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Leguan 165 Operator'S And Service Manual Download Page 3

 

     

 

        3 

 
_________________________________________________________________________________                                                    

15.10

 

A

DJUSTMENTS OF THE 

H

YDRAULIC SYSTEM

 

37

 

15.11

 

O

VERLOAD CONTROL COMPONENTS

 

38

 

15.12

 

E

LECTRIC SENSORS

 

39

 

15.13

 

T

ESTING OF SAFETY VALVES

 

41

 

16. REPAIR INSTRUCTIONS 

42

 

16.1

 

W

ELDING

 

42

 

17. INSTRUCTIONS FOR TEMPORARY STORAGE 

42

 

18. INSTRUCTIONS FOR DISPOSING OF THE MACHINE 

42

 

19. TROUBLESHOOTING 

43

 

20. PERFORMED SERVICES 

46

 

 

 
 

Attachments: 
Hydraulics schema 
Electric diagram 

 

 

 

Summary of Contents for 165

Page 1: ...Operator and Service Manual 2016 Edited 06 11 2018 165 ...

Page 2: ...at ground level 17 6 2 4 230V Connection and switches Option 18 6 2 5 Lower control panel Option 18 6 2 6 Safety functions override in emergency situations 19 7 STARTING THE ENGINE ELECTRIC MOTOR 20 7 1 ADDITIONAL INSTRUCTIONS FOR WINTER USE 21 8 DRIVE CONTROL 22 8 1 DEFINING THE GRADIENT OF THE SLOPE 23 8 2 CRAWLER TRACK CHASSIS 23 8 2 1 Instructions for working environment 24 8 2 2 Operating ins...

Page 3: ...M 37 15 11 OVERLOAD CONTROL COMPONENTS 38 15 12 ELECTRIC SENSORS 39 15 13 TESTING OF SAFETY VALVES 41 16 REPAIR INSTRUCTIONS 42 16 1 WELDING 42 17 INSTRUCTIONS FOR TEMPORARY STORAGE 42 18 INSTRUCTIONS FOR DISPOSING OF THE MACHINE 42 19 TROUBLESHOOTING 43 20 PERFORMED SERVICES 46 Attachments Hydraulics schema Electric diagram ...

Page 4: ...ure optimum safety The manufacturer does not warrant any damages which are the result of using the access platform It is not possible to give explicite operating instructions to all operating conditions of the machine Therefore the manufacturer is not responsible for any damage caused by eventual faults in this Operators Manual The manufacture does not accept any responsibility for consequential l...

Page 5: ...loads on the access platform sudden unexpected incident natural disaster damages caused by external mechanical or chemical reasons paint damages especially caused by stone chips air and environmental pollution and strong cleaning agents eventual visible patterns or unevenness of painted surfaces warranty claims that haven t been sent to the manufacturer within 14 days from the date the buyer has n...

Page 6: ...TIIVIN VAATIMUKSET 2004 108 EY THE MACHINE ALSO FULFILLS THE REQUIREMENTS LAID OUT IN THE DIRECTIVES 2004 108 EY SEURAAVIA EUROOPPALAISIA YHDENMUKAISIA STANDARDEJA ON SOVELLETTU SUUNNITTELUSSA EN280 2015 FOLLOWING EUROPEAN HARMONIZED STANDARDS ARE USED WHEN THE MACHINERY WAS DESIGNED EN280 2015 Teknisen tiedoston on valtuutettu kokoamaan LEGUAN LIFTS OY Storage address of original documents Ylötie...

Page 7: ...ms standars The picture below Picture 1 shows the main parts of this access platform 1 Chassis 2 Transmission either with wheels or with crawler tracks 3 Outrigger 4 Outrigger cylinder 5 Slewing ring 6 Connection box of control system with emergency lowering buttons 7 Lower controls option 8 Self levelling bar 1 9 Pedestal 10 Lift cylinder 11 Lower boom 1 12 Valve box 13 Linkage piece 1 14 Self le...

Page 8: ... _________________________________________________________________________________ Picture 1 Leguan 165 Access Platform main parts 26 25 24 22 23 21 19 20 27 18 17 16 15 14 13 12 11 10 9 8 6 5 4 7 1 3 2 ...

