Leguan L190 Operator'S And Service Manual Download Page 47 | Manualshive

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10. REPAIR

INSTRUCTIONS

10.1 Welding

All load carrying steel parts are manufactured from S650MC (EN 10149-2) sheet, S420MC EN10149
sheet and S355J2H EN10219 tubular pipe.

Welding repairs are only allowed to be carried out by professional welders. When welding, use only
methods and additives suited for above mentioned steel qualities.

SFS EN-ISO 5817 quality level D of imperfections in welding is suitable for all weldings, except for
load carrying parts.

Repair weldings in load carrying parts can be performed only by permission from the
manufacturer.

Before welding

:

-

Remove and cover the plus (+) and minus (-) terminals of the battery.

-

Disconnect all contacts of the logic controllers (picture 32). Connect the earth terminal of the
welding device directly to the part to be welded.

-

Do not touch the controller or electric cables with the welding electrode or the earth terminal of
the welding device.

ATTENTION! It is not allowed to change the construction and structure of this access

platform without a written permission from the manufacturer.

Picture 32. Contacts to the logic controllers (2 pcs)

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Summary of Contents for L190

Page 1: ...Operator and Service manual Edited 13 12 2019 NKA ...

Page 2: ...LINATION SENSOR INDICATOR LIGHT 17 4 1 5 BOOM CENTER POSITION INDICATOR SLEWING 17 4 1 6 BOOM TRANSPORT SUPPORT INDICATOR LIGHT 17 4 1 7 LOW FUEL LEVEL INDICATOR 18 4 2 LOWER CONTROLS PANEL 18 4 3 WIRELESS REMOTE CONTROL OPTION 19 4 4 EMERGENCY LOWERING BUTTON AT GROUND LEVEL OPTION 20 4 5 230 V CONNECTION AND SWITCHES OPTION 20 5 OPERATION 21 5 1 STARTING THE COMBUSTION ENGINE ELECTRIC MOTOR 21 5...

Page 3: ...E POSITION SENSOR PINS ON THE OUTRIGGERS 36 9 3 5 GREASING DIAGRAM 37 9 4 HANDLING OF FUEL AND REFUELING 38 9 5 HYDRAULIC OIL AND HYDRAULIC OIL FILTER REPLACEMENT 38 9 6 HYDRAULIC OIL LEVEL 39 9 7 BATTERY CHECK 39 9 8 CHECK OF SET UP CONTROL SYSTEM 39 9 9 WATER LEVEL CHECK 40 9 10 HYDRAULIC PRESSURES AND ADJUSTMENTS 40 9 11 PEDESTAL VALVE HOUSING 41 9 12 OVERLOAD CONTROL COMPONENTS 42 9 14 BOOM TR...

Page 4: ...tions 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 losses resulting from the use of this self propelled access platform 1 2 Warranty conditions This product is warranted for a period of twenty four 24 months without hour ...

Page 5: ...nt 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 noticed the defect In all conditions the buyer shall a...

Page 6: ...IVIN 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 1...

Page 7: ...tform standards The picture below Figure 1 shows the main parts of this access platform 1 Chassis 2 Transmission either with wheels or crawler tracks 3 Outrigger 4 Outrigger cylinder 5 Slewing ring 6 Connection box of control system 7 Lower controls 8 Self levelling bar 1 9 Pedestal 10 Lift cylinder 11 Lower boom 1 12 Valve box 13 Linkage piece 1 14 Self levelling bar 2 15 Lower boom 2 16 Linkage ...

Page 8: ...wed levelling inaccuracy 1 0º Platform rotation 45º Slewing 360º Gradeability 50 27º Gradeability sideways 35 20º Support dimensions 3 78 x 3 83 m Max gradient of slope for set up 22 13º Weight depending on equipment 2660 kg Drive system 4WD or tracks Drive speed max 2 6 km h Speed when drive motors connected in series option max 5 2 km h Lowest operating temperature 20 C storage 40 C Starter batt...

Page 9: ...9 _________________________________________________________________________________ 2 2 Reach diagram and support dimensions Figure 2 Reach diagram Figure 3 Support dimensions ...

Page 10: ...rce and wind speed 4 General user instructions 5 Daily inspection 6 Always use outriggers 7 Control symbols decal 8 Emergency lowering option 9 Residual current device 10 Electric motor voltage 11 Max outrigger force 12 Distance from energized electric wires 13 Tie down points 14 Tyre pressure 15 Leguan 190 decal 16 Lower controls decal 17 Lift points Figure 4 Signs and decals ...

