Leguan 135 NEO Operator'S And Service Manual Download

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Operator and Service manual

Version 7/2020
July 2020

Summary of Contents for 135 NEO

Page 1: ...Operator and Service manual Version 7 2020 July 2020 ...

Page 2: ...icator 19 LOWER CONTROLS PANEL 20 230 V CONNECTIONS AND SWITCHES 21 OPERATION 22 STARTING THE COMBUSTION ENGINE ELECTRIC MOTOR 22 Start stop function 22 DRIVE 23 Determining the gradient of the slope 24 General information tracks and their service life 24 Guidelines Operating environment of an access platform with tracks 25 Guidelines Operating an access platform with tracks 25 USE OF OUTRIGGERS 2...

Page 3: ...Telescoping Booms 42 Greasing of the Position Sensor Pins on the Outriggers 42 HANDLING OF FUEL AND REFUELLING 43 HYDRAULIC OIL AND HYDRAULIC OIL FILTER REPLACEMENT 43 HYDRAULIC OIL LEVEL 44 BATTERY CHECK 44 FUNCTIONING OF SET UP SYSTEM 45 HYDRAULIC SYSTEM SETTINGS 46 OVERLOAD PROTECTION COMPONENTS 47 ELECTRIC SENSORS 48 Transport position monitoring 48 Levelling monitoring 49 INSPECTION OF THE TR...

Page 4: ...uctions 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 manufacturer does not accept any responsibility for consequential losses resulting from the use of this self propelled access platform The lifespan of the track system of an access platform on rubber tracks is heavily dependent on th...

Page 5: ...s other than a manufacturing error acts of vandalism adjustments repair and the replacement of parts due to normal wear and tear negligent use or non compliance with the instructions for use exceptional strain placed on the access platform sudden and unforeseeable events natural disasters external mechanical or chemical causes damage to the paintwork such as scratches and abrasions caused by flyin...

Page 6: ...LSO FULFILLS THE REQUIREMENTS LAID OUT IN THE DIRECTIVES 2004 108 EC SEURAAVIA EUROOPPALAISIA YHDENMUKAISIA STANDARDEJA ON SOVELLETTU SUUNNITTELUSSA EN280 2013 A1 2015 FOLLOWING EUROPEAN HARMONIZED STANDARDS ARE USED WHEN THE MACHINERY WAS DESIGNED EN280 2013 A1 2015 Teknisen tiedoston on valtuutettu kokoamaan LEGUAN LIFTS OY Storage address of original documents Ylötie 1 FI 33470 Ylöjärvi Finland...

Page 7: ...e below shows the machine s main parts Except for its track system the track equipped machine is similar in structure to a device with wheels 1 Chassis a Extra side weight 4WD or Track frame TRD 2 Transmission with wheels or crawler tracks 3 Outrigger 4 Outrigger cylinder 5 Combustion engine 6 Lower boom 7 Boom lift cylinder 8 Upper boom 9 Telescope cylinder 10 Push lever 11 Upper rod b Tool box 1...

Page 8: ...5 m Max allowed levelling inaccuracy 1 0º Platform rotation 40º Slewing 360º Gradeability 50 27º Gradeability sideways 28 16º Support dimensions 3 07 x 3 14 m Max gradient of slope for set up 22 12º Weight depending on equipment 1650 kg Drive system hydraulic 4WD or tracks Drive speed max 2 5 km h Lowest operating temperature 20 C storage 40 C Starter battery electric system 60 Ah 12V Sound power ...

Page 9: ...9 Main dimensions Figure 2 135 NEO Main dimensions side Figure 3 135 NEO main dimensions rear ...

Page 10: ...10 Reach diagram and support dimensions Figure 4 Reach diagram Figure 5 Support dimensions ...

