TEUPEN LEO 15 GT Translation Of The Original Operating Instructions Download Page 125

Page: 125 / 208

Faults

The following section describes possible causes of

faults and the work to remedy them.
In case of faults that occur more than once, abbreviate

the maintenance intervals according to the actual uti-

lisation.
In case of faults that cannot be remedied using the fol-

lowing instructions, contact the manufacturer, see con-

tact data on page 2.

8.1

Safety instructions for fault repair

WARNING!
Danger to life from an unauthorised

restart!

In the event of an unauthorised restart of the

power supply while tracking down and recti-

fying a fault, there is a danger of serious inju-

ries or death for persons in the danger zone.
– Switch off all power supplies before

starting work and make sure they cannot

be switched on again.

Securing to prevent restart

Faults

13.02.2013

Aerial access platform Leo15GT 2012

121

Summary of Contents for LEO 15 GT

Page 1: ...Aerial access platform Translation of the original oper ating instructions Serial number _______________ ...

Page 2: ... GmbH Marie Curie Straße 13 D 48599 Gronau Telephone 49 0 2562 8161 0 Fax 49 0 2562 8161 888 email info teupen com Internet www teupen com Service Telephone 49 0 2562 8161 313 email service teupen com Leo15GT 2012_GB 13 02 2013 Aerial access platform Leo15GT 2012 2 ...

Page 3: ...micals 19 2 1 7 Danger due to traffic and vehicles 20 2 2 Proper use 21 2 3 Responsibility of the owner 21 2 4 Personnel requirements 23 2 4 1 Qualifications 23 2 4 2 Unauthorised persons 25 2 4 3 Training 25 2 5 Personal protective equipment 25 2 6 Safety equipment 27 2 6 1 Position of the safety equipment 27 2 6 2 Description of the installed safety equip ment 29 2 7 Symbols on the machine 31 2 ...

Page 4: ...ency and service ope ration 51 4 4 3 Display at the control box 52 4 5 Power connection 52 4 6 Work areas and danger zones 52 4 7 Accessories 53 4 7 1 Keys 53 4 7 2 Safety harness optional 53 4 7 3 Lifting device optional 53 5 Transport and storage 55 5 1 Safety instructions for transport 55 5 2 Transport inspection 55 5 3 Transport 56 5 4 Storage 61 6 Operation 63 6 1 Safety instructions for oper...

Page 5: ...r maintenance 103 7 2 Maintenance plan 105 7 2 1 Maintenance plan combustion engine 106 7 2 2 General maintenance plan 109 7 3 Maintenance work 110 7 3 1 Cleaning 110 7 3 2 Tensioning the chain 111 7 3 3 Lubricating the rotating drive 113 7 3 4 Checking the hydraulic oil level 114 7 3 5 Check the gearbox oil level of the crawler chassis 115 7 3 6 Replacing the filter insert 117 7 3 7 Lubrication p...

Page 6: ... instructions for disposal 137 9 2 Disposal 137 10 Index 139 Appendix 141 A Combustion engine 145 A 1 Gasoline engine Robin Subaru EX 21 147 A 2 Diesel engine Hatz 1B30 optional B Circuit diagram C Hydraulic plan Table of contents 13 02 2013 Aerial access platform Leo15GT 2012 6 ...

Page 7: ...evention regulations and general safety provisions for the area of application of the machine apply Figures in these instructions serve the purpose of basic understanding and can deviate from the actual model 1 2 Explanation of symbols Safety instructions are marked with symbols in these instructions The safety instructions are always intro duced by signal words which express the extent of the dan...

Page 8: ...fety instruc tions to draw attention to specific dangers DANGER This combination of symbol and signal word indicates an immediately dangerous situation due to electric shock If an instruction so marked is not heeded severe or even fatal injuries can be the consequence To emphasise operating instructions results lists refer ences and other elements the following markings are used in these instructi...

Page 9: ...ained personnel n Unauthorised changes n Technical alterations n Use of non approved spare parts For special models with the usage of additional order options or due to the latest technical changes the actual scope of delivery can deviate from the explana tions and depictions provided here Applicable are the obligations agreed upon in the delivery contract the general terms and conditions as well ...

Page 10: ...y card which is at the front of the machine record and send it back to Teupen directly after hand over of the machine to the customer If the warranty card is not filled out properly we cannot process the warranty application since important data which is necessary for the processing has not been made avail able to us Please send the warranty card to Teupen Maschinenbau GmbH Service Point Marie Cur...

Page 11: ...technical informa tion Please see page 2 for the contact data In addition our employees are constantly interested in new information and experiences which arise from usage and could be valuable for the improvement of our products General 13 02 2013 Aerial access platform Leo15GT 2012 11 ...

Page 12: ...General 13 02 2013 Aerial access platform Leo15GT 2012 12 ...

Page 13: ...erty damage and avoid dangerous situations the safety instructions listed here and the safety instructions in the other sections of these instructions must be followed 2 1 1 General hazards in the workplace WARNING Danger to life due to swivelling aerial access platform During operation the aerial access platform can swivel out This can cause severe injuries or even death Never step under or into ...

Page 14: ...ushed e g against a wall At wind speeds above 12 5 m s wind strength 6 Bft stop work immediately Always wear personal protective equip ment WARNING Danger to life from poisoning or suffoca tion due to exhaust gas When inhaled exhaust gases can lead to suf focation and cause severe poisoning as well a illness of the respiratory system Always ensure fresh air supply when working on the machine in co...

Page 15: ... supply immediately and have the machine repaired Never bypass fuses or take them out of operation When changing fuses adhere to the correct amperage Keep humidity away from voltage con ducting parts This can cause a short cir cuit Adhere to cable strengths according to Ä Cable lengths on page 42 Lay extension cables so that they cannot be driven over they do not come into con tact with liquids th...

Page 16: ...o repair them to change their form to remodel them or to dismantle them Always protect batteries from access by unauthorised persons In order to avoid fires overheating explo sions or escape of fluids do not subject batteries to heavy vibrations or shocks place heavy weights on them or subject them to other damaging exposures Liq uids which emanate from batteries can get inflamed Avoid contact wit...

Page 17: ... people supply lines or other objects are in the area around the supports Make sure that no people are in the danger zone when swivelling the machine Make sure that no people are in the danger zone when moving into transport position WARNING Danger of injury due to insufficient sta bility With insufficient stability there is a danger that the machine will tip This can cause severe injuries or even...

Page 18: ...NG Danger to life from hydraulic forces Hydraulically driven moving parts can cause grave injuries Work on the hydraulic system must only be carried out by trained hydraulics techni cians Before starting work on the hydraulic system ensure that it has been com pletely depressurised The pressure accu mulator must be completely relieved During operation do not reach into or handle moving parts Do no...

Page 19: ...water and anti freeze agent In case of body contact swallowing or inhalation of aerosols anti freeze agents can lead to severe health hazards Avoid contact with anti freeze materials Do not eat drink or smoke while handling anti freeze materials Wash hands before breaks and at the end of work Always wear protective gloves while working with anti freeze agents Measures to be undertaken upon contact...

Page 20: ...ning agents 2 1 7 Danger due to traffic and vehicles WARNING Danger to life due to parts protruding into the traffic area A failure to heed flowing traffic can cause accidents with the most severe injuries or even death Secure the danger zone around the aerial access platform completely and visibly even in case of poor visual conditions Always be prepared for possible traffic accidents especially ...

Page 21: ... side pull Do not use the aerial access platform in or near unprotected active parts of electrical systems Do not operate the aerial access platform in an atmosphere subject to explosion Claims of any type due to damage from misuse are excluded 2 3 Responsibility of the owner The term owner refers to the person who himself oper ates the machine for trade or commercial purposes or who surrenders th...

Page 22: ...ssary he must adapt the oper ating instructions n The owner must clearly regulate and specify the responsibilities for installation operation fault repair maintenance and cleaning n The owner must ensure that all employees who handle the machine have read and understood these instructions In addition the personnel must be trained by the owner and informed about the risks n The owner must provide t...

Page 23: ...e of aerial platforms and is sufficiently familiar with the appli cable state regulations accident prevention regulations and generally recognised rules of technology e g employer s liability insurance rules DIN standards VDE regulations technical rules of other member states of the European Union or other treaty states of the agree ment about the European Economic Community that he can assess the...

Page 24: ...el is able to carry out assigned work and to recognize and prevent possible dangers self reli antly due to its professional training knowledge and experience as well as profound knowledge of applicable regulations Trained people The trained people have been trained in demonstrable fashion in a training session by the owner about the proper use without additional prior knowledge of the method of fu...

