Leguan 135 NEO Operator's And Service Manual
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Leguan 135 NEO Operator's And Service Manual

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Operator and Service manual
Version 7/2020
July 2020

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Summary of Contents for Leguan 135 NEO

  • Page 1 Operator and Service manual Version 7/2020 July 2020...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION AND WARRANTY CONDITIONS ............4 ........................4 NTRODUCTION ......................4 ARRANTY CONDITIONS GENERAL INFORMATION ....................7 ..................... 8 ECHNICAL SPECIFICATIONS ....................... 9 AIN DIMENSIONS ................10 EACH DIAGRAM AND SUPPORT DIMENSIONS ......................11 IGNS AND MARKINGS SAFETY INSTRUCTIONS ....................
  • Page 3 .......................... 51 ELDING INSTRUCTIONS FOR TEMPORARY STORAGE ............... 52 INSTRUCTIONS FOR DISPOSING THE ACCESS PLATFORM ........... 53 TROUBLESHOOTING ....................54 BLOCK DIAGRAMS FOR LEGUAN 135 NEO SAFETY FUNCTIONS ........57 PERFORMED SERVICE ....................65 Appendices: Hydraulic diagram Electrical diagram Owner’s Manual (Combustion engine)

  • Page 4: Introduction And Warranty Conditions

    INTRODUCTION AND WARRANTY CONDITIONS Introduction LEGUAN LIFTS wants to thank you for purchasing this LEGUAN access platform. It is the result of Leguan’s long experience in design and manufacturing of access equipment. We ask you to read and understand the contents of this manual completely before operating the access platform.
  • Page 5 Warranty is limited to the repair of a faulty access platform without cost at an authorised Leguan service workshop. The warranty period for parts that are changed in connection with the repair will end when the warranty period for the access platform ends. Parts that have been changed in the warranty repair will remain Leguan Lifts’...
  • Page 6 TÄTEN VAKUUTAMME, ETTÄ HEREWITH DECLARES THAT HENKILÖNOSTIN NIMELLISKUORMA LEGUAN 250 kg AERIAL PLATFORM NOMINAL LOAD MALLI NOSTOKORKEUS 11,4 m 135 NEO MODEL PLATFORM HEIGHT SARJANUMERO VALMISTUSVUOSI 20xx 007xxxx SERIAL NR YEAR OF CONSTRUCTION ON KONEDIREKTIIVIN 2006/42/EY ASIAAN KUUULUVIEN SÄÄNNÖSTEN MUKAINEN...

  • Page 7: General Information

    GENERAL INFORMATION LEGUAN 135 NEO is a self-propelled Mobile Elevating Work Platform – commonly called an ‘access platform’, designed for indoor and outdoor use. Access platforms are designed for the lifting of persons and their equipment only. Using an access platform as a crane is prohibited.

  • Page 8: Technical Specifications

    Technical specifications Working height 13.4 m Max. platform height 11.4 m Max. outreach @ 120 kg 7.1 m Max. outreach @ 250 kg 6.6 m Safe working load 250 kg Transport length 4.55 m Transport length without platform 3.85 m Transport height 1.93 m Width,...

  • Page 9: Main Dimensions

    Main dimensions Figure 2 135 NEO Main dimensions, side Figure 3 135 NEO main dimensions, rear...

  • Page 10: Reach Diagram And Support Dimensions

    Reach diagram and support dimensions Figure 4 Reach diagram Figure 5 Support dimensions...

  • Page 11: Signs And Markings

    12. Tie down points (4) 5. Max. outrigger force 13. Tyre pressure 6. Distance from energized electric 14. Leguan 135 decal wires 15. Lower controls’ decal 7. General user instructions 16. Lift points (4) Figure 6 Signs and decals...

  • Page 12: Safety Instructions

    SAFETY INSTRUCTIONS The operator must know and follow all safety instructions. The operator must receive sufficient instructions in order to be able to use the lift correctly and safely. This Operator’s Manual must always be kept in the machine. To prevent unauthorised use of the access platform, take the main switch key with you after concluding operation if the machine is left unsupervised.

  • Page 13: Risk Of Tipping Over

    To ensure the safe operation of this access platform the manufacturer has conducted approved tests for the LEGUAN 135 NEO in accordance with the standard EN 280:2013+A1:2015 static stability test in accordance with paragraph 6.1.4.2.1 and dynamic overload test in accordance with paragraph 6.1.4.3 of the EN 280:2013+A1:2015.

  • Page 14: Risk Of Electric Shock

    Make sure that there are no overhead obstacles on the work site that could prohibit lifting of the platform, or objects that might cause a collision Do not operate this access platform in the working area of another overhead lifting device or similar equipment that is moving, unless this lifting device is secured so that there is no risk of collision Beware of crushing hazard when holding the handrail of the platform in a potential collision...

