between pad and its housing, pry on the screwdriver to remove the pad
- Insert the new pad and screw the brake unit back onto the Manipulator
For brakes adjustment see chap. 4.2

Check the pneumatic circuit

- Carry out a general check of the fittings and hose, checking that the connections are fastened tightly and
that there is no air loss.

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QUALIFICATION
3
Maintenance
technician
MAINTENANCE AND TROUBLESHOOTING 8
Check rope and pulleys
- Check for wear and tear on the rope and pulleys and,
if necessary, replace them (see rope check register
par 8.5). Pulleys
Rope

8.1.1 Information on residual risks for the maintenance operator

Rischi residui

Il manutentore deve essere un tecnico qualificato, vedi qualifica

Manutenzione degli operatori, e deve attenersi alle indicazioni del manuale
della macchina istruzioni. Prima di eseguire le operazioni di manutenzione portare
il manipolatore nella posizione di fine lavoro.

Accesso ai posti di
lavoro e ai punti
Utilizzare una piattaforma o un apposito ponteggio per operare a
d'intervento Possibile caduta
livelli più alti non raggiungibili da terra.
utilizzati per la
manutenzione

Isolamento delle
fonti di
Isolare il manipolatore dalla fonte di energia pneumatica/elettrica.
alimentazione di
energia

Il manutentore deve operare con estrema prudenza per evitare

Intervento Possibile
rischi di schiacciamento delle dita durante la verifica dei dispositivi
operatore schiacciamento
di sicurezza / sensore presenza pezzo.

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 QUALIFICATION

8 MAINTENANCE AND TROUBLESHOOTING

3
Maintenance
technician

8.2 SCHEDULED MAINTENANCE

A suitable planned maintenance schedule is a prerequisite requirement for safety, Manipulator life and
correct operating. For this reason we recommend a list of controls and actions to be carried out only by
maintenance staff.
If the Manipulator is not often used, less than 50.000 working cycles per year, carry out the check of the
safety devices and the routine maintenance operations once a year.

Every 50.000 Every 150.000 Every 300.000

Safety devices check working cycles working cycles working cycles

Non-return valve *
Safety valve *
Anti-release valve *
Piloted non-return valve *
Pressure limiter *
Bimanual control *
Stop valve *
Lock device *
Double vacuum circuit *
Sound device *
Closing device *

Anti-fall device in case of electric power loss *

• For the type of device mounted and how to check it, please refer to chap. 7

Every 50.000 Every 150.000

Routine operations working cycles or working cycles or
once a year once a year

Check that bolts and screws of the Manipulator, of the gripping tooling and of the possible
*
suspension system and motorization are tightly fastened
Remove the condensate from the pneumatic reservoir using the special tap *
Cleaning of the silencers (if the manipulator working environment is dusty, servicing intervals
*
should be shorter)
Check the brake system *
Carry out a general check of the fittings and hose, checking that the connections are fastened
*
tightly and that there is no air loss
Check for wear and tear on the rope and pulleys *

█ In case of replacement of spare parts important for health and safety it is necessary to use Dalmec original
spares. For the part specifications refer to the list of the pneumatic components (see par. 9.2).
█ When ordering spare parts, please refer always to the Manipulator serial number.
█ Should replacement prove difficult, please call Dalmec Maintenance Service or Dalmec authorized
technicians.

42
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QUALIFICATION
3
Maintenance
technician
MAINTENANCE AND TROUBLESHOOTING 8
8.2.1 Cycle counter
000000000

- Inside the pneumatic box there is a counter which counts the working
cycles.
000000000

Cycle indicator

Pneumatic box

8.3 SPECIAL MAINTENANCE

Balancing cylinder overhaul
Replace the balancing cylinder seals, lubricate the internal
barrel of the cylinder and the sealing gaskets, applying a
thin layer of grease on the parts.
Type: Semi-synthetic grease POLYMER 400/000 with
Liquilon (Dalmec code 36.01.0025). 1 Piston
2 Rod
Quantity: 5cc. 3 Barrel

Replacement of the rope

1. Position the tooling on a platform, disconnect the air supply
Pulley cover
and tooling from the supporting ropes. casing
Pneumatic box

2. Unscrew the fixing screws of the pneumatic box and

slowly remove it. Rope cover casing
Transport hook

3. Unscrew the fixing screws of the rope cover casing, Supporting bolts
Spacers
transport hook and pulley cover casing, and remove all.

