Operating Instructions LEO 23 GT
Contents
1. Beispiele Zugangstechnik Korbdrehen 180 Korbanordnung aussermittig Technical Data 17 Drive motor Kubota Z 602 Volumetric displacement 599 cm Fuel type Diesel fuel Accessories Electric motor EBS 90 L X 4 Power consumption 12 9A Additional weight approx 25 kg Alternative battery drive Hydraulic unit 48 V 6 kW 18 Technical Data Position of Control Elements 19 3 2 Position of Control Elements Control panel in work cage with control elements for platform support and chain functions Turn key switch on the front left of the control panel to Platform symbol Ground control panel with control elements for platform support and chain functions Turn key switch to I turn key switch at work cage to 0 20 Position of Control Elements Box level for level alignment of the aerial work platform Locking mechanism for supports wide and narrow make su2. avoiding deposits and cavitation and preventing undesired reactions caused by penetrating water The hydraulic oils listed below have been used successfully in our systems We recommend the use of these oils or equivalent products Einsatztemperatur Application temperature Temp rature d applicatio ISO VG BP Energol HLP D 22 HLPD OEL 22 Renolin MR 5 Shell Hydrol DO 22 44 General Maintenance Instructions 8 3 Oil Levels Only check the oil level of the hydraulic system and refill oil if necessar when the cylinders are retracted i e in transport position of the machine Mixing of different oils is not permissible Otherwise the whole plant may be damaged Only use oils according to the enclosed oil recommendation Check the hydraulic oil level weekly and if necessary refill with Fuchs Plantohyd 32 S until oil is present in the filter insert Filling volume of hydraulic system approx 90 Filling volume of hydraulic tank approx 45 Filling level between min and max approx 6l General Maintenance Instructions 45 Oil level in drive engine OPTION The drive engine is filled with Engine oil Titan 15 W 40 At the drive engine check engine oil level weekly according to Kubota operating instruc tions Filling volume in drive engine see Kubota operating instructions When oil level is low see dipstick refill oil according to Kubota operating instruc tions Fuel The drive engine is operated wit
3. Mobile Elevation Platforms Design Calculations and Stability Criteria In the case of plants which must be approved by official authorities the owner must have the machine inspected by accredited inspection authorities TUV DEKRA or au thorized persons prior to first commissioning as well as at the specified inspection in tervals Other national or international standards are not applied Inspections according to other standards must be carried out separately 6 Introduction and Proper Use In case structural or other modifications are carried out at the machine without the manufacturer s express approval the EU Declaration of Conformity shall become invalid 1 1 Proper Use The machine may only be used for the transport of persons and tools up to the permissible carrying capacity to enable work at aerial locations see technical data sheet Any other use exceeding the scope of use mentioned above shall be consid ered as an improper use Teupen Maschinenbau GmbH shall not be held liable for any damage resulting from such an improper use Proper use also includes in particular e the compliance with all information given in the operating instructions e the proper performance of the specified inspection and maintenance work As we do our best to always keep our product up to date we reserve the right to mod ify and upgrade our aerial work platforms at any time without notification Symbols Used 7 1 2 Symbols Used Two s
4. OPTION charge starter battery check replace if Faults Causes and Repair no function possible key switch in work cage from ground control on platform em stop pushbutton pressed wrong position of switch in work cage em stop pushbutton pressed incorrect support no platform function possible from cage turn key switch to 0 unlock switch toggle switch to platform support correctly 51 52 extension of upper arm not possible lowering of upper arm not possible Faults Causes and Repair no supply voltage possibly too low r c c b tripped upper arm in transport support upper arm not lifted up far enough upper arm not above carriage check switch on lift up for a short time lift up upper arm turn upper arm to ward carriage extension of lower arm not possible lifting and lowering of Faults Causes and Repair lower arm not erected erect completely fully telescope not retracted retract completely lower arm not possible fully slewing not possible green lamp in work cage flashing upper arm telescope still in transport support lift up telescope not supported correctly support correctly support locking devices not locked lock 53 54 Faults Causes and Repair red light lights up con control lever actuated pr
5. Operating Instructions for Aerial Work Platform LEO 23 GT Machine no 140671 Technical specifications are subject to change without notification TEUPEN Maschinenbaugesellschaft mbH Place of business Marie Curie Strasse 13 D 48599 Gronau Telephone 02562 8161 0 Telefax 02562 8161 888 Postal address Postfach 1951 D 48580 Gronau Internet http www teupen info E mail mail teupen info Copyright The copyright relating to these operating instructions remains with TEUPEN Maschinenbaugesellschaft mbH These operating instructions are intended for use by the owner of the machine and their staff only The owner of the machine may copy these operating instructions for internal pur poses only 11 04 08 TEUPEN Maschinenbaugesellschaft mbH Table of Contents Contents 1 Introduction 1 1 Proper use 1 2 Explanation of symbols used Safety instructions and warnings Particular features 3 1 Technical data 3 2 Position of control elements Electrical power supply The hydr rubber chain running gear 5 1 Driving by means of the hydr rubber chain drive 5 2 Adjusting the height of the chain running gears Page 5 6 Page 6 Page 7 Page 8 12 Page 13 14 Page 15 18 Page 19 21 Page 22 24 Page 25 26 Page 27 Pag