  • Page 15: Daily Inspections Before Starting Work

    Daily inspections before starting work ground control devices supports access routes horizontal position platform emergency stop button oil leakage emergency lowering 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.

  • Page 16: Controls And Switches

    CONTROLS AND SWITCHES Control devices on the platform The platform’s controls and indicators on the control panel may be slightly different in different models. Indicators and switches that are marked as optional are not installed on all models. Figure 7 Platform control panel 1.

  • Page 17: Platform Overload Indicator Light

    If the red fault light blinks, return booms onto their transport positions, perform daily inspection and remove possible cause of the error. If the problem persists, contact your Leguan dealer. When a FAULT occurs, the red fault light will stay ON continuously.

  • Page 18: Inclination Sensor Indicator Light

    Return booms on their transport supports, stop working with the equipment and contact your local Leguan dealer. Possible errors and faults can be diagnosed with a separate service display (option). Fault light BLINKS_INTERMITTENT (option).

  • Page 19: Boom Centre Position Indicator (Slewing)

    Boom centre position indicator (slewing) The slew ring of the access platform is equipped with inductive sensor which lights the green boom centre position indicator light whenever the 1 boom is above the transport support. Indicator light is only an aid and does not guarantee that booms will lower straight to transport supports.

  • Page 20: Lower Controls Panel

    Lower controls panel Figure 8 Lower controls panel 1. Hour meter 7. Ignition key / upper/lower 2. Safety functions override switch controls selector switch 3. Emergency stop switch 8. Boom raise switch / choke 4. Indicator lights 9. Telescope in/out switch - Inclination sensor 10.

  • Page 21: 230 V Connections And Switches

    230 V connections and switches Leguan 135 NEO can be powered by an electric motor (optional item). The standard motor must be connected to a 230 V / 50 Hz / 16 A outlet. Connections and switches pictured below. 1. 230 V / 50 Hz / 16 A connection lead 2.

  • Page 22: Operation

    OPERATION Read this Operator’s Manual and the Operator’s Manual for the engine carefully before commencing operation. Read the safety instructions in this manual and make sure you understand them before commencing operation. It is the operator’s responsibility to understand and follow all operating and safety instructions. An access platform is designed only for the lifting of persons and their equipment;...

  • Page 23: Drive

    Drive When transferring the platform, pay attention to the following factors: Do not exceed maximum inclination for the drive. Make sure the driving surface is solid. Secure tools and other materials to prevent them from falling or shifting. Operator should wear safety harnesses and keep them fastened whenever operating the machine.

  • Page 24: Determining The Gradient Of The Slope

    Determining the gradient of the slope Measure the slope with a digital clinometer, or do as follows: Take a water level, a straight piece of wood (at least 1 m long), and a pocket tape measure. Place the wood on the gradient. Put the water level on the lower edge of the stick and lift the stick until it is in a horizontal position.

  • Page 25: Guidelines: Operating Environment Of An Access Platform With Tracks

    Guidelines: Operating environment of an access platform with tracks To extend the lifespan of the track system, avoid driving on the following terrains or work sites: Environments with crushed stone, iron bars, scrap metal or similar recycling material. Rubber tracks are not designed for such environments. Daily/continuous driving on asphalt or concrete.

  • Page 26: Use Of Outriggers

    Use of outriggers The outriggers must be deployed, and the chassis of the access platform must be levelled before any boom operations. The chassis can be levelled by either using automatic levelling function or controlling individual outriggers manually. The maximum allowed levelling inaccuracy is 1,0°.

  • Page 27: Setting The Outriggers To Transport Position

    Setting the outriggers to transport position Lower all booms on to their transport supports. Green indicator light of boom transport support (see 4.1.6) and boom centre position must be lit. Press the upper button of the automatic levelling switch (Figure 7 (18)). The button doesn’t need to be held down.

  • Page 28: Use Of Booms

    (Figure 7 (14)) 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.

  • Page 29: Back To Work Position

    Back to work position Back to work position-function is activated by turning the Back to work position/Home-switch (figure 7, switch 7) counter clockwise to Back to work position-position and holding it there while using the function. When using the function boom will move automatically to position from where Home-function where activated last time after using the joystick.

  • Page 30: Additional Instructions For Winter Use

    Additional instructions for winter use The minimum allowed operating temperature for the access platform is -20 °C. Do the following actions 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.

  • Page 31: Back-Up Lowering And Emergency Use

    BACK-UP LOWERING AND EMERGENCY USE Functions described in chapter 6 are for emergency and fault situation use only! Normal operation is not allowed using the functions mentioned in this chapter. Back-up lowering procedure If the operating power supply cuts off (fuel running out, power cut or damage to the extension cord), the booms can be lowered as follows: Back-up lowering button is located on the platform control panel and and back-up lowering switch is located in the lower controls panel.