4. Disconnect the pneumatic connection from the safety

valve and unscrew it from the balancing cylinder. Safety valve

Pneumatic
box fixing Balancing cylinder
5. Remove the balancing cylinder supporting bolt. screw supporting bolts

6. Remove the spacers. Should you have any difficulty, Rope holder screws
loosen the Manipulator supporting bolts and repeat the
operation once again.
Supporting structure

Rope holder

Balancing cylinder

When ordering spare parts, please refer always to the Manipulator serial number.
█
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 QUALIFICATION

8 MAINTENANCE AND TROUBLESHOOTING

3
Maintenance
technician

7. Remove the balancing cylinder from the support structure,

Ropes
keeping the ropes in the special slot to avoid that they twist
and lock the exit of the cylinder. Slot rope
passways

Supporting structure
8. Unscrew the rope holder screws and pull out the rope.

Balancing
9. Bend the new rope in two parts and lock it in the holder. cylinder
To facilitate the rope winding, clearly mark the rope ends with
Fig. 4
different color tapes.

Rope way: Holder -A-B-C-D

10. Starting from the holder, wind the rope as indicated in the
picture. Carefully follow the arrows. Do not braid the rope ends. B A

D C

11. Grease the side spherical holders

Type of grease: AGIP -GR MU/EP2
Rope holder Spherical holder

12. Insert the rope through the passways.

Position the balancing cylinder in the support structure pulling B A
the rope to avoid its fleeting. Keep the ropes in the special slot
(fig. 4) to avoid that they twist and lock the enter of the cylinder.
Insert the supporting bolts of the balancing cylinder.
Insert the spacers.
Pull the nuts of the bearing bolts, if they are loosened (M14 tightening torque 100 Nm) (M16 tightening torque
130 Nm).
Insert the safety valve.
Mount the pneumatic box. Rope passways

Position the rope cover casing.

Position the pulley cover casing.
Hook the tooling.
Connect the compressed air supply.

13. Insert the rope in the rope terminal: the rope end must
come out from the short shoulder of the rope terminal.
Rope
Insert the wedge to lock the sliding of the rope.
Rope end
Position the hook, insert the pin and its cotter.
Wrap the rope end with tape.
Rope terminal
Rope terminal short
shoulder
Rope terminal long
shoulder

Wedge

44
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QUALIFICATION
3
Maintenance
technician
MAINTENANCE AND TROUBLESHOOTING 8
8.4 TROUBLESHOOTING
List of the main problems causing the Manipulator to malfunction, why they occur and the actions to be taken.
If your problems are other than the ones listed herein, call Dalmec Maintenance Service or Dalmec Authorized
Technicians.

Problem - Main causes Intervention Ref. pneumatic

diagram

The Manipulator does not balance without load

Adjust the supply pressure through the regulator-filter-
The supply pressure is lower than required 9
group
The regulator-filter group is broken Replace the regulator-filter group 9
The no-load balancing is not well adjusted Adjust the no-load balancing regulator 8
The no-load balancing regulator is broken Replace the no-load balancing regulator 8
The non-return valve is inefficient Clean or replace the valve 14
Sensible loss from the pneumatic cylinder Replace the seals on the balancing cylinder 1
The silencer positioned on the relay is inefficient Check the silencer and, if necessary, replace it 3
The pneumatic relay is inefficient Check the relay 6
Loss from the pneumatic circuit Replace the leaky fittings or hose
The pressure selector is inefficient Replace the selector 7

The Manipulator does not balance with load

Adjust the supply pressure through the regulator-filter-
The supply pressure is lower than required 9
group
The regulator-filter group is broken Replace the regulator-filter group 9
The load balancing is not well adjusted Adjust the load balancing regulator 19
The load balancing regulator is broken Replace the load balancing regulator 19
The non-return valve is inefficient Clean or replace the valve 14
Sensible loss from the pneumatic cylinder Replace the seals on the balancing cylinder 1
The silencer positioned on the relay is inefficient Check the silencer and, if necessary, replace it 3
The pneumatic relay is inefficient Check the relay 6
Loss from the pneumatic circuit Replace the leaky fittings or hose
The pressure selector is inefficient Replace the selector 7
The lever valve is inefficient Replace the valve