Page 25: ...ques tion and ask them to leave the danger and working zone Cease work while unauthorised persons are in the danger and working zone 2 4 3 Training The customer has been trained by the owner The per sonnel must be trained by the owner accordingly 2 5 Personal protective equipment Personal protective equipment serves to protect people against hazards to their safety and health while working The per...

Page 26: ...ntended to protect against slipping hazards or foot hazards like heavy gear Safety harness The safety harness is used as a protection against falling where there is an increased risk of falling Such a risk exists if certain height differentials are exceeded and the work location is not safeguarded by a railing Put on the safety harness so that the lifeline is con nected to the safety harness as we...

Page 27: ...y or death Check that all safety devices are fully functional and correctly installed before starting work Never disable or bypass safety devices Ensure that all safety devices are always accessible 2 6 1 Position of the safety equipment The following illustrations shows the position of the safety equipment Safety 13 02 2013 Aerial access platform Leo15GT 2012 27 ...

Page 28: ...1 Limit switch outriggers 2 Limit switch transport lock lower boom 3 Valves for emergency service operation chains bracing function 4 Limit switch locking bolts View from the left side Safety 13 02 2013 Aerial access platform Leo15GT 2012 28 ...

Page 29: ...form function 2 6 2 Description of the installed safety equipment By pressing the Emergency Stop button the machine is stopped due to immediate switching off of the power supply After the Emergency Stop button has been pressed it must be unlocked by turning it in order to switch the machine on again View from the right side Emergency Stop button Fig 4 Emergency Stop button Safety 13 02 2013 Aerial...

Page 30: ...nger Limit switch retrieve the correct positioning of certain components For example the limit switches can pre vent the inadvertent movement of the machine During automatic bracing the aerial access platform is aligned horizontally automatically with the help of the tilt sensor Fig 6 The maximum permissible inclination is 1 this must be checked visually with the circular level Fig 7 Limit switch ...

Page 31: ...of time stickers and signs can get soiled or become illegible in other ways so that hazards are not recognised and necessary operating instructions cannot be followed This creates a danger of injury Always keep all safety warning and oper ating instructions in easily legible condi tion Replace damaged signs or stickers imme diately With specification of the item number the stickers can be ordered ...

Page 32: ... 9 1 This item number can be attached to various location on the sticker The item numbers always consist of the numeric sequence 3912 followed by a 4 digit number In the example Fig 9 3912 1030 Sample item number Safety 13 02 2013 Aerial access platform Leo15GT 2012 32 ...

Page 33: ... 0117 3914 0117 2 3 1 43914 0050 weiß white 3914 0042 schwarz black 3914 00166 weiß white 3914 0041 schwarz black 3914 00165 weiß white 3914 0043 schwarz black 3914 00167 weiß white 3914 0044 schwarz black 3914 00168 ...

Page 34: ...914 0056 3914 0024 3914 0021 3914 0056 3914 0024 3914 0021 zz 3914 0020 Pos Plantohydi32 S 3914 0263 PanoliniHLPiSi46 3914 0012 zz z 300587 PT_EN weißi iwhite 3912 1130 schwarzi iblack 3912 1131 weißi iwhite 3912 1533 schwarzi iblack 300172 3914 0033 3914 0035 3914 0033 3914 0035 ...

Page 35: ...3914 0015 3914 0030 3914 0013 3914 0016 3914 0049 3914 0002 3914 0005 3914 0085 Pos Diesel Egazole Benzin Epetrol Eessence 3914 0086 3914 0017 3914 0091 Pos DE EN NL FR 3914 0086 300592 PT_EN ...

Page 36: ...914 0023 3914 0019 weißN Nwhite 3912 1130 schwarzN Nblack 3912 1131 3914 0017 3914 0091 Pos DE EN NL FR 3914 0114 3914 0172 300590 weißN Nwhite 3914 0046 schwarzN Nblack 3914 0045 rotN Nred 3914 0105 gelbN Nyellow 3912 0219 3914 0016 ...

Page 37: ...3914 0095 3914 0021 3914 0054 3914 0021 3914 0053 ...

Page 38: ...3914 0003 3914 0027 3914 0014 3914 0038 3914 0038 3914 0006 3914 0016 3914 0143 Pos SpracheF FLanguage DE_EN NL_FR LeoF15FGT 3914 0061 3914 0095 ...

Page 39: ......

Page 40: ...evices n Provided your own health is not in danger rescue all personnel from the danger area n If necessary initiate first aid measures n Alert the fire department and or emergency medical services n In case of fire provided your own health is not in danger extinguish the fire using fire extinguishing equipment and continue to do so until the fire department arrives n Notify the person in charge a...

Page 41: ...aterials which might harm the envi ronment are used Cleaning liquids incorporating solvents contain toxic substances They must not be allowed to escape into the environment Disposal must be carried out by a spe cialist disposal company Lubricants such as greases and oils contain toxic sub stances They must not be allowed to escape into the environment Disposal must be carried out by a special ised...

Page 42: ... cialist disposal company Rechargeable batteries and batteries contain toxic heavy metals They are subject to special waste treat ment and must be handed in to municipal collection points or disposed of by a specialist company Cooling water frost protection Rechargeable batteries or bat teries Safety 13 02 2013 Aerial access platform Leo15GT 2012 38 ...

Page 43: ...3 Technical data 3 1 Dimension sheet 3 1 1 Main dimensions Fig 12 Main dimensions 3 1 2 Work diagram Fig 13 Work diagram Technical data 13 02 2013 Aerial access platform Leo15GT 2012 39 ...

Page 44: ...ght deviation due to n 1 production tolerance n 2 5 production tolerance and permanently installed accessories 3 3 Platform system Data Value Unit Max working height at 200 kg 14 70 m Lateral outreach at 80 kg 7 60 m Lateral outreach at 200 kg 7 60 m Max basket load 200 kg Working basket 0 7x1 4 x1 1 m Max working range 355 3 4 Chassis Data Value Unit Height adjustable 12 cm Width adjustable 18 cm...

Page 45: ...width 2 95 m Bracing pad Ø 0 2 m Bracing possible up to slope of 13 23 Max chassis clearance 42 cm 3 6 Drive 3 6 1 Combustion engines Data Value Unit Output 5 1 7 0 kW PS Tank capacity 3 6 l Fuel Petrol Data Value Unit Output 5 4 7 3 kW PS Tank capacity 5 0 l Fuel Diesel Robin Subaru EX 21 Hatz Diesel 1B30 optional Technical data 13 02 2013 Aerial access platform Leo15GT 2012 41 ...

Page 46: ...sions Data Value Unit Noise during e motor propulsion 70 dB A Noise during combustion engine propulsion 89 dB A 3 8 Operating conditions Data Value Unit Maximum permissible wind speed in operation 12 5 6 m s Bft Temperature range 15 to 40 C 3 9 Hydraulic system Data Value Unit Platform functions 150 bar EMG EBS 90 LX4 Cable lengths Response pressure of the pres sure limiting valves Technical data ...

Page 47: ...idge 0 5 kg High perform ance lubricant 3917 0130 bucket 1 kg upon order please specify order quantity in litres The hydraulic system of the aerial access platform is filled with the above mentioned hydraulic oil at the fac tory It is recommended that you continue to use this hydraulic oil or that you replace it with one of the fol lowing hydraulic oils Operation tem perature BP Esso Fuchs Shell 1...

Page 48: ...n Manufacturer n Type n Serial number n Year of manufacture n Net weight n Load capacity n Permitted number of people n Payload n Maximum permissible lateral force n Maximum permissible wind speed n Maximum electrical connection values n Maximum permissible slope n Time of the annual check n CE mark Technical data 13 02 2013 Aerial access platform Leo15GT 2012 44 ...

Page 49: ...control and 230 V outlet 5 Working basket 6 Cable bag 7 Control box cover 8 Left crawler chassis 9 Height width adjustment of the crawler chassis optional 10 Valve cover for bracing chain function 11 Cover for electric motor and hydraulic tank Overview from the left side Structure and function 13 02 2013 Aerial access platform Leo15GT 2012 45 ...

Page 50: ...a control panel Fig 15 4 which can also be used as a cable remote control In order to put the aerial access platform in work position the chassis is lifted using the outriggers 1 to 4 Fig 15 1 and 3 as well as Fig 16 1 and 3 using the automatic bracing or manually Only when the chassis is levelled correctly visual check using the cir cular level can platform operation be started The working basket...

Page 51: ...ion engine Fig 16 9 4 3 Assembly description 4 3 1 Platform Fig 17 Platform similar to illustration The work platform consists essentially of the lift arm holder Fig 17 1 the lower boom Fig 17 2 the linkage Fig 17 3 and the upper boom Fig 17 4 with telescopic arm Fig 17 5 Structure and function 13 02 2013 Aerial access platform Leo15GT 2012 47 ...