6. al Work Platform LEO 23 GT Continuous proportional controls Upper and lower arm telescopeable Driven via diesel engine or battery Starting stopping the diesel engine is possible from the platform Sensitive electro hydraulic distance control for chassis to enable exact position ing Width and height of chain running gear adjustable Narrow support on one side and narrow support on both sides Fuzzy control Parallel guiding of the work cage by hydrostatic compensation system 180 turning work cage Eccentrically suspended work cage has the effect of an accessible cage arm Technical Data Ergonomically shaped work cage with access opening Installation monitoring Covers above electric case and bottom control panel Start support transport position lower arm prevents incorrect landing of the lower arm in transport position Technical Data 15 3 1 Technical Data LEO 23 GT Platform height approx 21 00 m Cage load max 200 kg Turning cage 180 Minimum passage width min 0 98 m Dead weight approx 3000 kg Min support width middle of support disk min 2 30 m Area load in standard work position ca 1 8 kN m Limited turning range narrow on both sides 2x 15 Supportable up to ground slope of ca 26 transverse to driving direction ca 26 Energy supply chain internal 16 Technical Data
7. and material damage may be the conse quence 48 General Maintenance Instructions Re lubrication intervals In the case of difficult outdoor conditions re lubricate every 100 to 200 operating hours Additionally torque bearings must be re lubricated after each cleaning e g water steam spraying etc before and after extended standstill periods e g inactive winter months General Maintenance Instructions 49 General Maintenance Instructions hydraulic hoses must be checked for damage and leaks at least once every month hydraulic hoses must be replaced completely after 6 years check all components visually for deformation and cracks check bolts and nuts regularly for tight fit check rubber chains for wear and tear and proper tension check function of limit switches at chassis and check if they are clean each time the aerial work platform is used it is vital that the machine be checked for proper function before the work is started 50 Faults Causes and Repair 9 Faults Causes and Repair rel note fuel type drive engine fuse defec replace tive starter battery empty with power supply via safety devices triggered check and switch on on site power supply fuse r c c b safety organs station no functions motor circuit breaker extension cable defec tive necessary wrong cable cross select cable cross section with long exten section sion cable no drive engine func tion
8. ated joint and slide areas depending on degree of soiling at least monthly with 2 General Maintenance Instructions SL T es Li 41 42 General Maintenance Instructions 8 2 Recommended oil When it leaves our workshop the hydraulic system of this machine is filled with PLANTOHYD 32 S Environmentally friendly multi use hydraulic fluid Mixing with hydraulic oils of other viscosity classes is not permissible for safety reasons If for any reason an other conventional hydraulic oil is to be used the hydrau lic oil of the complete hydraulic system must be replaced In this case we recommend the hydraulic oil Renolin MR 5 or a hydraulic oil according to the following oil recommendation General Maintenance Instructions 43 Oil Recommendation A proper function perfect operational safety and a long service life mainly depend on a careful selection of the hydraulic oils For the hydraulic system we recommend hydraulic oils which contain in addition to the additives improving the corrosion protection and the ageing resistance and reducing the wear and tear additives improving the stick slip behavior
9. e 28 29 4 Table of Contents 6 The support system 6 1 Bringing the machine in working position 6 2 Bringing the machine in transport position 7 Operation of aerial work platform 7 1 Ground control 7 2 Emergency control platform chassis 8 General maintenance instructions 8 1 Lubrication plan 8 2 Oil recommendation 8 3 Oil levels 8 4 Maintenance instructions for live ring general 9 Faults causes and repair 10 Disposal Page 30 31 Page 32 Page 33 Page 34 35 Page 36 37 Page 38 39 Page 40 Page 40 41 Page 42 43 Page 44 45 Page 46 49 Page 50 55 Page 56 Introduction 5 1 Introduction The purpose of these operating instructions is to provide the owner of the Aerial Work Platform with information on the correct handling use and maintenance of the machine In order to ensure a proper and safe operation of the aerial work platform please read these operating instructions carefully and follow the instructions given in these operating instructions strictly These operating instructions contain important information on how to operate the aerial work platform in a safe proper and efficient manner Comply with these in structions strictly to avoid hazards reduce repair costs and downtimes and to in crease the service life of the aerial work platform This aerial work platform complies with BGG 945 of the Hauptverband der gewerblichen Berufsgenossenschaften and is manufactured in accordance with EN 280