Page 9: ...s W x L 2 persons Platform rotation 1330 x 750 mm 45º Slewing 360º Gradeability 35 20º Max allowed levelling inaccuracy 1 0º Support dimensions outrigger spread 3464 x 3453 mm Max gradient of slope for set up 21 12 0º Weight depending on equipment 2520 2600 kg Drive system 4WD or rubber tracks Drive speed max 2 6 km h Speed when drive motors connected in series max 5 2 km h Lowest operating temper...

Page 10: ...10 _________________________________________________________________________________ Picture 2 Reach diagram Picture 3 Support dimensions ...

Page 11: ...ontal force and wind speed 12 Distance from energized 4 General user instructions electric wires 5 Daily inspection 13 Tie down points 6 Always use outriggers 14 Tyre pressure 7 Symbol stickers pictograms of controls 15 LEGUAN 165 sticker 8 Emergency lowering 16 Lower controls stickers 9 Residual current device 17 Lift points 4 points Picture 4 Leguan 165 signs and stickers 3 4 5 7 6 8 9 2 1 10 11...

Page 12: ...RLY CONNECTED TO THE PLATFORM 5 1 Before starting operation All warnings and labels must be read carefully Only persons with min 18 years of age are allowed to use the access platform They must have received sufficient operating instrucions Operator must know all the functions of this access platform as well as the Safe Working Load loading instructions and safety instructions If there is heavy tr...

Page 13: ...will weaken the stability of the access platform Weight must be equally distributed on the platform Make sure that additional weight cannot shift on the platform Do not drive on gradients that are steeper than the max values given for this access platform and for the slope Never use this access platform as a crane or an elevator This access platform is intended for lifting of the max allowed numbe...

Page 14: ...with voltage carrying parts or when approaching them Do not touch the machine if it comes in contact with voltage carrying electric line Persons on the platform or at ground level must not touch or operate the platform before power has been cut off from the electric line During welding repairs it is not allowed to use any part of this access platform as earth conductor Do not use this access platf...

Page 15: ... in a place where the ground may be too soft Beware of soft grounds and potholes in particular 5 8 Use of emergency stop switches To use an emergency stop or killswitch just press down the switch s red cap Picture 5 9 Killswitches are used in emergency situations when normal shutting down procedures are not possible For example in accidents and other dangerous situations involving the lift or its ...

Page 16: ...rol lever telescope boom 13 Control lever jib boom 14 Control lever platform tilting 15 Drive speed selector switch option 16 Outrigger monitoring override button 17 Horn option 18 Control panel platform worklight switch option 19 Emergency lowering selector and button 20 Engine overheating indicator 21 Boom center position indicator Slewing 22 Engine oil pressure indicator Outrigger monitoring ov...

Page 17: ...oms are not in transport position 6 2 2 Controls on the control valve box at ground level 1 Drive control levers 2 Water level 3 Hand throttle 4 Outriggers in support position indicator 5 Outrigger blinkers on off switch option 6 Outrigger control levers Picture 6 Controls on control valve box 6 2 3 Emergency lowering buttons at ground level 1 Hour meter 2 Emergency lowering selector switch and bu...

Page 18: ... Diesel engine or electric motor option 4 Glow indicator diesel 5 Platform overload indicator 6 Dead man button option 7 Emergency stop switch 8 Outrigger monitoring or Emergency stop platform load monitoring override switch 9 Lower boom lever 10 Upper boom lever 11 Slewing lever 12 Telescope lever 13 Upper boom lever Picture 9 Lower controls Use of lower controls 1 The ignition switch at main ele...

Page 19: ... platform when the platform has tilted down in long term storage and outriggers cannot be used safely The switch has to be held turned to desired function see first line during which the booms can be operated Safety functions override switch can only be used in extreme emergencies for example if lifts operator has lost consciousness in the platform emergency stop switch has been pressed and the op...

Page 20: ... the switch if it is switched on Fasten safety harnesses on the fastening points at platform mounting bracket and close the gate Select desired propelling with the switch no 2 at platform electric motor combustion engine see page 15 picture 5 and select slower drive speed If electric motor is selected start the electric motor by turning the ignition switch to the Start position to the right Starti...