Page 52: ...on The outriggers are num bered consecutively according to the position numbers 4 3 3 Working basket In the working basket Fig 19 1 there is space for a maximum of two people The control panel Fig 19 3 is located in the control head Fig 19 2 it can be taken out and used as a remote control Fig 19 Working basket Structure and function 13 02 2013 Aerial access platform Leo15GT 2012 48 ...

Page 53: ...echanically Ä Chapter 6 8 Height and width adjustment crawler chassis optional on page 84 4 3 5 Combustion engine The combustion engine Ä Chapter 4 3 5 Combustion engine on page 49 1 together with the hydraulic aggregate supplies the necessary hydraulic pressure 4 3 6 Electric motor As an alternative to the combustion engine the neces sary hydraulic pressure can be generated by the elec tric motor...

Page 54: ... are explained in detail below Using the rocker switch function selection the platform bracing and chain function are selected Depending on the operating function selected and the position of the pre selection lever the functions marked in colour can be executed with the left control lever After switching on the voltage supply the red light blinks until the machine is ready for operation The green...

Page 55: ...he combustion engine The Emergency Stop button is on the control panel Ä Emergency Stop button on page 29 After activa tion it must be unlocked by turning it so that the machine is ready for operation again 4 4 2 Controller for emergency and service operation The aerial access platform can be operated manually during power failure or during service operation using the valve component group Fig 24 ...

Page 56: ... provided via a 230 V cable Fig 26 1 It is connected to the power supply construction site power supply by using an extension cord Ä Cable lengths on page 42 4 6 Work areas and danger zones The work area and danger zones are within and verti cally below the swivel range of the machine Fig 25 Display Fig 26 230V connection Fig 27 Work area and danger zone Structure and function 13 02 2013 Aerial ac...

Page 57: ... for the contact data Item no 8300 0174 4 7 3 Lifting device optional No aerial access platform must be installed on the Leo13GT and Leo15GT with control connection at the chassis Optionally a lifting device Fig 29 can be mounted instead of the working basket Operation takes place via the cable remote control See also the separate oper ating instructions for the lifting device Item no 0900 0446 Fi...

Page 58: ...Structure and function 13 02 2013 Aerial access platform Leo15GT 2012 54 ...

Page 59: ...hment points provided 5 2 Transport inspection Check the delivery immediately upon receipt to ensure that it is complete and there is no evidence of transport damage In case of transport damage which is visible from the outside proceed as follows n Do not accept the delivery or accept it only with res ervations n Note scope of the damage on the transport docu ments or on the transporter s delivery...

Page 60: ... Attachment points for transport with a fork lift continuous 3 Lashing eyes for transport on a trailer on both sides Attachment points for transport with a crane Fork eyes for transport with a fork lift Attachment points Fig 31 Attachment point Fig 32 Fork eyes Transport and storage 13 02 2013 Aerial access platform Leo15GT 2012 56 ...

Page 61: ...of the aerial access platform n The user must be authorised to operate the crane n The machine must be in the transport position Ä Chapter 6 7 Putting the machine in transport position on page 79 n Belts and chains must be the same length and suffi ciently long Fig 33 Lashing eye Transport with a crane Transport and storage 13 02 2013 Aerial access platform Leo15GT 2012 57 ...

Page 62: ... attachment points are marked with the Fig 35 symbol Align the boom of the crane so that the lifting accessories are evenly loaded 5 If necessary protect the paint of the aerial access platform with suitable underlay materials 6 Begin transport The machine can be transported with a fork lift under the following conditions n The fork lift must be designed for the weight of the aerial access platfor...

Page 63: ...de 5 Lift the machine and begin transport The machine can be transported on a trailer or trans porter under the following conditions n The trailer or transporter must be designed for the weight and the dimensions of the machine n The machine must be in the transport position Ä Chapter 6 7 Putting the machine in transport position on page 79 n The machine must be anchored to the means of transport ...

Page 64: ...turn the aerial access platform on the ramp or loading area NOTICE Property damage due to improper lashing The use of unsuitable attachment points can cause damage to the machine Only use the lashing eyes specified here Fig 38 Transport on a trailer 1 Move the aerial access platform forwards on the ramps Fig 38 1 2 When the machine begins to tip on the loading area Fig 38 2 slow down When the aeri...

Page 65: ... the tipping point it is safe to speed up again 5 4 Storage Store the machine under the following conditions n Do not store outdoors n Store dry and dust free n Do not subject to any aggressive media n Protect against solar radiation n Avoid mechanical shocks n Storage temperature 15 to 35 C n Relative humidity max 60 n In case of storage longer than 3 months check the condition of all parts regul...

Page 66: ...Transport and storage 13 02 2013 Aerial access platform Leo15GT 2012 62 ...

Page 67: ...fety equipment are installed and functioning properly Make sure that there are no people in the danger zone Never take safety equipment out of service or bypass it during operation 6 2 Switching the machine on off Personnel n Trained people Protective equipment n Protective clothing n Safety boots n Protective helmet The power is supplied either by the power network construction side feed using an...

Page 68: ...plug Never bypass fuses or take them out of operation When changing fuses adhere to the correct amperage Keep humidity away from voltage con ducting parts This can cause a short cir cuit 1 Connect the plug Fig 41 1 to the 230 V extension cable Here heed the required cable lengths Ä Cable lengths on page 42 ð The red light on the control panel begins to blink 2 Wait until the red light goes out app...

Page 69: ...ctions for the combustion engine see supplier documents in appendix of machine record NOTICE Voltage drop of the starter battery Frequent starting of the combustion engine can cause a voltage drop of the starter bat tery Avoid frequent starting of the combustion engine Switching off Fig 42 230V connection Operation 13 02 2013 Aerial access platform Leo15GT 2012 65 ...

Page 70: ...the combustion engine push the motor switch Fig 45 downwards to and hold it until the combustion engine stops 6 3 Shutting down in case of emergency In dangerous situations movements of components must be stopped as quickly as possible and the power supply switched off In case of emergency proceed as follows 1 Trigger immediate emergency stop with Emer gency Stop button 2 If there is no danger to ...

Page 71: ...easures 4 Inform the fire brigade and or rescue service 5 Inform responsible people in the deployment loca tion 6 Switch off the machine and secure against switching on again Operation 13 02 2013 Aerial access platform Leo15GT 2012 67 ...

Page 72: ... 4 Moving the machine Personnel n Trained people Protective equipment n Protective clothing n Safety boots n Protective helmet n Safety harness Operation 13 02 2013 Aerial access platform Leo15GT 2012 68 ...

Page 73: ...mum working basket load of 200 kg Heed openings in the floor when moving Do not drive over materials with sharp edges Do not make any abrupt changes of direc tion In case of stop on an incline secure the machine against rolling away Make sure that the ladder is folded up and locked When moving across the slope max 10 5 or 20 do not stay on the down slope side next to the aerial access plat form In...

Page 74: ... 46 in centre position to chain function red 3 With the pre selection lever select fast Fig 47 1 or crawl speed Fig 47 2 4 Move machine according to Ä Table Moving the machine on page 71 By pressing the control levers slowly the speed can be adapted The machine may only be operated in crawl speed when on slopes or inclines Fig 46 Function selection switch Fig 47 Move function Operation 13 02 2013 ...

Page 75: ...rol lever back wards The machine turns backwards in a clockwise direction 6 Press only the right control lever for wards The machine turns forwards in an anti clock wise direction 7 Pull only the left control lever back wards The machine turns backwards in an anti clockwise direction 8 Press only the left control lever for wards The machine turns forwards in a clockwise direction The possible turn...

Page 76: ...er 3 Technical data on page 39 Heed maximum guard rail angle Ä Chapter 3 Technical data on page 39 If necessary use base plates Make sure that the base plates are aligned horizontally maximum deviation of 8 Do not anchor the outriggers with chains ropes pegs etc Always observe the movement of the out riggers when extending Make sure that no people supply lines or other objects are in the area arou...

Page 77: ...e 63 2 Set function selection switch Fig 49 to outrigger function yellow 3 With the pre selection lever select the outriggers 1 and 2 Fig 50 1 or 3 and 4 Fig 50 2 Manual bracing Fig 49 Function selection switch Fig 50 Outrigger function Operation 13 02 2013 Aerial access platform Leo15GT 2012 73 ...

Page 78: ...control lever forwards Outrigger 4 extends By pressing the control levers slowly the speed of the outriggers can be adapted 5 Bring the chassis in a horizontal position by aligning the outriggers according to the circular level Fig 51 Item no 4001 0298 The bubble Fig 51 1 of the circular level must be within the 1 circle Fig 51 2 ð With proper bracing the green light on the con trol panel remains ...