Page 11: ...nd wind speed 5 Max outrigger force 6 Distance from energized electric wires 7 General user instructions 8 Daily inspection 9 Emergency lowering 2 10 Residual current device 11 Electric motor voltage 12 Tie down points 4 13 Tyre pressure 14 Leguan 135 decal 15 Lower controls decal 16 Lift points 4 Figure 6 Signs and decals ...

Page 12: ...r use carefully before operating the machine only persons aged 18 or older who have received sufficient training may use the access platform the operator must know all the functions of this access platform as well as its Rated Load loading instructions and safety instructions if there is heavy traffic in the working area it must be fenced off and marked with a fence or line Road traffic regulation...

Page 13: ...annot 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 This access platform is intended for lifting the max allowed number of persons and additional load only Check and make sure that all tyres are in good condition If the tyres are full of air make sure that there is corr...

Page 14: ... has been cut off from the electric line During welding repairs using any part of this access platform as an earth conductor is prohibited Do not use this access platform during a thunderstorm or in high winds Leave clearance for electric lines taking into account movements of the platform movements of electric lines and high winds and gusts The minimum safety clearances for overhead cables are sh...

Page 15: ...owering control devices access routes platform oil leakage work area NOTE If you notice faults or missing equipment on this access platform do not use the machine before the faults have been corrected Never set the access platform up in a place where the ground may be too soft Beware of soft ground and potholes ...

Page 16: ...Home Switch 5 Platform tilt enabler button 6 Platform rotation 7 Telescope in out buttons 8 Joystick 9 Platform overload indicator 10 Outreach control indicator 11 Fault light 12 Boom centre position indicator 13 Boom transport position indicator 14 Low fuel indicator 15 Inclination sensor indicator 16 Outrigger switches manual 17 Automatic levelling switches 18 Automatic levelling indication ligh...

Page 17: ...e boom is about to reach the current maximum outreach The frequency of the blinking light as well as the audible sound will increase as the telescopic boom closes the maximum outreach When the maximum outreach is achieved red dynamic outreach control signal light will stay continuously on and Telescope boom movement out is prevented Continuous audible sound will signal that the maximum outreach is...

Page 18: ...machine is running Inclination sensor indicator light This access platform is equipped with inclination sensor which alerts when the inclination of the chassis exceeds the given limits If the limits are exceeded while driving an orange indicator light will blink and give an audible alert can be heard Drive the machine to more even surface While using booms If the ALARM limit is exceeded Orange ind...

Page 19: ...ys visually ensure that the booms are properly placed on their transport supports Boom transport support indicator light Boom transport support indicator light will stay continuously green when all booms are properly placed on their transport supports Boom transport position light is in blinking when boom is on raised transport position This situation is used to cross high obstacles Driving is pos...

Page 20: ...e lower control 1 The ignition key figure 8 switch 7 must be turned to lower control position 2 Turn on combustion engine or electric motor with the start switch figure 8 switch 6 3 To use the booms figure 8 switches 8 11 you must also select movement speed with the speed selector switch switch 13 The speed selector also works as a dead man s switch so it must be kept turned to the desired speed o...

Page 21: ...on lead 2 Booster point pole 3 Booster point pole on the chassis 4 Residual current device Figure 10 Residual Current Device The residual current device or RDC unit switch 1 must be up 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 2 in the unit If the switch in the unit will not go down there is either...

Page 22: ...EST button can also be used to test the power supply 4 Attach the safety harness to the attachment points and close the gate 5 Switch on the petrol engine or electric motor by pushing the ignition button for desired power source 6 Use choke only if the petrol engine doesn t start automatically figure 7 switch 21 or lower controls figure 8 switch 8 7 Engine or electric motor is turned off by pushin...

Page 23: ...ver To move forward push the joystick forward and backward to reverse To turn the machine left or right simply turn the joystick to the desired direction NOTE The machine is controlled with skid steer method and the control properties vary depending on terrain so great care must be taken when starting to drive NOTE The access platform can only be driven when all booms are in transport position The...