  • Page 32: Override Of Boom Safety Functions When Motor Is Running

    Override of boom safety functions when motor is running For possible emergencies this access platform is equipped with a safety functions override switch (p. 20, figure 8, switch 2), which enables boom movements without outriggers being correctly set down. This function can be used for example in a situation when booms have moved off their transport support during transportation.

  • Page 33: Override Of Transport Position Monitoring

    drive prevention speed selector switch Override of transport position monitoring The transport position of the booms can be overridden with the override switch in the lower controls panel. This enables outrigger operation even if the booms are not in transport position or if the sensor monitoring transport position is faulty.
  • Page 34 separate power source and cables to activate the valves. The ignition switch (p.20, figure 8) must be turned off before following this procedure! To use emergency lowering without the logic controller, use separate wires to connect a 12 VDC battery to the coils of the control 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.

  • Page 35: Transportation

    TRANSPORTATION The chassis and outriggers are equipped with lifting and binding points which are indicated with symbols. The machine may only be secured for transport from these binding points. The machine must always be lifted from the designated lifting points. When lifting, it is advisable to use a lifting beam to prevent the outriggers from getting damaged.

  • Page 36: Instructions: Service, Maintenance And Inspection

    Make sure that all labels are in place and readable. NOTE! All spare parts – especially electric components and sensors – must be original Leguan parts. Battery handling When handling the battery, bear in mind that: The battery contains corrosive sulfuric acid – handle the battery with care! When handling the battery, wear protective clothing and eyewear.

  • Page 37: Handling Of Fuel And Oil Products

    If any signs of a leak are observed, place a piece of cardboard underneath the suspected component to determine the source. If you find a fault, operation of the access platform must be stopped immediately and the hose or the component must be replaced. Contact the Leguan service.

  • Page 38: Service Instructions

    SERVICE INSTRUCTIONS Maintenance and inspections, service schedule Regarding the service of the engine, also see the engine manufacturer’s Operator’s Manual. EM = engine manual = check = clean = replace = adjust = first service after 50 h 200 h / 12 400 h / 24 Measure month...

  • Page 39: Crawler Track And 4Wd Wheel Nuts

    Recommended oil: FUCHS HYDRAULIC OIL 131 HP Hydraulic system oil volume: Oil tank 25 l, complete system 55 l Engine oil: See engine manufacturer’s manual Grease: Lithium NLGI 2 grease (not MoS2), Slewing ring grease: grease containing EP (extreme pressure) component (e.g.

  • Page 40: Greasing

    Greasing Greasing of the machine is of utmost importance to prevent wear in joints. Most of the joints are service free - however the 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.

  • Page 41: Greasing Of The Slew Ring

    Greasing of the slew ring The slewing ring of the access platform must be greased monthly, according to the maintenance schedule. It is important to notice that the slewing ring has four (4) separate greasing points (Figure 15) which all must be greased individually. There are 3 grease nipples on the backside of the slewing ring are connected to the gear and its bearings.

  • Page 42: Greasing Of Telescoping Booms

    Grease nipples are located on both ends of the telescopic boom. One grease nipple is located under the telescopic boom in the platform end of the boom (Figure 16). Two more nipples are located under a protective cover in the front end of the upper boom (Figure 17). Greasing of Telescoping Booms Glide surfaces of the telescoping booms (bottom surface, picture 18) should be greased with water resistant grease (e.g.

  • Page 43: Handling Of Fuel And Refuelling

    Handling of fuel and refuelling Check the fuel level and refuel if necessary (1). Before refuelling, check whether the engine runs on petrol or diesel. Petrol specified by the manufacturer in its manual must be used in a machine with a petrol engine. Figure 19 Combustion engine Hydraulic oil and hydraulic oil filter replacement The hydraulic return oil filter (figure 20, (1)) is located on the side of the oil tank inside the...

  • Page 44: Hydraulic Oil Level

    Hydraulic oil level The level of hydraulic oil can be checked from the oil level sight glass. The sight glass is located in the right side of the chassis, between the wheels or track wheels (Figure 21 (1)). The oil level should be at the top of the sight glass when the access platform is in transport position.

  • Page 45: Functioning Of Set Up System

    Functioning of set up system Outriggers are monitored with an inductive switch. There is one switch in each outrigger which tracks whether an outrigger has been set to the ground or not. Monitoring is based on a spring- loaded pin, which is pushed up when an outrigger is laid on the ground. Switches location in the outrigger pictured below (Figure 23 (1)).