Page 11: ...M 3 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 instructions 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 traffic in the working area i...

Page 12: ...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 number of persons...

Page 13: ...ng 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 platform during thunderstorm or high winds Leave clearance to electric lines taking into account movements of platform moveme...

Page 14: ...he driving surface is solid 3 Fasten tools and other materials to prevent them falling 4 Wear safety harnesses and keep them fastened whenever operating the machine 3 10 Defining the gradient of the slope Measure the slope with a digital clinometer or do as follows Take a water level a straight piece of wood at least 1 m long and a pocket tape measure Place the wood on the gradient Put the water l...

Page 15: ...ontrol switches see 5 4 2 7 Platform overload indicator light see 4 1 1 8 Outreach control indicator light see 4 1 2 9 Fault light see 4 1 3 10 Boom center position indicator slewing see 4 1 5 11 Boom transport support indicator light see 4 1 6 12 Low fuel level indicator 13 Inclination sensor indicator light see 4 1 4 14 1st Boom control lever 15 2nd boom control lever 16 Boom slewing control lev...

Page 16: ...achieved red dynamic outreach control signal light will stay continuously on and Telescope boom movement out is prevented 2nd boom movement down is prevented Continuous audible sound will signal that the maximum outreach is achieved 2nd boom cannot be lowered before moving the telescope boom slightly in 4 1 3 Fault light The fault light will signal errors and faults on the equipment Possible fault...

Page 17: ...ht will stay on continuously and give an audible alert can be heard Telescope boom movement out is prevented 2nd boom movement down is prevented Return all booms CAREFULLY on to their transport support Check that the ground is solid enough Re level 4 1 5 Boom center position indicator slewing The slew ring of the access platform is equipped with inductive sensor which lights the green boom center ...

Page 18: ...lower controls 2 Diesel and electric motor start and stop button see 5 1 3 Glow light see 5 1 1 4 Emergency stop switch see 3 8 5 Inclination sensor indicator light see 4 1 4 6 Platform overload indicator light see 4 1 1 7 Dynamic outreach control indicator light see 4 1 2 8 Dead man switch boom use option remote control selection switch option 9 Outrigger control platform emergency stop and platf...

Page 19: ...harger Protect the remote from snow and ice If lower controls is not selected keep the remote in the storage enclosure The minimum temperature for the remote storage and use is 20 C store the remote indoors if necessary Figure 8 Wireless remote 1 Emergency stop button The remote emergency stop will only operate when the remote control use is selected 2 Automatic levelling switch 3 Start button for...

Page 20: ...n 2 Residual current device 3 Battery charger Two Led indicators will indicate the battery level Yellow battery level low Yellow green battery level almost fully charged Green battery fully charged trickle charge The RCD unit switch 1 must be up in order to have any 230 V device working including the 230 V outlets at platform One can test the function of the RCD unit by pressing the test button in...

Page 21: ...understand all safety instructions before starting operation 5 1 1 Combustion engine 1 Choose preferred control position lower controls or platform controls 2 Press combustion engine start button the button does not need to be held down 3 Combustion engine red glow light will be lit and the engine will glow the required time and start automatically 4 Press start stop button again to stop the engin...

Page 22: ...side lever 1 Drive levers 2 Water level To operate drive function 1 Ensure all booms are on their transport supports all four outriggers are lifted from the ground and the wheels tracks are firmly against ground Make sure boom transport support indicator light is lit see 4 1 6 Make sure that the green automatic leveling light Figure 5 5 is not continuously on or blink 2 Start the desired engine 3 ...

Page 23: ...cks can normally not be repaired they must be replaced Warranty doesn t cover tracks that get damaged in this kind of conditions Work sites with corrosive substances fuels oil salt or fertilizers Corrosive substances can oxidize 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 ope...

Page 24: ...sly Check the leveling from the water level Figure 10 2 5 Booms can be operated if the chassis is leveled according to the water level also Setting the outriggers to transport position 1 Lower all booms on to their transport supports 2 Green indicator light of boom transport support see 4 1 6 must be lit 3 Press the upper button of the automatic leveling switch Figure 5 4 The button doesn t need t...

Page 25: ... and the platform has tilted operate the control lever of platform self levelling carefully especially when the booms are up 5 5 1 Automatic slewing stop function Leguan 190 has an automatic boom rotation slewing stop function when returning to transport position The stop function is activated when the upper boom 2nd boom is lowered close to transport position and the telescope boom is pulled almo...