Page 24: ...fe An access platform with a skid steer chassis equipped with a crawler track chassis offers many advantages compared with a machine on wheels However certain things regarding operation and the working environment must be taken into account with an access platform on tracks To achieve the maximum service life for the rubber tracks and crawler track chassis follow the instructions below The lifespa...

Page 25: ...uidelines Operating an access platform with tracks Check the tightness of the tracks regularly o Tracks that are too loose may fall off the sprockets Make sure not to tighten the tracks too much as this results in a loss of power and causes strain on the tracks and the track chassis see chapter 9 1 1 Change turning direction as often as possible o Turning only in one direction causes uneven wear o...

Page 26: ...ile levelling is running 8 When the chassis is levelled the green light of the automatic levelling Figure 7 19 will stay on continuously 9 Booms can be operated any time when the green levelling ok light is lit 10 Make sure wheels tracks are not on ground after levelling is done Push automatic levelling again if necessary to raise machine higher from ground Manual levelling 1 Switch on the machine...

Page 27: ... outriggers a little off from the ground which allows the user to operate drive functions 5 If the outriggers need to be driven to their transport positions press down the upper button of the automatic levelling switch and keep it held down until outriggers reach their transport positions NOTE If the green lifting light switches on even though the outriggers are not appropriately positioned using ...

Page 28: ...reached Figure 7 14 5 Leguan 135 NEO has a unique Home Switch Figure 7 7 which can be used to drive the booms to transport position See chapter 5 4 2 Beware of your surroundings when using this function Collision with buildings and other surroundings can cause the lift to fall over and cause serious damage to people and property around the lift Operate the joystick with ease and without hesitation...

Page 29: ... joystick forwards Also the platform tilt can be used without outriggers in a similar fashion To activate the platform tilt without outriggers press the platform tilt button figure 1 5 simultaneously while tilting the joystick forwards to raise platform or backwards to lower it Boom can be operated without outriggers from lower controls also Function is similar than on using the upper controls End...

Page 30: ...ns during winter time Check that the limit switches are free from snow ice and dirt Let the engine run for a few minutes before moving the machine First use drive mode for a while to warm the hydraulic oil Then use the outriggers and lastly operate the booms This way the oil in the whole system heats up and warm oil flows to the cylinders ...

Page 31: ...using the back up lowering button and Home button simultaneously To operate back up lowering from the lower controls panel 1 Turn the switch figure 8 switch 12 to the right and hold it turned simultaneously turn the speed selector switch dead man switch figure 8 switch 13 to either left or right and hold it turned 2 Use the boom switch figure 8 switch 8 to lower the boom 3 If you want to use other...

Page 32: ...ring automatic platform levelling is operational overrides telescope chain monitoring overrides outrigger monitoring overrides speed selector switch dead man s switch allows telescope in movement to remove overload Override of boom safety functions using the hand pump This function is activated from the lower controls panel with the emergency stop switch pushed down and the only available power su...

Page 33: ...ch in the lower controls panel of the access platform With this switch platform load monitoring and platform emergency stop switch can be overridden in an emergency Using the switch is allowed only in an extreme emergency for example when the operator has collapsed on the platform pressed down the emergency stop switch and they have to be lowered immediately for their safety The manufacturer is no...

Page 34: ... valve block you wish to use e g boom lift valve It is possible to use either the starter battery of the access platform or a different external battery When the battery is connected to the desired valve use the hand pump on the inside the valve casing to power the wanted function Note Platform levelling automation does not work when this procedure is followed and the platform can tilt into a dang...

Page 35: ...ported on the platform There is an automatic hydraulic brake in the rear axle that engages automatically when the combustion engine electric motor is not running DO NOT TOW Towing can cause severe damage to the hydraulic motors and other parts of the chassis If the machine is transported on a trailer a lorry or a similar vehicle it must be secured carefully There are four binding points marked on ...