Page 21: ... in addition to the normal actions when starting to use the lift 1 Check that the limit switches are free from snow ice and dirt 2 See page 20 Starting of combustion engine for instructions on starting the engine in cold weather 3 Let the engine run for a few minutes before moving the machine 4 First use drive mode for a while then use outriggers and lastly use the booms This way the oil in the wh...

Page 22: ...ers of the drive control valve see page 16 By pushing the left lever left side wheels turn forward by pulling the lever left side wheels turn backward Right side wheels turn in the same manner by pushing and pulling the right side lever 4 Turning of the machine is based on the skid steer principle When you want to turn the machine either to the right or to the left push pull the drive control leve...

Page 23: ...king The operator can increase the lifespan by following the below mentioned operating and maintenance instructions If the access platform is being used in terrains with stones or gravel on demolition sites where there is concrete or in an environment with scrap metal the lifespan of the track system can be significantly reduced Because of this damages on the tracks track rollers or crawler track ...

Page 24: ...xizide the metal parts in rubber tracks If such substances come in contact with the surface of the rubber track the tracks must be flushed with water immediately after ending operation 8 2 2 Operating instructions Change turning direction as often as possible Turning continuously only in one direction will cause uneven wear of the sprocket and the rubber track Check condition of the track system r...

Page 25: ...ground if necessary 4 Drive the outriggers down on the ground firmly enough They must be driven down so much that all wheels lift off the ground Usually it is not necessary to push the outriggers further unless it is necessary to reach higher Make sure that the wheels do not touch the ground before starting to lift the booms 5 When all outriggers are firmly on the ground and wheels lifted off the ...

Page 26: ...0 kg safe working load is exceeded Should this happen there is an audible warning signal and an indicator lights up at the control panel The booms can be operated again after the overload has been removed from the platform Never overload the platform ATTENTION Always lift the lower booms first from transport support before operating other movements When lowering the booms make sure to drive them s...

Page 27: ... position of the main switch Emergency lowering valves are protected with a 10A fuse which is located in the connection box on the side at ground level 2 Before lowering the booms to transport supports always make sure that they are properly aligned and going straight down to transport supports If necessary the booms can be rotated at the end of the slewing ring shaft either with a 22 mm key or wi...

Page 28: ...e them with you harnesses must be kept in their place and in their box package 5 Move the ignition key in the coupling box to 0 p 16 picture 7 position and take the key with you 6 Move the main disconnect switch to horizontal position and take the key with you 7 If the machine stays in a place where it can be connected to 230VAC mains current it is recommended to connect it in order to charge the ...

Page 29: ...an automatic hydraulic brake in the rear axle which engages automatically when the engine motor is not running If the machine is transported on a trailer or on a lorry or similar vehicle it must be tied down properly There are four tie down points marked on the corners of the chassis which make it easy to tie down the machine Always tie the machine down diagonally from every corner picture 11 Pict...

Page 30: ...ce with this Operators Manual and with the Service Manual of the engine manufacturer Stop the engine before starting any service or inspection operation DISCONNECT ALSO THE 230V MAINS CURRENT Do not smoke during service and inspection operations Keep the machine and especially the platform clean Make sure that the operating instructions are complete readable and in their place in the box at the pl...

Page 31: ...if hydraulic fluid penetrates your skin Wash carefully with water and soap any body part that has come in contact with hydraulic oil Hydraulic oil is also harmful to the environment prevent oil leakages Only use hydraulic oil type approved by the manufacturer Never handle pressurized hydraulic components because in case of failure on a fitting or component ejection of high pressure hydraulic fluid...

Page 32: ...ectric wires CH Hydraulic fittings and hoses FCH CH Cylinders load holding check valves FCH CH Function of emergency lowering FCH CH Function of emergency stop circuit FCH CH Function of set up system FCH CH Hydraulic pressure adjustments FCH CH Function of control valves FCH CH Mounting of booms on the chassis CH Condition of steel construction CH Movement speeds of booms FCH CH A Greasing of the...

Page 33: ... to prevent wear in joints Most of the joints are service free however the slewing ring must be greased in accordance with the maintenance schedule using grease that contains EP extreme pressure additive Outrigger bearings and articulation bearings in all hydraulic cylinders must be greased in accordance with the maintenance schedule Greasing of the Slewing Ring The lift s Slewing Ring must be gre...