Page 26: ...ng the operation 1 Lower the booms down to transport position 2 Lift the outriggers completely up to transport position 3 Stop the combustion engine electric motor by pressing the stop button of the motor 4 Remove safety harnesses from the platform and take them with you harnesses must be kept in their place and in their box package 5 Turn the ignition key switch to 0 and take it with you 6 If the...

Page 27: ...level see 4 4 By pushing the button the selected boom comes slowly down as long as the button is being pushed Emergency lowering button can only be operated from the selected control position If the ignition key switch is at 0 position it is possible to use the emergency lowering from platform since in that case the button takes its power directly from the battery Emergency lowering valves are pro...

Page 28: ...ble alarm will be given and the movements will stop after 1 5 seconds The override switch must be released for one second and activated again to enable boom movements again for 1 5 seconds Override switch may only be used for operating the booms close to their transport supports RISK OF TIPPING OVER 6 4 Platform load control and platform emergency stop button override For possible emergency situat...

Page 29: ...ds after the machine has turned on push down the override button figure 5 20 in the platform control panel pushing down the button switches the controls to the upper control panel from the lower control panel 3 Keep the override button pushed down the whole time you wish to use the function 4 Start the engine or electric motor from the platform control panel figure 5 1 while holding down the overr...

Page 30: ...ere the ropes are mounted in order to prevent the outriggers from being damaged There is an automatic hydraulic brake in the rear axle which engages automatically when the combustion engine electric motor is not running The access platform must not be parked in steep slopes If the machine is transported on a trailer or on a lorry or a similar vehicle it must be tied down properly There are four ti...

Page 31: ...latform must be repaired before starting operation Only professional persons are allowed to open the covers and handle the electric etc components Risk of serious injury Make sure that services are made in accordance 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 230 V MAINS C...

Page 32: ... oil filters FR R Battery CH Coolant FCH CH R Locking of bearings and pivot pins FCH CH Electric wires CH Hydraulic fittings and hoses FCH CH Cylinders load holding and check valves FCH CH Function of emergency lowering FCH CH Function of emergency stop circuit FCH CH Function of set up system FCH CH Pressure adjustments FCH CH Function of control valves FCH CH Mounting of booms on the chassis CH ...

Page 33: ...g the access platform s 10 year service Tightening torque of the M16 fastening bolts of the slewing ring is 210 Nm torque must be checked once a year and bolts must be changed every 5 years If a bolt has loosened it must be replaced with a new bolt Above mentioned service intervals are recommendations If the operating conditions are very hard and or the machine is in heavy duty use the service and...

Page 34: ...es The fuses of this access platform are located on the left side of the machine inside the electric box 1 Fuses voltage when ignition key switch is ON lower or platform controls selected 2 Fuses constant voltage from battery 3 Spare fuses Figure 14 Fuses Do not exceed original fuse size 3 2 1 ...

Page 35: ...d individually The grease nipples on the outside of the slewing ring are connected to the gear and its bearings Two 2 grease nipples on the inside of the slewing ring are connected to the ring s ball bearings Easiest way to apply grease on these two grease nipples is through the service hatch on the bottom of the chassis Figure 15 Slewing ring greasing 9 3 2 Greasing the telescopic boom chain pull...

Page 36: ...Figure 18 Width of the greased surface on Middle Boom and Extension highlighted with red lines 9 3 4 Greasing of the Position Sensor Pins on the Outriggers The position sensor pins on the outriggers should be cleaned and greased with water resistant e g Mobil XHP 222 during the yearly maintenance of the access platform The pin is removed from the outrigger by opening the locking screw on the end o...

Page 37: ...37 _________________________________________________________________________________ 9 3 5 Greasing diagram Figure 20 Greasing diagram ...

Page 38: ...ilter by removing the filter cap and replacing the filter cartridge When replacing the hydraulic oil the oil can be removed with a suction pump from the opening of breather cap 1 or by opening the drain plug In both cases it is important to clean the magnetic drain plug Hydraulic pressure filter cartridge 3 must be changed always when return filter is changed Take off the filter bracket lift up th...

Page 39: ...Drive outriggers manually against ground If the green automatic leveling signal light will blink before all four outriggers touch the ground the outrigger control system there is a malfunction or a fault in the system and the operation must be stopped immediately excluding the situation where automatic leveling has been activated The cause of the malfunction can be found out on the splitter box Fi...