Page 36: ...re that maintenance is performed in accordance with this Operator s Manual and the engine manufacturer s Service Manual Stop the engine before starting any service or inspection operation ALSO DISCONNECT THE 230 VAC PLUG Do not smoke during service and inspection operations Keep the machine and particularly the platform clean Ensure that the instructions for use are complete and legible and that t...

Page 37: ...ctor immediately if hydraulic fluid penetrates your skin Wash any body part that has come in contact with hydraulic oil carefully with water and soap Hydraulic oil is also harmful to the environment prevent oil leakages Only use hydraulic oil types approved by the manufacturer Never handle pressurised hydraulic components because in case of failure on a fitting or component a spray of high pressur...

Page 38: ...H Hydraulic oil R Hydraulic oil level FCH CH Hydraulic oil suction filter CL Hydraulic oil filters FR R Battery water CH Locking of bearings and pivot pins FCH CH Electrical wires CH Hydraulic fittings and hoses FCH CH Cylinders load holding and check valves FCH CH Functioning of emergency lowering FCH CH Function of emergency stop circuit FCH CH Functioning of set up system FCH CH Pressure adjust...

Page 39: ...rvice and change intervals must be shortened 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 10 years If a bolt has loosened it must be replaced with a new bolt Crawler track and 4WD wheel nuts For 4WD chassis machines the tightening torque for the wheel nuts is as follows First tighten the nuts to 150 Nm...

Page 40: ... slewing bearings must be greased in accordance with the maintenance schedule using grease that contains EP extreme pressure additive Outrigger bearings and articulation bearings in all hydraulic cylinders must be greased in accordance with the maintenance schedule Greasing directions below Greasing diagram Figure 14 Greasing diagram ...

Page 41: ...is connected to the ring s ball bearings When applying grease to this grease nipple it is important to apply it around the bearing after applying grease turn the slewing ring approximately 20 degrees and apply grease again Repeat until the ring has gone around a full circle 360 degrees Figure 15 Slewing ring greasing Greasing the telescopic boom chain pulley and inspection of the chain A pair of l...

Page 42: ...s when the telescope is fully extended picture 18 Apply only a thin layer 1 mm of grease on the surface by using a brush for example Figure 18 Width of the greased surface on Middle Boom and Extension highlighted with red lines 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 durin...

Page 43: ...ted on the side of the oil tank inside the chassis Replace the filter 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 the breather cap 2 or by opening the drain plug in the bottom of the chassis In both cases it is important to clean the magnetic drain plug The hydraulic pressure filter ca...

Page 44: ...ass Battery check The original battery is maintenance free In order to secure the starting and safe operation the battery must be checked regularly Inspect and clean battery terminals regularly Check also condition and fastening of battery cables and terminal insulators Make sure that battery cables cannot chafe against any sharp edges Check also condition and fastening of battery disconnect switc...

Page 45: ...ggers manually against ground If the green automatic levelling signal light will blink before all four outriggers touch the ground there is a malfunction or a fault in the system and the operation must be stopped immediately excluding the situation where automatic levelling has been activated Check the functioning of the outrigger s inductive switch from the led light on the switch the light shoul...

Page 46: ...vements in case of for example a hydraulic hose failure Figure 24 Cylinder hydraulic manifolds JIB cylinder left and lift cylinder right When the lower boom emergency lowering is used the electric solenoid 2 located in the lift cylinder s hydraulic manifold engages oil flow into the tank and the booms move downwards The oil from the lift cylinder is directed to other cylinders if other emergency l...

Page 47: ...A MRW in the platform Maximum platform load has been adjusted to 250 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 7 4 and upper control Figure 7 10 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 load sensor ...

Page 48: ... the upper boom sensor is a capacitive sensor 2 which monitors the condition of the upper boom sensor s measuring wire In addition there is a levelling sensor in the connection box see chapter 9 10 3 and its levelling angle is compared with the angle of the upper boom sensor to ensure that the boom is in transport position Figure 26 Slewing angle sensor Figure 27 Upper boom sensors Slewing ring po...