Page 79: ...wing press the control lever for automatic bracing full speed for downward movement of the outriggers only until all support pads have made contact with the ground Then throttle back the speed by approximately 50 by pulling the control lever back Pre selection lever position Operation Symbol Effect Press left or right control lever for wards All outriggers extend simulta neously ð The chassis alig...

Page 80: ...e process immediately and align the machine manually Have the automatic bracing checked by Service 5 Check alignment on the circular level Fig 54 Item no 4001 0298 The bubble Fig 54 1 of the circular level must be within the 1 circle Fig 54 2 ð With proper bracing the green light on the con trol panel remains lit Fig 54 Circular level Operation 13 02 2013 Aerial access platform Leo15GT 2012 76 ...

Page 81: ...round in order to activate the emergency control if necessary Make sure that the ladder is folded up and locked Do not climb onto the safety fence around the basket Do not work on or near high voltage lines Watch out for high obstacles Make sure that when moving the working basket no body parts are crushed e g against a wall At wind speeds above 12 5 m s wind strength 6 stop work immediately 1 Put...

Page 82: ...ft the lower boom Pull left control lever back wards Lower the lower boom Press right control lever for wards Lift the upper boom Pull right control lever back wards Lower the upper boom Press left control lever for wards Swivel the platform clock wise seen from above Pull left control lever back wards Swivel the platform anti clockwise seen from above Press right control lever for wards Extend th...

Page 83: ...s slowly the speed of the platform can be adapted 6 7 Putting the machine in transport position Personnel n Trained people Protective equipment n Protective clothing n Safety boots n Protective helmet n Safety harness Definition of transport position n The outriggers Fig 58 1 are retracted n The lower boom Fig 58 2 is on the transport lock Fig 58 3 n The upper boom Fig 58 5 is on the transport loc...

Page 84: ...machine in transport position the outriggers can be retracted manually or automatically Lowering the machine can optionally be carried out from the working basket or with the control panel as remote control 1 Switch on the machine Ä Chapter 6 2 Switching the machine on off on page 63 2 If necessary retract the upper boom Ä Chapter 6 6 Operating the machine on page 77 3 NOTICE Property damage due t...

Page 85: ... 5 Set function selection switch Fig 60 to outrigger function yellow 6 With the pre selection lever select the outriggers 1 and 2 Fig 61 1 or 3 and 4 Fig 61 2 Fig 60 Function selection switch Fig 61 Outrigger function Operation 13 02 2013 Aerial access platform Leo15GT 2012 81 ...

Page 86: ...ontrol lever forwards Outrigger 3 retracts Press right control lever forwards Outrigger 4 retracts By pressing the control levers slowly the speed at which the outriggers retract can be adapted 1 Switch on the machine Ä Chapter 6 2 Switching the machine on off on page 63 2 If necessary retract the upper boom Ä Chapter 6 6 Operating the machine on page 77 Automatic control Operation 13 02 2013 Aeri...

Page 87: ...er 6 6 Operating the machine on page 77 5 Set function selection switch Fig 63 to outrigger function yellow 6 Using the pre selection lever select the auto function Fig 64 centre position 7 Retract the outriggers evenly according to the table Pre selection lever position Operation Symbol Effect Pull left or right control lever backwards All outriggers retract simulta neously By pressing the contro...

Page 88: ...t two people Both crawler chassis can be adjusted independently of one another in their height and thus simultaneously in their width 1 Switch on the machine Ä Chapter 6 2 Switching the machine on off on page 63 2 Put the machine in working position Ä Chapter 6 5 Putting the machine in work posi tion on page 72 3 Lift the machine up using the outriggers until the crawler chassis is unloaded Fig 65...

Page 89: ...rrow ð The crawler chassis slips out down to the floor 6 Let go of the locking lever Fig 66 1 and remove 7 Carefully continue to lower the outriggers on the side of the crawler chassis to be moved out meaning lift the chassis on this side until the crawler chassis loses contact with the floor Ä Chapter 6 5 Putting the machine in work posi tion on page 72 ð The crawler chassis extends until the loc...

Page 90: ...at there are no limbs between the crawler chassis and the floor 5 Release the locking mechanism by pressing the locking lever Fig 69 1 in the direction of the arrow ð The crawler chassis slips out down to the floor 6 Hold the locking lever Fig 69 1 in an open posi tion and carefully lift the two outriggers on the crawler chassis side meaning lowering the chassis on that side in order for the crawl...

Page 91: ...hine in transport position on page 79 2 Remove the provided open ended wrench from the document box Fig 71 2 3 Use open ended wrench to loosen mounting screw Fig 71 1 The mounting screw Fig 71 1 remains in the hole of the working basket 4 Pull the spring cotter pin Fig 72 1 out of the fas tening bolts Fig 72 2 Removing the working basket Fig 71 Mounting screw working basket Fig 72 Pulling out the ...

Page 92: ...at an angle For easier moving of the working basket two rollers are attached to the bottom By tipping it appropriately the working basket can be moved on the rollers Fig 73 Pulling out the fas tening bolts Fig 74 Lifting the working basket Fig 75 Pulling out the working basket Operation 13 02 2013 Aerial access platform Leo15GT 2012 88 ...

Page 93: ...ith the attachments Fig 76 1 on the bolts Fig 76 2 10 Insert the fastening bolts Fig 77 1 11 Secure the fastening bolts Fig 78 2 with the spring cotter pin Fig 78 1 Inserting the working basket Fig 76 Inserting the working basket Fig 77 Inserting the fastening bolts Fig 78 Securing the fastening bolts Operation 13 02 2013 Aerial access platform Leo15GT 2012 89 ...

Page 94: ...tion of the control console in the working basket and the cable remote control See also the separate operating instruc tions for the lifting device The lifting device is optional To operate follow the operating instructions attached to the machine file 6 11 Emergency operation Personnel n Trained people Protective equipment n Protective clothing n Safety boots n Protective helmet The aerial lift p...

Page 95: ...n the transport position 1 Pull the mains plug 2 Loosen the knurled thumb screws of the cover Fig 81 1 and 2 and remove the cover The valves for platform operation Ä Chapter 6 13 1 Valve setting for plat form on page 99 are under the cover Fig 81 1 and the valves for outrigger operation Ä Chapter 6 13 2 Valve set ting outriggers on page 101 are under the cover Fig 81 2 3 Remove the hand lever Fig ...

Page 96: ...1 of the crawler chassis valve 6 Using the lever Fig 85 1 turn the outrigger and platform valve to the right to the outrigger and platform function Fig 85 1 Fig 83 Operating lever Fig 84 Unscrew emergency hand activator Fig 85 Adjusting outrigger and platform functions Operation 13 02 2013 Aerial access platform Leo15GT 2012 92 ...

Page 97: ...These are black white valves that is the speed of the platform movement cannot be regulated There are only the posi tions open or closed Activate the desired valve Fig 88 3 by pressing in with the operating lever Fig 88 2 and simulta neously pumping with the hand pump Fig 88 1 10 Move the machine according to Ä Chapter 6 13 Valve settings on page 99 until the desired position is reached 11 Remove ...

Page 98: ...hout support of the control Fully hydraulic operation with power supply from electric motor or combustion engine In this case use of the control is not intended since this can create problems Service operation is only permitted when the aerial access platform is in perfect technical condition Service operation can be required or useful for instance during maintenance work The service operation is ...

Page 99: ... 90 1 and 2 The valves for platform operation Ä Chapter 6 13 1 Valve setting for plat form on page 99 are under the cover Fig 90 1 and the valves for outrigger operation Ä Chapter 6 13 2 Valve set ting outriggers on page 101 are under the cover Fig 90 2 3 Unscrew and remove the emergency hand lever Fig 91 1 of the crawler chassis valve Fig 90 Removing the cover Fig 91 Unscrew emergency hand activa...

Page 100: ...ckwise up to the stop Always screw in only one valve Fig 94 1 or 2 The other one must be unscrewed 7 To carry out the desired machine movements press the valves for outrigger and platform function according to the valve setting Ä Chapter 6 12 1 Service operation bracing and platform functions on page 95 and at the same time press the green button for the service opera tion 8 After completing work ...

Page 101: ... operation and the front emergency hand lever Fig 96 1 at the same time Emergency hand lever to the right right crawler chassis drives forward Emergency hand lever to the left right crawler chassis drives backward To drive the left crawler chassis press the green button for service operation and the rear emer gency hand lever Fig 96 2 at the same time Emergency hand lever to the right left crawler...

Page 102: ...hassis can also be driven simultaneously To do this press the green button for service operation and turn the corresponding emergency hand levers in the desired direction Operation 13 02 2013 Aerial access platform Leo15GT 2012 98 ...