Page 40: ...the adjustment both lengthwise and sideways 9 10 Hydraulic pressures and adjustments The hydraulic system has been adjusted to correct values at the factory and usually there is no need to adjust them All pressure measurement nipples are located inside the chassis in the hydraulic pump manifold Easiest way to access the measurement nipples is to open the bottom plate of the chassis 1 Main pressure...

Page 41: ... 3 Lower controls boom solenoid K99 All boom cylinders except master levelling cylinder are equipped with load control valves 1 which prevent boom movements in case e g a hydraulic hose fails When using electric emergency lowering see 6 2 option of the booms the electric solenoid 2 valve in the cylinder opens and oil flows through the adjustable restrictor valve into the tank allowing the booms to...

Page 42: ...d Figure 29 Load cell unit MOBA MRW Maximum platform load has been adjusted to 230 kg In an overload situation the use of booms is prevented and you will hear a sound alarm and see a red indicator light in the lower Figure 6 6 and upper control Figure 5 7 panels Remove excess load from the platform Both alarms will go OFF Use of booms is possible again after removing the load from the platform The...

Page 43: ...nsor MUST BE ON If the leds don t light up adjust the sensor s horizontal position correct distance to the pin is approx 3 mm Tighten the two nuts DO NOT OVERTIGHTEN The sensor must not touch the pin After adjusting ensure the led lights in the sensor will go OFF when the boom is lowered in the transport support Figure 30 Lower boom transport support The upper transport support sensor is located i...

Page 44: ... 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 Figure 32 Jib boom sensor Figure 33 Upper boom sensor Upper boom angle and telescopic boom outreach is monitored with a sensor which is located inside the upper boom located in the front side of the access platform Figure 33 1 The condition of the outreac...

Page 45: ... movements also in the lower controls Boom operation must work normally 5 Lower all booms on their transport supports 6 Test the safety valve K92 Make sure the lower controls are selected all outriggers are firmly against ground and the green boom operation allowed light is lit Figure 5 5 Test that boom movements work in lower controls panel Lower all booms on their transport supports Open the bot...

Page 46: ...omponents only when the engine is stopped and with pressure released from the hydraulic system Do not operate the machine if you have noticed faults or leaks in hydraulic system Ejection of hydraulic fluid can cause burns or penetrate the skin and cause serious injuries Consult a doctor immediately if hydraulic fluid penetrates your skin Wash carefully with water and soap any body part that has co...

Page 47: ...able for all weldings except for load carrying parts Repair weldings in load carrying parts can be performed only by permission from the manufacturer Before welding Remove and cover the plus and minus terminals of the battery Disconnect all contacts of the logic controllers picture 32 Connect the earth terminal of the welding device directly to the part to be welded Do not touch the controller or ...

Page 48: ...mental issues After long storage period perform necessary checks and maintenance routines according to the service schedule ATTENTION See also engine manufacturer s instructions for the storage of the engine 12 INSTRUCTIONS FOR DISPOSING THE ACCESS PLATFORM When the access platforms lifecycle comes to an end it has to be dissembled and disposed of in an environmentally friendly way Battery and oth...

Page 49: ...e manufacturer s Operators Manual Motor is too cold Fuel tank is empty Empty start battery Burnt fuse Issue in fuel delivery Issue in air intake Start button broken Restart the engine use maximum glow time see 5 1 1 Refill see 9 4 Charge battery by connecting 230 V or use jumper cables option replace battery if necessary Replace fuse see 0 Check fuel tank fuel lines fuel filter and fuel pump Clean...

Page 50: ...lectric motor is running Failure in hydraulic system e g hydraulic pump broken Overload on platform Check hydraulic pressure If there is no pressure check function of hydraulic pump safety valve Remove overload Combustion engine electric motor stops when booms are lifted from transport support Outriggers are not correctly deployed down to support position green indicator lamp is not lit Lower the ...

Page 51: ...e with compressed air if that doesn t help change valve Change cylinder seals Automatic leveling does not work the access platform will level the chassis but booms are not operational The green light does not blink One of the four outriggers is not firmly against ground or the outrigger limit switch is defective Ensure all outriggers are properly deployed check outrigger sensors see 9 8 Automatic ...

Page 52: ...fault light on outriggers will not operate Telescopic boom not entire in boom transport supports not properly adjusted Make sure all the booms including the telescopic boom are on their supports check transport support sensor adjustments see 9 14 Contact Leguan service Motor will not start fault light outreach light and overload light on Emergency stop button is active telescope angle sensor defec...

Page 53: ...ave 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 see 9 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 eg first service Notifications additional repairs etc 1 2...

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