Page 49: ...nation sensor chassis Inspection of the track tightness and adjustment The tightness of the track is inspected and adjusted with the access platform raised on the outriggers The tracks must be inspected for the first time and adjusted if necessary after one hour of use After this initial inspection the tracks should be checked once a week and adjusted if necessary At the same time the sprocket bol...

Page 50: ... track If you find that a track has loosened after inspecting the tracks as described in chapter 9 12 tighten the track as follows The track is tightened with a preloaded spring To tighten the track loosen the nuts marked A and B in figure 32 Then tighten nuts D and E and hold bolts C or vice versa This pulls the bolts figure 32 C and the adjustment plate towards the middle of the track and tighte...

Page 51: ... about whether the damage can be repaired by welding contact the manufacturer Before welding Remove and cover the plus and minus terminals of the battery Disconnect all contacts of the logic controllers Figure 33 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 w...

Page 52: ...onth The access platform must be protected and stored in an indoor storage facility or other covered space that cannot be accessed by unauthorised persons a locked space Make sure that chemical leaks during storage will not cause environmental harm such as problems related to wastewater Note Also see the engine manufacturer s instructions about storage of the engine ...

Page 53: ... of in an environmentally friendly way Battery and other electronic components should be recycled or disposed of according to local regulations Oil should be collected and recycled according to local regulations Plastic parts should be recycled according to local regulations Metal parts should be recycled according to local regulations ...

Page 54: ...op switch by turning it Use the choke Open the fuel faucet petrol engine Refill Charge the battery by connecting the 230 V plug Replace the fuse also see the engine manual The motor does not start when the START button is pushed see also the engine manual Connection flaw in the wiring Faulty START switch Use a meter to check voltages wires and connections Replace the switch The electric motor does...

Page 55: ...ctioning of the hydraulic pump safety valve Remove the excess load The combustion engine electric motor stops when the booms are lifted from the transport support Outriggers are not correctly positioned in the support position the green indicator lamp is not lit Lower the booms down to transport supports with emergency lowering restart the combustion engine electric motor and deploy the outriggers...

Page 56: ...ir Change the valve Change the cylinder seals The platform tilts backwards by itself when the booms are down on the transport supports Air in the hydraulic system Dirt in the load control valve or a defective valve Cylinder seals faulty Start the combustion engine electric motor drive the platform to the extreme end positions If this doesn t help do the air bleeding of the platform self levelling ...

Page 57: ...57 BLOCK DIAGRAMS FOR LEGUAN 135 NEO SAFETY FUNCTIONS Figure 33 Emergency stop from the platform Figure 34 Emergency stop from lower controls ...

Page 58: ...58 Figure 35 Emergency stop from remote controller wired Figure 36 Emergency stop from remote controller wireless ...

Page 59: ...59 Figure 37 Load control of the platform Figure 38 Boom position monitoring ...

Page 60: ...60 Figure 39 Platform levelling monitoring Figure 40 Outrigger monitoring ...

Page 61: ...61 Figure 41 Transport position monitoring Figure 42 Prevention of drive function ...

Page 62: ...62 Figure 43 Selection of the platform control position Figure 44 Selection of the lower control position ...

Page 63: ...63 Figure 45 Selection of the remote control position Figure 46 Platform emergency stop button override ...

Page 64: ...64 Figure 47 Platform load monitoring override Figure 48 Override of Safety Functions ...

Page 65: ...uring the warranty period must be noted on the list below otherwise the manufacturer s warranty will not be valid The service operations mentioned in the maintenance schedule on page 24 must be recorded as follows FIRST SERVICE 1 MONTH SERVICE 6 MONTH SERVICE ETC Performed service e g 12 month service Operating hours Performed by Date Additional information ...

Page 66: ...66 Performed service e g 12 month service Access Platform operating hours Performed by Date Additional information ...

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