  • Page 46: Hydraulic System Settings

    Hydraulic system settings The hydraulic system has been adjusted to correct values at the factory and usually there is no need to adjust them. All boom cylinders are equipped with two load control valves (Figure 24 (1)) which prevent boom movements in case of, for example, a hydraulic hose failure. Figure 24 Cylinder hydraulic manifolds.

  • Page 47: Overload Protection Components

    Overload protection components Overload control has been set to the correct values at the factory and it is strictly forbidden to change its settings. THERE IS A RISK OF THE ACCESS PLATFORM TIPPING OVER! Overload control mechanism is located between the working platform and the platform support (Figure 25).

  • Page 48: Electric Sensors

    Electric sensors Transport position monitoring Transport position of the access platform is tracked by three sensors: slewing angle sensor (Figure 26, (1)), which activates when the slewing ring is in the middle position. Upper boom sensor (Figure 27, (1)) tracking the position of the telescope and the boom angle. Combined with the upper boom sensor is a capacitive sensor (2), which monitors the condition of the upper boom sensor’s measuring wire.

  • Page 49: Levelling Monitoring

    Levelling monitoring This access platform is equipped with automatic and manual levelling and the state of levelling is monitored with an inclination sensor. The sensor is located inside the connection box on the right side of the chassis (figure 31). Similar sensor also tracks the angle of the platform and the platforms automatic levelling is based on it.

  • Page 50: Adjustment Of The Tightness Of The Track

    Figure 31 Leguan 135 NEO tracks To inspect the tightness of the tracks: Raise the access platform off the ground using the outriggers. The tracks should be off the ground minimum 5 cm. The tightness is correct if the gap between the track and the track...

  • Page 51: Repair Instructions

    REPAIR INSTRUCTIONS Welding All load-carrying steel parts are manufactured from S420MC EN10149 sheet and S420MH/S355J2H EN10219 tubular pipe. Welding repairs may only be carried out by professional welders. When welding, use only methods and additives suited for the abovementioned steel qualities. SFS EN-ISO 5817 quality level D is suitable for all welding, except for load-bearing parts.

  • Page 52: Instructions For Temporary Storage

    INSTRUCTIONS FOR TEMPORARY STORAGE The cable of the + pole of the battery should be disconnected, if the access platform is being stored for a period longer than one month. 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.

  • Page 53: Instructions For Disposing The Access Platform

    INSTRUCTIONS FOR DISPOSING THE ACCESS PLATFORM When the access platforms lifecycle comes to an end, it must be dissembled and disposed of in an environmentally friendly way: Battery and other electronic components should be recycled or disposed of according to local regulations.

  • Page 54: Troubleshooting

    TROUBLESHOOTING The following table shows failures and malfunctions of the access platform and the ways to repair them. ISSUE CAUSE CORRECTIVE ACTION the motor does not start when The main power switch is in the Turn the switch on. the START button is pushed ‘OFF’...
  • Page 55 ISSUE CAUSE CORRECTIVE ACTION The electric motor stops Power failure. Lower the booms by using the suddenly during operation. emergency lowering. Check that there is current in the mains. Release all emergency stop The emergency stop button was buttons. pressed accidentally. Wait for approx.
  • Page 56 ISSUE CAUSE CORRECTIVE ACTION Outrigger gives way. Make sure that the ground does Put extra support plates under not give way. the outriggers or move the machine to another place Air in the outrigger cylinder(s). Drive outriggers all the way up and down a few of times.

  • Page 57: Block Diagrams For Leguan 135 Neo Safety Functions

    BLOCK DIAGRAMS FOR LEGUAN 135 NEO SAFETY FUNCTIONS Figure 33 Emergency stop from the platform Figure 34 Emergency stop from lower controls...
  • Page 58 Figure 35 Emergency stop from remote controller (wired) Figure 36 Emergency stop from remote controller (wireless)
  • Page 59 Figure 37 Load control of the platform Figure 38 Boom position monitoring...
  • Page 60 Figure 39 Platform levelling monitoring Figure 40 Outrigger monitoring...
  • Page 61 Figure 41 Transport position monitoring Figure 42 Prevention of drive function...
  • Page 62 Figure 43 Selection of the platform control position Figure 44 Selection of the lower control position...
  • Page 63 Figure 45 Selection of the remote-control position Figure 46 Platform emergency stop button override...
  • Page 64 Figure 47 Platform load monitoring override Figure 48 Override of Safety Functions...

  • Page 65: Performed Service

    PERFORMED SERVICE It is advisable to write down all service operations that are included in the periodical service. All services that have been performed during 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.
  • Page 66 Performed Access service Platform Performed by Date Additional information (e.g. 12 month operating service) hours...

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