Page 103: ... for platform Explanation of symbols for upper valve row Tip working basket forwards Swivel the plat form anti clock wise seen from above Lift the lower boom Lift the upper boom Extend the transport of the upper boom Operation 13 02 2013 Aerial access platform Leo15GT 2012 99 ...

Page 104: ...er valve row Tip working basket back wards Swivel the plat form clockwise seen from above Lower the lower boom Lower the upper boom Retract the transport of the upper boom Operation 13 02 2013 Aerial access platform Leo15GT 2012 100 ...

Page 105: ...ccording to the outrigger number Fig 98 Valve setting outriggers 1 Retract outrigger 1 2 Retract outrigger 2 3 Retract outrigger 3 4 Retract outrigger 4 5 Extend outrigger 4 6 Extend outrigger 3 7 Extend outrigger 2 8 Extend outrigger 1 Operation 13 02 2013 Aerial access platform Leo15GT 2012 101 ...

Page 106: ...Operation 13 02 2013 Aerial access platform Leo15GT 2012 102 ...

Page 107: ...unauthorised restart of the power supply during maintenance there is a danger of serious injuries or death for per sons in the danger zone Switch off all power supplies before starting work and make sure they cannot be switched on again Securing to prevent restart Maintenance 13 02 2013 Aerial access platform Leo15GT 2012 103 ...

Page 108: ...ing points Make sure that all maintenance work is performed and completed according to the details and instructions in these instructions Make sure that there are no people in the danger zone Make sure that all covers and safety equipment are installed and functioning properly WARNING Danger of injury due to hot surfaces Surfaces of engine components can get heated up considerably during operation...

Page 109: ...ping used or surplus grease and dispose of in accordance with applicable local regulations n Catch replaced oils in suitable containers and dis pose of in accordance with applicable local regula tions 7 2 Maintenance plan The next sections describe the maintenance work that is required for optimal and fault free operation of the machine Insofar as increased wear can be detected during reg ular che...

Page 110: ...le Every 100 hours of operation Change engine oil Qualified per sonnel Clean spark plugs Qualified per sonnel Every 200 hours of operation or monthly Replace air filter insert Qualified per sonnel Clean rough fuel filter Qualified per sonnel Clean spark plugs and adjust electrodes Qualified per sonnel Every 300 hours of operation Check set valve play Qualified per sonnel Every 500 hours of operati...

Page 111: ...es empty the dust collection container Trained people Check the intake area of the combustion and cooling air Trained people Check the air filter maintenance display Trained people Check the water precipitator Trained people Every 250 operating hours or every 12 month whichever occurs first Change engine oil Qualified personnel Every 250 hours of operation Maintenance of the oil bath air filter Qu...

Page 112: ...l Maintenance work Personnel Service the dry air filter Qualified personnel Every 1000 hours of operation Clean the oil filter Qualified personnel Maintenance 13 02 2013 Aerial access platform Leo15GT 2012 108 ...

Page 113: ...rsonnel Grease the grease nipple on the rotary drive Ä Chapter 7 3 7 Lubrication plan on page 118 Qualified personnel Lubricate the bolts Ä Chapter 7 3 7 Lubrication plan on page 118 Qualified personnel Check the hydraulic oil level Ä Chapter 7 3 4 Checking the hydraulic oil level on page 114 Qualified personnel monthly Lubricate transport guide slide bearing Ä Chapter 7 3 7 Lubrication plan on pa...

Page 114: ... thoroughly with clear water 1 Pull the mains plug 2 Make sure that all covers are mounted properly 3 Loosen coarse dirt with the high pressure cleaner Do not clean the appropriately marked compo nents Fig 99 with the high pressure cleaner 4 Clean machine with a sponge acid free household cleanser and a water hose 5 After cleaning the machine lubricate it according to Ä Chapter 7 3 7 Lubrication p...

Page 115: ...i tion on page 72 The machine must be braced completely and the chains may no longer touch the floor 2 Loosen the screws Fig 100 1 and remove the cover Fig 100 2 3 Using a grease gun insert sufficient multi purpose lubricant Item no 3917 0095 on the grease nipple Fig 101 1 of the tensioning cylinder Fig 101 2 until the chain has slack Fig 102 X of 10 15 mm Fig 100 Removing the cover Fig 101 Forcin...

Page 116: ...hat no lubricant escapes on the grease nipple Fig 101 1 5 Mount the cover Fig 103 2 with the screws Fig 103 1 Fig 102 Slack X Fig 103 Mounting the cover Maintenance 13 02 2013 Aerial access platform Leo15GT 2012 112 ...

Page 117: ...6 5 Putting the machine in work posi tion on page 72 2 Use the grease gun on the grease nipples Fig 104 1 of the rotating drive to insert high per formance lubricant Item no 3917 0130 3 Remove the excess lubricant and dispose of it properly 4 Check the water drain hole Fig 104 2 on the underside of the rotary drive to see if it is soiled clean if necessary Fig 104 Lubricating the rotating drive Ma...

Page 118: ...he machine in transport position Ä Chapter 6 7 Putting the machine in transport position on page 79 2 Make sure that the aerial access platform is aligned horizontally 3 Pull the mains plug 4 Unscrew the cover Fig 105 1 from the hydraulic oil tank 5 Check the oil level visually if necessary use a pocket flash light The oil level must be approx 2 cm below the top of the tank Fig 106 6 If necessary ...

Page 119: ...Ä Chapter 3 10 Lubricants on page 43 The chain drives each have a separate gearbox The following instructions apply for one gearbox 1 Put the machine in transport position Ä Chapter 6 7 Putting the machine in transport position on page 79 2 Align the aerial access platform so that the lower edge of the screw connection Fig 107 1 is on the middle axis Fig 107 2 of the gearbox unit Fig 107 3 3 Make ...

Page 120: ...3 10 Lubricants on page 43 To do this tip oil slowly through the hole Fig 109 2 until it reaches the lower edge of the threaded hole Fig 109 1 8 Make sure that the seals and copper washers of the screw connections are present and in order 9 Re tighten the screw connections Fig 110 1 and 2 with the seals or copper washers Fig 108 Unscrewing the screw connections Fig 109 Checking the oil level Fig 1...

Page 121: ...sport position on page 79 2 Pull the mains plug 3 Unscrew all knurled thumb screws Fig 111 2 of the cover Fig 111 1 and remove the cover 4 Place a suitable container for hydraulic oil under the high pressure filter Fig 112 1 5 Carefully unscrew the filter bowl Fig 112 2 6 Catch escaping hydraulic oil and dispose of it prop erly Fig 111 Loosen the cover Fig 112 Unscrewing the filter bowl Maintenanc...

Page 122: ... with the knurled thumb screws Fig 115 2 10 Check the hydraulic oil level Ä Chapter 7 3 4 Checking the hydraulic oil level on page 114 7 3 7 Lubrication plan When handling lubricants always heed the manufacturer s safety data sheet With speci fication of the item number the lubricants can be ordered from the manufacturer Please see page 2 for the contact data Fig 113 Filter insert Fig 114 High pre...

Page 123: ...terval 1 Bolts Lubricant spray 3917 0005 Weekly 2 Transport guides slide bearing White paste spray 3917 0037 monthly 3 Rotating drive 3 grease nipples Grease 3917 0130 Weekly 4 Transducer cylinder grease nipple Grease 3917 0095 Weekly Maintenance 13 02 2013 Aerial access platform Leo15GT 2012 119 ...

Page 124: ...ceed the maximum allowable tightening torque Check the tightening torques regularly Always heed the relevant guidelines and design criteria for screw connections The table shows the required tightening torques for ach ieving the most reliable initial tension for the screws of the rotating assembly Screw size Screw quality Tightening torque M 12 10 9 110 Nm M16 10 9 270 Nm Maintenance 13 02 2013 Ae...

Page 125: ... manufacturer see con tact data on page 2 8 1 Safety instructions for fault repair WARNING Danger to life from an unauthorised restart In the event of an unauthorised restart of the power supply while tracking down and recti fying a fault there is a danger of serious inju ries or death for persons in the danger zone Switch off all power supplies before starting work and make sure they cannot be sw...

Page 126: ...owing points Make sure that all fault repair work is performed and completed according to the details and instructions in these instructions Make sure that there are no people in the danger zone Make sure that all covers and safety equipment are installed and functioning properly WARNING Danger of injury due to hot surfaces Surfaces of engine components can get heated up considerably during operat...

Page 127: ...ause of the fault 3 If fault rectification requires work in the danger zone shut down the machine and secure to pre vent restarting Immediately notify those responsible at the place of use about the fault 4 Depending on the nature of the fault have it recti fied by authorised specialised personnel or rectify it yourself The fault table below provides information about who is authorised to rectify ...