Page 34: ...34 _________________________________________________________________________________ 15 3 Greasing diagram Picture 13 Greasing points ...

Page 35: ...ge When changing hydraulic oil the oil can be removed with a suction pump from the opening of breather cap no 3 or by opening the drain plug In both cases it is important to clean the magnetic drain plug Hydraulic pressure filter cartridge no 4 must be changed always when return filter is changed Take off the filter bracket lift up the filter open and replace the filter cartridge Pressure filter c...

Page 36: ...icator light is lit up or lights up before all 4 outriggers are set to the ground or when you turn the selector switch to boom mode when the outriggers are not set to the ground there is a malfunction or a fault in the system and the operation must be stopped immediately The malfunction can be found out on the splitter box Picture 18 in the back of the chassis In the box connectors 1 4 are equival...

Page 37: ...evels are in the same position Do the adjustment both lengthwise and sideways 15 10 Adjustments of the Hydraulic system The hydraulic system has been adjusted to correct values at the factory and normally there is no need to adjust them Picture 19 shows the components inside the drive and outrigger valve box 1 Drive Control Valve Solenoid K98B Outriggers 2 Drive valve 3 Selector valve of lower con...

Page 38: ...en adjusted to 230 kg In an overload situation the use of booms is prevented and you will hear a sound alarm and see a indicator light in the lower and upper control panels Use of the machine is possible again after removing the load from the platform The load sensor should be checked regularly for physical damage Damage might cause incorrect sensor values If the sensor has to be replaced due to f...

Page 39: ...of the sensor is not lit After this the boom is lifted from the support and the sensor s horizontal position is adjusted with 2 nuts on the sensors distance to the pin approx 3 mm the distance is correct when the led light on the sensor lights up when the boom is lifted from the support The sensor must not touch the pin The position can be tested by lowering the boom down to the support the led li...

Page 40: ...ures whether the JIB boom is in transport position or not The sensor is located at the tip of the telescope boom on the top surface The sensor is adjusted like the two sensors before When the JIB boom is in transport position the sensor should be facing the notch on the boom The led light on the sensor should not be lit when the boom is in transport position Picture 24 JIB boom sensor ...

Page 41: ...s a signal for outriggers being set on the ground If the green light does not light up see section 15 7 page 34 5 Switch the selector switch to Boom position upper control panel Test the function of all control levers including lower controls if installed Only boom levers should work at this point either in lower or upper control panel depending on which is chosen 6 Remove the valve cap K94 of the...

Page 42: ...CTIONS FOR TEMPORARY STORAGE The cable of the pole of the battery should be disconnected if the access platform is being stored for a period longer than 1 month The machine shall be covered and if possible stored inside or under roof in a place where unauthorized persons don t have access Make sure that eventual leaks during storage will not cause waste water or similar environmental problems ATTE...

Page 43: ...oved to START position See also engine manufacturer s Operators Manual Main Disconnect Switch is in OFF position Petrol engine ignition switch is in OFF position Engine electric motor selector switch at platform is in wrong position Emergency stop switch is pushed down Engine is cold Fuel tank is empty Empty start battery Fuse inside the connection box is broken The fuses are at the end of the ter...

Page 44: ...tton accidentally pushed down Electric motor thermal overload relay F1 in connection box has gone off Connection fault in mains or 12V wiring Lower the booms by using the emergency lowering Check that there is current in mains Release emergency stop and restart Wait for approx 2 min and start the motor the relay will return to ON automatically Find out the reason for overload Check voltages and wi...

Page 45: ...in outrigger cylinder s Dirt in outrigger cylinder check valve Faulty check valve Faulty outrigger cylinder seals Put extra support plates under the outriggers or move the machine to another place Drive outriggers up and down a couple of times Clean valve with compressed air Change valve Change outrigger cylinder seals Platform tilts backward by itself when booms are down on transport supports Air...

Page 46: ...ve been made during the warranty period must be noted on the list below otherwise the manufacturer s warranty will void The service operations mentioned in the maintenance schedule on chapter 15 1 shall be noted as follows First Service 50 hours 100 hour Service 200 hour 1 Year Service etc Date dd mm yyyy Operating Hours Type of Service e g First service 50 h Notifications additional repairs etc 1...

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