The Manipulator does not insert the load balancing

The pushbutton is inefficient Replace the pushbutton 17
The impulse valve is inefficient Replace the valve 23

The Manipulator does not disconnect the load

balancing
The pushbutton is inefficient Replace the pushbutton 22
The impulse valve is inefficient Replace the valve 23

The brake system does not operate

The brake pushbutton is inefficient Replace the pushbutton 24
The distance between pads and brake disk is out- Adjust the distance between the pads and the brake disk,
of-adjustment or the pads are worn. as described in the manual, or replace the wear pads

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 QUALIFICATION

8 MAINTENANCE AND TROUBLESHOOTING

3
Maintenance
technician

8.4.1 Pneumatic relay

The pneumatic relay is the most important valve which enables the balancing of the equipment with or without
load. Its abnormal working involves a bad working of the whole manipulator. The principal malfunctions are
analyzed in the table below.

Pneumatic relay

Exhaust connection
Main valve

Vent

0.3 mm hole

Nozzle

Problem Check Cause Action

No air passing trough Remove the nozzle and clean the 0.3 mm hole using a very
the vent. thin copper wire or a needle and then blow in compressed-
The exhaust pressure The nozzle is clogged. air. If the nozzle can not be fully cleaned, replace it with a
can not be adjusted. new one. If not available, use the regulator with the nozzle
The exhaust pressure slightly loosened.
can be adjusted
loosening the nozzle.

Too much dust in the seat of the

Remove the valve from its holder and clean its seat.
main valve or in the exhaust valve.

Too much air comes There is a loss over 2

NL/min although there is
out of the exhaust
no exhaust due to back The seat of one of these valves is
connection.
pressure. damaged.
Replace the relay.
Irregular contact of the exhaust
valve.

Remove the nozzle and clean the 0.3 mm hole using a very
The exhaust pressure
The exhaust pressure The nozzle has been blocked thin copper wire ar a needle and then blow in compressed-
settles by loosening the
is unstable. beyond the limit. air. If the nozzle can bot be fully cleaned, replace it with a
nozzle.
new one.

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QUALIFICATION

Maintenance
technician
3
MAINTENANCE AND TROUBLESHOOTING 8
8.5 CHECK REGISTERS

Register of scheduled and special maintenance actions

Manipulator serial No. Check executor Date

- For the type of device mounted and how to check it, please Efficiency Malfunctions noticed -
refer to chap. 7 YES NO comments
Non-return valve
Safety valve
Safety devices check

Anti-release valve
Piloted non-return valve
Pressure limiter
Bimanual control
Stop valve
Lock device
Double vacuum circuit
Sound device
Closing device
Anti-fall device in case of electric power loss

Carried out Malfunctions noticed -

- For the routine maintenance instructions see par 8.1
YES NO comments
Removal of the condensate
Clean the silencers
Check the brake system
Check the pneumatic system
Check that bolts and screws of the manipulator and of the possible
suspension system are tightly fastened
Check the shelters or the protective devices
Check of the gripping suction cups
Check the covering of the gripping jaws
Routine actions

Check the load presence sensor

Check the gripping mandrel
Cleaning of vacuum filter
Check of the gripping references
Check of the gripping jaws kinematic motion
Cleaning of drum filter
Cleaning of bag filter
Check the booster
Check the oil in the reducer and in the motorization’s lubricator
Check the rack-pinion assembly
Check the ropes and pulleys
Check the earth bonding
Cleaning of the Manipulator
Cleaning of the magnet
Lubrication of the rack-pinion assembly

Carried out Malfunctions noticed -

- For the maintenance instructions see par 8.3
YES NO comments
Special
actions

Balancing cylider overhaul

Rotating joint overhaul
Replacement of the rope

Presence of the identification plate

General

Identification of controls
actions

Quality and cleanliness of the air supply

Electric supply line (where it is present)
Electric harness (where it is present)

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 QUALIFICATION

8 MAINTENANCE AND TROUBLESHOOTING

3
Maintenance
technician

Six-monthly register of the indicative number of working cycles

Indicative No. of working

Period from... to... Comments and signature
cycles

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QUALIFICATION
3
Maintenance
technician
MAINTENANCE AND TROUBLESHOOTING 8
Rope check register