Page 128: ...r Check safety equipment and switch on or replace if necessary Ä Chapter 8 5 1 Changing fuses on page 133 or Ä Chapter 8 5 2 Switching the circuit breaker on off on page 135 Trained people Bracing not pos sible Switch position on the control panel incorrect Move function selection switch to Out riggers Ä Chapter 6 5 Putting the machine in work position on page 72 Trained people Machine not in tran...

Page 129: ...chine on page 77 Trained people Safety equipment has been trig gered fuse FI circuit breaker Check safety equipment and switch on or replace if necessary Ä Chapter 8 5 1 Changing fuses on page 133 or Ä Chapter 8 5 2 Switching the circuit breaker on off on page 135 Trained people Swivelling not possible Upper and lower boom still in the transport lock Lift lower boom out of the transport lock Ä Cha...

Page 130: ...ive Take machine out of service immedi ately and call service Trained people Loud motor pump noise and movements get slower and then stop Too little hydraulic oil in the tank Check hydraulic oil level and top up if necessary Ä Chapter 7 3 4 Checking the hydraulic oil level on page 114 Trained people Hydraulic system is leaking Call service Trained people Outlet in the working basket has no voltage...

Page 131: ...e error hardware error 2 Software error hardware error 3 Software error hardware error 4 Hardware error microprocessor 5 Check inputs floor pressure and outrigger 1 lock 6 Check inputs floor pressure and outrigger 2 lock 7 Check inputs floor pressure and outrigger 3 lock 8 Check inputs floor pressure and outrigger 4 lock 9 Check inputs for the position switch wide braced outrigger 1 10 Check input...

Page 132: ...on 1 of bottom control pressed or defective 28 Button 2 of bottom control pressed or defective 29 Button 3 of bottom control pressed or defective 30 Button 4 of bottom control pressed or defective 31 Toggle switch to activate basket swivel on bottom control pressed or defective 32 Toggle switch to activate movements on bottom control is pressed or defective 33 Toggle switch to activate auto bracin...

Page 133: ...or several days and must be restarted 56 Different input information of the safety functions between the master and slave 57 Different input information of the safety functions between the master and slave 58 Different input information of the safety functions between the master and slave 59 Different input information of the safety functions between the master and slave 60 Check safety relay 1 mo...

Page 134: ...Calibrated values of joysticks wrong check values or load factory settings 83 Second control cannot be reached via internal CAN bus Check CAN connection and second control 84 Upon starting the controller the second controller was already started Check voltage supply and CAN bus 85 Check internal CAN bus 86 Check internal CAN bus 87 Check internal CAN bus 88 Software error 89 Check internal CAN bus...

Page 135: ...ror hardware error 111 Software error hardware error 112 Software error hardware error 113 Software error hardware error 114 Software error hardware error 115 Software error hardware error 116 Software error hardware error 117 Software error hardware error 118 The bracing angle is in invalid range or tilt sensor is defective 119 Error was detected by other control Read out error memory on 2nd cont...

Page 136: ...ive wheel n Increased wear with use on very sandy ground Heed chain tension The metal core can become bent by great wear This can cause breaks with progres sive wear Change rubber tracks early Wear of the profile n Normal occurrence n Depending on the area of application earlier or later Depending on the area of application the rubber tracks must be replaced appropriately early Essen tially howeve...

Page 137: ...life due to electric current In case of contact with live components there is danger to life Switched on electric compo nents can make uncontrolled movements and cause extremely severe injuries Before starting work switch off the voltage supply and secure against switching on again When changing fuses adhere to the cor rect amperage 1 Pull the mains plug 2 Unscrew all knurled thumb screws Fig 118 ...

Page 138: ...It is attached to the control box door from the inside 4 Replace defective fuse with a new fuse of equal amperage 5 Close control box door Fig 119 1 and lock with the double bit key 6 Replace the cover Fig 120 2 and screw on with the knurled thumb screws Fig 120 1 Fig 119 Opening the control box door Fig 120 Fastening the cover Faults 13 02 2013 Aerial access platform Leo15GT 2012 134 ...

Page 139: ...he voltage supply and secure against switching on again When changing fuses adhere to the cor rect amperage 1 Pull the mains plug 2 Unscrew all knurled thumb screws Fig 121 2 of the cover Fig 121 1 and remove the cover 3 Open cover Fig 122 1 of the FI box Fig 122 2 4 Switch the FI circuit breaker or safety switch for outlet on the working basket Ä Chapter 8 5 2 Switching the circuit breaker on off...

Page 140: ...d in the control box For the precise assignment consult the circuit diagram Ä Appendix B Circuit diagram on page 201 8 6 2 Working basket fuse and FI circuit breaker 1 Safety switch on plug in working basket 2 FI circuit breaker Fig 123 Replacing cover Fig 124 Fuzzy IV control card Fig 125 Circuit breaker Faults 13 02 2013 Aerial access platform Leo15GT 2012 136 ...

Page 141: ...ay be subject to uncontrolled movements and may cause grave injury Before starting the dismantling switch off the electric power supply and disconnect completely 9 2 Disposal If no return or disposal agreement has been made send the dismantled components for recycling n Scrap metals n Send plastic elements for recycling n Sort and dispose of other components in accord ance with their material comp...

Page 142: ... components lubricants and other auxiliary materials must be disposed of by authorised spe cialist companies If in doubt obtain information about dis posal in accordance with the environ mental regulations from the local munic ipal authorities or specialised waste disposal companies Disposal 13 02 2013 Aerial access platform Leo15GT 2012 138 ...

Page 143: ...49 Emergency 66 Emergency operation 51 Emergency Stop 66 Emergency Stop button 29 51 Emissions 42 E Motor 42 Engine switch 51 Environmental protection Batteries 38 Cleaning liquids 37 Cooling water frost protection 38 Fuels 37 Hydraulic oil 37 Lubricants 37 Rechargeable batteries 38 Error code list 127 F Fault indication 127 Fault table 123 FI circuit breaker 136 Fire 36 First aid 36 Fuses 136 Fuz...

Page 144: ...ipment 28 Safety harness 53 Screw tightening torque 120 Service 11 Service operation 51 Storage 61 Symbols in the instructions 7 language neutral 33 language specific 34 on the machine 31 T Tightening torque 120 Tilt sensor 30 Transport crane 57 Fork lift 58 Trailer 59 Transport inspection 55 Transport position 79 Type plate 44 U Use 21 V Valve component group 51 Valves Emergency operation 31 Serv...

Page 145: ...Appendix Appendix 13 02 2013 Aerial access platform Leo15GT 2012 141 ...

Page 146: ...Appendix 13 02 2013 Aerial access platform Leo15GT 2012 142 ...

Page 147: ...ts of the appendix A Combustion engine 145 A 1 Gasoline engine Robin Subaru EX 21 147 A 2 Diesel engine Hatz 1B30 optional B Circuit diagram C Hydraulic plan Appendix 13 02 2013 Aerial access platform Leo15GT 2012 143 ...

Page 148: ...Appendix 13 02 2013 Aerial access platform Leo15GT 2012 144 ...

Page 149: ...A Combustion engine Combustion engine 13 02 2013 Aerial access platform Leo15GT 2012 145 ...

Page 150: ...Combustion engine 13 02 2013 Aerial access platform Leo15GT 2012 146 ...

Page 151: ...A 1 Gasoline engine Robin Subaru EX 21 Combustion engine 13 02 2013 Aerial access platform Leo15GT 2012 147 ...

Page 152: ...Combustion engine 13 02 2013 Aerial access platform Leo15GT 2012 148 ...

Page 153: ...cations are subject to change without notice When ordering spare parts always give us the MODEL PRODUCTION NUMBER and SERIAL NUMBER of your engine Please fill in the following blanks after checking the production number on your engine Location of label is different depending on the engine specification SER No Stamping PROD No SER No Label NOTICE The engines which have emission label are allowed to...

Page 154: ...or other flammable materials Keep cooling air intake recoil starter area and muffler side of the engine at least 1 meter 3 feet away from buildings obstructions and other burnable objects Keep the engine away from flammables and other hazardous materials trash rags lubricants explosives OTHER SAFETY PRECAUTIONS Place the protective covers over the rotating parts If rotating parts such as the drive...

Page 155: ...looseness and fuel leakage Leaked fuel creates a potentially dangerous situation Check bolts and nuts for looseness A loose bolt or nut may cause serious engine trouble Check the engine oil and refill if necessary Check the fuel level and refill if necessary Take care not to overfill the tank Keep cylinder fins and recoil starter free of dirt grass and other debris Wear snug fitting working clothe...

Page 156: ...back cover for Fig 1 1 1 1 1 to 8 8 8 8 8 indicated in the sentence Add oil Engine oil On Run Engine start Electric start Engine stop Fast Slow Fuel shut off Fuel system failure malfunction Fuel gasoline Choke Battery Stay clear of the hot surface Stop the engine before refueling Check for leakage from hose and fittings Shutt off fuel valve when the engine is not in use HOT avoid touching the hot ...

Page 157: ...es or sparks near a battery especially during charging Be sure to confirm Battery polarity Connect positive terminal first when mounting battery and disconnect negative terminal first when dismounting Battery electrolyte contains sulphuric acid Protect your eyes skin and clothing In case of contact flush thoroughly with water and get prompt medical attention especially if your eyes are affected WA...

Page 158: ...ngine body or machine with ground wire 3 When installing the key switch on the machine install with its drain hole at the bottom Make sure the polarity of battery terminals Never connect the battery cable with the battery negative terminal When connecting the battery cable with the battery negative terminal diode rectifier chips will be burned out or damaged in a moment CAUTION When installing the...

Page 159: ...oper Improper Spacer Key Key should be within this portion Key Belt Pulley Installation Install the belt pulley in the no over hang condition as shown in the illustration Correct Pulley Incorrect Crankshaft PTO Pulley Crankshaft PTO Large over hang SAE inch keyway type crankshaft Washer Use the washer material SS41P with the thickness described below 0 177 4 5 or over in mm 0 248 6 3 or over EX13 ...

Page 160: ...ay stop See Fig 4 y FOR ELECTRIC STARTER MODELS Insert the key into the key slot and set it at the I ON position Turn it to the right START position to start the engine See Fig 4 t Do not operate the electric starter continuously for more than 5 secounds even if the engine dose not start If the engine failed to start set the key to the I ON position and wait for about 10 secounds before retrying N...

Page 161: ...njury pay attention to the hot oil CAUTION Every 100 hours 2 PERIODIC INSPECTION Periodic maintenance is vital to the safe and efficient operation of your engine Check the table below for periodic maintenance intervals Should the engine be operated in extremely dusty condition or in heavier loading condition the maintenance intervals must be shortened depending on the contamination of oil clogging...

Page 162: ...frame before cleaning elements 5 CLEANING FUEL CUP See Fig 7 7 7 7 7 t t t t t WARNING Flame Prohibited WARNING Flame Prohibited 8 CHECKING BOLTS NUTS AND SCREWS Retighten loose bolts and nuts Check for fuel and oil leaks Replace damaged parts with new ones 9 CHECK BATTERY 7 FUEL HOSE REPLACEMENT See Fig 7 7 7 7 7 1 1 1 1 1 Replace the fuel hose every 2 years If fuel leaks from fuel hose replace t...

Page 163: ...y when the oil level falls below the prescribed limit Unless the oil level is raised above the prescribed limit the engine will stop immediately after starting 3 Is the spark plug wet with gasoline 1 Is the fuel cock opened 2 Choke close choke lever and pull the starter handle five or six times Remove the plug and check if its electrode is wet If the electrode is wet fuel is well supplied to your ...

Page 164: ...peration in the cold weather condition will be improved by means of optional Cold Weather Kit Please consult with your nearest ROBIN dealer or distributor The following optional parts are also available at ROBIN distributor and or dealer 1 Air Cleaner Oil bath type Pre cleaner type etc 2 Magneto for lighting usage 12V 15W 40W 200W 3 Fuel Tank with fuel level gauge Dry Weight Starting System Spark ...

Page 165: ...A 2 Diesel engine Hatz 1B30 optional Combustion engine 13 02 2013 Aerial access platform Leo15GT 2012 161 ...

Page 166: ...Combustion engine 13 02 2013 Aerial access platform Leo15GT 2012 162 ...

Page 167: ...INSTRUCTION BOOK 43380207 ENG 10 05 3 Printed in Germany 33 1B20 1B27 1B30 1B40 1B50 ...

Page 168: ...void accidents ensure that you operate the engine correctly and assist you in complying with the mainte nance intervals in order to ensure long lasting reliable performance Please pass this Instruction Manual on to the next user or to the following engine owner The worldwide HATZ Service Network is at your disposal to advise you supply with spare parts and undertake servicing work You will find th...

Page 169: ...ing the water trap 20 Page 5 3 Maintenance every 250 operating hours 21 5 3 1 Oilbath air cleaner maintenance 21 5 3 2 Changing engine oil 22 5 3 3 Checking and adjusting valve clearances 23 5 3 4 Cleaning cooling air area 24 5 3 5 Checking screw connections 24 5 3 6 Cleaning the exhaust mesh inlet 25 5 4 Maintenance every 500 operating hours 26 5 4 1 Renewing fuel filter 26 5 4 2 Air cleaner main...

Page 170: ...he electrical system may cause sparking and must there fore be avoided Provide protection against contact with rotating parts once the engine is connected to the driven equipment or machine HATZ protective guards are available for the belt drive of the cooling fan and alternator drive sys tems Always observe the start up information in the operating instructions before starting the engine this is ...

Page 171: ...on the engine while it is running Please don t wear necklaces bracelets or any other things which you could get caught with Please pay attention to all advice and warning stickers placed on the engine and keep them in legi ble condition Contact your next HATZ service station if a sticker comes off or is illegible and ask for a new one We accept no liability for damage resulting from improper modif...

Page 172: ...tarter motor 7 Voltage regulator 8 Crankshaft power take off 9 Oil drain plug 10 Speed adjustment lever 11 Oil filter 12 Engine mountings 13 Ignition key 14 LED display 15 Intake opening for cooling and combustion air 16 Oil filler pipe and dipstick 17 Recoil starter 18 Engine shutdown pin 19 Dry type air cleaner 20 Lifting lug see also Fig 41 Pos 1 21 Fuel tank cap 22 Noise insulating hood ...

Page 173: ...p with oil sump l approx l approx 0 9 1 2 6 1 0 9 1 1 1 1 2 8 1 1 5 1 3 2 1 1 5 1 Difference between max and min levels without oil sump with oil sump l approx l approx 0 5 1 1 6 1 0 5 1 0 5 1 1 8 1 0 8 1 2 2 1 0 8 1 Lubricating oil consumption after running in max 1 of fuel consumption at full load Lubricating oil pressure oil temperature 100 C approx 2 5 bars at 3000 r p m Direction of rotation ...

Page 174: ...onents 3 4 Load on engine Operating the engine for a lengthy period off load or at very low loads can affect its running quality We therefore recommend a minimum engine load of 15 If operated at such low loads it is best to operate the engine at a signifi cantly higher load for a short period before switching it off F 15 N STOP 76 5 STOP START F 30 N M 2 3 Nm 3 5 Type plate 3 The type plate is pla...

Page 175: ...s to 150 hours of operation Oil viscosity 5 Select the viscosity class according to the ambient temperature for cold starts 40 30 20 10 0 10 20 30 40 50 104 86 68 50 32 14 4 22 40 OIL SAE C F 5W 30 5W 40 10W 40 10W 30 15W 40 30 40 122 10W When adding oil or checking the oil level the engine must be horizontal 6 Remove oil filler screw and add engine oil Lubricating oil capacity see Chapter 3 1 7 T...

Page 176: ... that sealing ring 3 is correctly seated and fasteners 4 are tight 2444 5 2440 10 4 1 3 Fuel Stop the engine before refilling the fuel tank Never refuel near a naked flame or sparks which could start a fire Don t smoke Use only pure fuel and clean filling equipment Take care not to spill fuel All diesel fuels which satisfy the following speci fications are suitable EN 590 or BS 2869 A1 A2 or ASTM ...

Page 177: ... advance 4 2 Starting Do not run the engine in closed or badly ventilated rooms danger of poisoning Before starting the engine ensure that no one is in the danger area close to the engine or equipment and that all protective guards are fitted 4 2 1 Preparations for starting If possible disengage the engine from any driven equipment The auxiliary equipment should always be placed in neutral First o...

Page 178: ...ove speed adjuster to the START RUN position Now the engine is ready for starting 15 Never use starting sprays Important After long time standstill approx 6 months or even longer or first operation operate engine with low adjusted speed and without load for approx 20 sec after start This measure assures a lubrication of all bearings before increasing speed and load It also prevents an insufficient...

Page 179: ...e engine Devices which are not securely fastened should be restrained with the foot 17 Grip the handle with both hands 18 Commence pulling the starting cable vigorous ly and at an increasing speed do not jerk it violently until the engine starts Note If after several attempts of starting the exhaust begins to emit white smoke move the speed ad justment lever to the STOP position and pull the start...

Page 180: ...n there during engine operation The battery charge and oil pressure lights should extinguish directly after the engine starts The display lamp 1 lights up to show that the engine is running Prior to starting up again the key has to be returned to position 0 When the engine is running the starter repeat lock in the ignition switch will prevent the starter from engaging and suffering damage Preheate...