ROPE SPECIFICATIONS
Description: stainless steel
Minimum breaking load: 8,5 KN
Rope type: 18 x 7 Duty load (max capacity + tooling weight) Kg ...........
Construction: 18 x 7 + WSC
Rope winding direction: right
Rope winding type: crossed
Nominal diameter: 4 mm
Duty starting date:
Quality: AISI 316 Measured diameter: mm ............
Core: metallic With a charge of: Kg .............
Rope lenght: 24000 mm

External wire External wire General Demage and

Corrosion
breaks abrasion evaluation deformations
Rope diameter No. of measured
Date Signature
Number out of a reduction% sections
Deterioration Deterioration Deterioration
section long six Nature
degree* degree* degree*
times the ø

Further observations:
* In this column indicate: null, slight, medium, very serious, replacement.
The rope check or replacement criteria are in conformity with ISO 4309 rule.

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9 DIAGRAMS

9
Diagrams

The pneumatic and/or electric diagram with the relative lists

of components are illustrated in this chapter.
9.1 PNEUMATIC DIAGRAM
 DIAGRAMS 9
9.2 LIST OF THE PNEUMATIC COMPONENTS

Ref. Qty Description Dalmec code Producer Producer code

1 1 Cylinder ass. D100 H460 Posifil double rope 00.08.0325 DALMEC S.p.A. 00.08.0325
2 1 Safety valve 2 00.79.0024 DALMEC S.p.A. 00.79.0024
3 1 Silencer 3/8” M model AN 20.17.0024 SMC AN30-03
4 1 Impulse counter 8 figures without reset 00.79.0381 DALMEC S.p.A. 00.79.0381
5 1 Pressure gauge D40 1/4”G 0>1 MPa / 0>145 psi 00.79.0095 DALMEC S.p.A. 00.79.0095
6 1 Pneumatic relay 1/2” G - piloted 00.79.0510 DALMEC S.p.A. 00.79.0510
7 1 Selector OR 1/4” 00.79.0308 DALMEC S.p.A. 00.79.0308
8 1 Precision regulator 1/4”G 0\>0.4 MPa 00.79.0484 DALMEC S.p.A. 00.79.0484
9 1 Filter regulator 3/8” 00.79.0312 DALMEC S.p.A. 00.79.0312
10 1 Pressure gauge D50 1/8”G 0\>1 MPa / 0\>145 psi 00.79.0085 DALMEC S.p.A. 00.79.0085
11 1 Quick exhaust 1/8” G tube D4 00.79.0666 DALMEC S.p.A. 00.79.0666
12 1 Quick exhaust 1/8” G tube D4 00.79.0666 DALMEC S.p.A. 00.79.0666
13 1 1-way 3/8” joint G- M-16x1.5 00.52.0063 DALMEC S.p.A. 00.52.0063
14 1 Non-return valve 3/8” gas 00.79.0086 DALMEC S.p.A. 00.79.0086
15 1 Brake group 00.34.0203 DALMEC S.p.A. 00.34.0203
16 1 Brake group 00.34.0203 DALMEC S.p.A. 00.34.0203
17 1 Black button 00.91.0270 DALMEC S.p.A. 00.91.0270
18 1 3/2 way valve D4 N/C 00.79.0607 DALMEC S.p.A. 00.79.0607
19 1 Pre-selector disc D85 00.79.0157 DALMEC S.p.A. 00.79.0157
20 1 Pressure gauge D40 1/8”G 0>1 MPa / 0>145 psi 00.79.0084 DALMEC S.p.A. 00.79.0084
21 1 3/2 way valve D4 N/C 00.79.0607 DALMEC S.p.A. 00.79.0607
22 1 Red button 00.91.0315 DALMEC S.p.A. 00.91.0315
23 1 Base D4 + preferential bistable valve P10.5 00.79.0461 DALMEC S.p.A. 00.79.0461
24 1 Red mushroom pushbutton with detent D=40 00.79.0207 DALMEC S.p.A. 00.79.0207
25 1 3/2-way panel mounting valve D4 NO 00.79.0220 DALMEC S.p.A. 00.79.0220
26 1 Quick exhaust valve one touch fitting D4 20.28.0032 SMC 240F-04-00

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 10 EC DECLARATION OF CONFORMITY
10
EC Declaration of Conformity
(Ann. IIA DIR. 2006/42/EC)