Page 181: ...ly after a period of emergency run ning ascertain the cause of the fault and have it rectified Chapter 6 Have the emergency starting lever sealed once again by a HATZ service point When the automatic electrical shutdown system is used the emergency start described above means that liability for risks must be accepted by the operator Motorenfabrik HATZ assumes no liability In case of difficulty con...

Page 182: ...atic shutdown monitoring the oil level must be checked every 8 15 operat ing hours Chapter 5 2 1 4 3 Stopping the engine Speed adjuster standard version 23 Move the speed adjustment lever 1 back to the STOP position The engine cuts out Note Engines with a fixed lower idling speed cannot be switched off using the speed adjustment lever See the paragraph entitled Other ways of switching off the engi...

Page 183: ...to its initial position Depending upon the model the battery charge indicator 2 and oil pressure warning indicator 3 will come on again after the engine comes to a stop Fig 25 and Fig 26 Turn the key to position 0 and remove it All the indicator lights must go out Fig 25 and Fig 26 Note Failure to return the starter key to position 0 may result in the battery being totally discharged If operation ...

Page 184: ... or before each daily start up Check oil level Examine the lower section of the oilbath air cleaner to ensure correct oil level and freedom from con tamination change the oil if it contains sludge On version with cyclone type dust trap empty the dust collector Check combustion and cooling air intake zone Check air cleaner maintenance indicator Check the water trap 5 2 1 4 1 2 5 3 1 5 3 1 5 2 2 5 2...

Page 185: ...il Chapter 5 3 2 Check valve clearances and adjust if necessary Chapter 5 3 3 Examine screw connections chapter 5 3 5 Do not tighten the cylinder head fastening If the engine is not used frequently change the engine oil after 12 months at the latest regard less of the actual number of hours it has been in operation 18 AUTOM 8 15 250 052 502 00 OIL OIL 40 30 20 10 0 10 20 30 40 50 104 86 68 50 32 1...

Page 186: ...necessary add oil to the max mark Chapter 4 1 1 5 2 2 Check air intake area for combustion and cooling Heavy contamination is an indication that in creased dust accumulation necessitates a corre spondingly shorter maintenance interval Chapter 5 3 1 5 3 4 and 5 4 2 max 29 Check air intake points for severe blockage due to leaves heavy dust accumulation etc and if necessary clean them 30 For models ...

Page 187: ...lows several times per day 1 2440 13 5 2 4 Checking the water trap The intervals at which you should check the water trap depend entirely on the amount of water in the fuel and the care taken when re fuelling The normal interval is once a week 33 Loosen hexagon screw 1 with approx 3 4 rotations Trap the drops which emerge in a transparent vessel Since water has a greater specific grav ity than die...

Page 188: ...cleaner maintenance 35 Trap the old oil and dispose of it in accordance with local legislation Take off the oil tank 1 Remove contaminated oil and sludge from the oil tank and clean it out Rinse out filter element 2 in diesel oil allow it to drip thoroughly and wipe it down before re assembling the air cleaner If severely contaminated clean filter housing 3 Never attempt to repair the oilbath air ...

Page 189: ...nut 5 3 2 Changing engine oil The engine must be standing level and be switched off Only change the oil when the engine is warm Danger of scalding from hot oil Trap the old oil and dispose of it in accordance with local legislation 2440 13 37 38 Take out oil drain plug 1 and allow the oil to drain out Fig 37 without oil sump Fig 38 with oil sump Clean the oil drain plug 1 fit a new washer 2 insert...

Page 190: ...an chapter 5 1 Only carry out adjustments when the engine is cold 10 30 C 39 Remove cover to air filter 40 Remove noise insulating hood 2443 12 41 On version with oilbath air cleaner remove screw 2 and take off cover plate with noise insulating hood Remove any contamination adhering to the cover for the cylinder head 42 Remove screws 1 and take off the cylinder head cover with gasket 2 1 2 2442 18...

Page 191: ... retight ened Fit cover for cylinder head and tighten evenly always using a new gasket Re attach parts previously removed from engine Do not forget replace the rubber cap at the inspection hole cover Carry out a brief test run then check the cover for leaks 5 3 4 Cleaning cooling air area The engine must be switched off and cooled down before cleaning If severely contaminated clean the cooling fin...

Page 192: ...gine is running or until it has cooled down after being stopped 46 Unscrew hex nut and remove the exhaust mesh insert 2442 6 Remove any deposits in the mesh insert by means of a wire brush Check the exhaust mesh insert for cracks or damage and if necessary replace with a new one 47 Screw on hexagon nut 1 by approx 1 turn 48 Insert exhaust screen with hook 1 into hole them pull outwards again so th...

Page 193: ... filter 1 Fig 49 and a replaceable cartridge filter which is installed in the tank Fig 50 The advantage of this system consists in retaining dirt particles which might get into the fuel system on filter replacement upstream of the following external filter so that they can not endanger the injection system Important This external filter must not be replaced Only replace the fuel filter installed i...

Page 194: ...sert the new filter Always renew the fuel filter Note the arrows indicating the correct direction of flow Secure the filter to its mount Fill the fuel tank with diesel oil Chapter 4 1 3 Air is vented from the fuel system automati cally Check the fuel filter and lines for leaks after a short test run 5 4 2 Air cleaner maintenance The filter cartridge should only be cleaned when the maintenance lamp...

Page 195: ...tion 57 Use compressed air to blow through the filter cartridge from the inside outwards until no fur ther dirt emerges Important The pressure must not exceed 5 bar Persons handling compressed air must wear protective goggles Moist or oily contamination Renew the filter cartridge Checking the filter cartridge Check filter cartridge s gasket surface 1 for damage Fig 57 Check the filter cartridge fo...

Page 196: ... removed The engine must be standing horizontally and switched off Danger of scalding from hot oil Trap the old oil and dispose of it in accordance with local legislation 58 Loosen screw 1 with approx 5 rotations 59 Remove oil filter from housing 60 Use an air line to blow out oil filter dirt from the inside outwards Persons handling compressed air must wear protective goggles 2445 10 29 ...

Page 197: ... and correctly fitted replace oil filter if neces sary Lubricate joint washer before fitting 62 Put in oil filter and press until limit stop Check whether tension springs sit close to oil filter with both ends 1 before tightening screw Check the oil level and restore to the max level if required Chapter 4 1 1 30 ...

Page 198: ... inadequate resistance to low temperatures Move lever to START position Move to operating position by pulling the pin gently Add fuel Systematically check the entire fuel supply system If still no fault found check engine feed line check fuel filter Check valve clearances adjust if necessary See workshop manual See workshop manual Operate preheater optional extra Disengage engine from equip ment i...

Page 199: ...ked One of the automatic shut down s monitoring elements has initiated a stop signal See also Chapter 6 4 Fault in the electrical system Battery and or other cables incorrectly connected up Cable connections loose and or oxidised Battery faulty and or flat Starter motor faulty Faulty relays monitoring element Change lubricating oil and add oil of the correct viscosity class Check the battery if ne...

Page 200: ...ange fuel filter Ensure adequte tank venting Check fuel system for penetration of air Check air vent valve Contact a HATZ service station Localise the monitoring element responsible and clear the fault or contact a HATZ service station Check oil lubrication Check air cooling zone for con tamination See workshop manual Add fuel Change fuel filter Provide adequate tank breathing Check fuel system fo...

Page 201: ...n engine Inadequate cooling Contamination of entire cooling air zone Air duct panels not properly sealed Operation off load for a prolonged period Drain off lubricating oil as far as upper mark on dipstick Clean cooling air zone Check cooling air deflector plates and shafts for complete ness and airtight seal Operate the machine at about 70 load until moisture no longer emerges from the ex haust 5...

Page 202: ... case of an emergency start in manual mode leave the battery which might be dis charged connected to the engine Before starting emergency operation without battery proceed as follows before starting disconnect plug connection to voltage regulator for engine models with mounted instrument box picture 25 Turn key to off position 0 and remove disconnect plug connection to instrument box for engine mo...

Page 203: ...CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm ...

Page 204: ......

Page 205: ...B Circuit diagram Circuit diagram 13 02 2013 Aerial access platform Leo15GT 2012 201 ...

Page 206: ...Circuit diagram 13 02 2013 Aerial access platform Leo15GT 2012 202 ...

Page 207: ...C Hydraulic plan Hydraulic plan 13 02 2013 Aerial access platform Leo15GT 2012 203 ...

Page 208: ...Hydraulic plan 13 02 2013 Aerial access platform Leo15GT 2012 204 ...

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TEUPEN LEO 15 GT, Translation Of The Original Operating Instructions

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