10. ess em stop and tinuously during the start operation start control system again and stalling below chassis pressure filter dirty open and replace filter insert cylinders lower auto hydraulic system dirty immediately matically call service motor pump running hand wheel of manual close hand wheel but no pressure in pump loosened turn clockwise system Faults Causes and Repair 55 load motor pump noise too little hydraulic oil in check and if neces and travel movements tank sary refill hydraulic slow down until stand oil still note oil type hydraulic plant leaking check and call ser vice socket outlet in work mains supply inter check cage without voltage rupted 56 Disposal 10 Disposal When it comes to final decommissioning and scrapping of the machine it is important that all materials used be disposed of properly The hydraulic and motor oils as well as the hydraulic hoses used are to be disposed of by specialized companies in accordance with the local requirements The metals i e steel and aluminum must be supplied to the local metal disposal systems and reused if possible Plastic and rubber materials tires are to be recycled according to the local require ments The operating instructions are to be supplied to the local paper disposal system
11. h diesel fuel no 2 D ASTM D975 The filling level of the fuel tank is approx 12 46 General Maintenance Instructions 8 4 Maintenance Instructions for Live Rin Checking the fixing screws AN The fixing screws must be checked every 700 operating hours or every 6 months at the latest This period is to be adapted accordingly in the case of special operating conditions Check the tightening torques after the first 100 operating hours in order to compen sate possible settling effects Retighten the screws with the following tightening torques Screw size Screw quality Tightening torque M 12 10 9 109 Nm M 16 10 9 270 Nm General Maintenance Instructions 47 After that retighten the screws every 700 operating hours or at shorter inter vals if required due to special operating conditions or every six months at the latest AN If this requirement is not met personal and material damage may be the consequence Checking the screws for loosening replacing the screws Relieve the screws of any external load Check the tightening torque using a torque wrench and adjust it to the values listed above Replace loose screws Check the tilting play Wear and tear in the bearing system results in a changed bearing play For this rea son the bearing play must be checked at regular intervals Check the tilting play after 2000 operating hours or after 12 months at the latest If this requirement is not met personal
12. ing gears Adjust the supports such that the aerial work platform cannot fall over max inclination 14 5 26 When adjusting the chain running gear always adjust the supports to wide support position Caution Risk of Injuries With narrow adjusted chain running gear never loosen the locks if the aerial work platform is supported high chain running gear shoots down Procedure for pushing the chain running gears inward narrow adjustment To push in the chain running gear jack it up by means of the supports until the chain running gear has no ground contact anymore max 10 20 mm off the ground The Hydraulic Rubber Chain Drive 29 hen loosen the two locks by means of the manual pump lever 1 person Move up the corresponding columns carefully until the chain running gear has ground contact and is pushed in 2 person When the required position is reached allow the locks to engage again Important Before subjecting the chain running gear to load check if the locks have engaged properly Both levers must have returned to the mark red ar row automatically Procedure for pushing the chain running gears outward wide adjustment To push out the chain running gear it must be lifted up by means of the support until the chain running gear has no ground contact anymore max 10 20 mm off the ground Then loosen the two locks by means of the manual pump lever 1 person Move down the corresponding column
13. l which is connected to the socket outlet at the chassis by means of a bayonet catch By moving the two control levers for ward and backward you can achieve a very sensitive starting behavior of the two rubber chains in both direc tions al By moving the two levers in opposite direction you can achieve a turn movement at a minimum radius on the spot if the ground is level The Hydraulic Rubber Chain Drive 27 5 1 Driving by means of the hydr rubber chain drive In order to drive through narrow aisles or doors you can turn the work cage without having to support the aerial work platform control element at ground control see Chapter 3 2 Driving by means of the rubber chain drive from the cage is only permissi ble up to a slope of 8 15 Switch on power supply see Chapter 4 Connect cable remote control to outlet at chassis and select the required speed symbol hare or turtle Switch toggle switch on ground control panel to chain symbol Move the two levers forward or backward at the same time to obtain a for ward backward movement and select the speed Move the levers in opposite direction to turn the machine in the required direction Interrupt power supply 28 The Hydraulic Rubber Chain Drive 5 2 Adjusting the Height of the Chain Running Gears Caution Danger of Tilting In any case two persons are required to adjust the height of the chain runn
14. lat form mode Now you can position the aerial work platform as required using the corresponding pushbutton in combination with the speed controller 38 Emergency Control In emergency control mode the upper and lower arm must be retracted completely be 7 2 Emergency Control Plat fore lowering them operation with the manual pump is only intended for down retracting and rotat ing movements TOWARD THE TRANSPORT POSITION fix the platform chassis valve on the valve block which is situated under the hydrau lic tank on symbol platform and lock the power regulation valve beside the valve block Take the tube for the manual pump from the holder and slip it on the pinion of the manual pump check if handwheel is select the required direction by pumping and actuating the corresponding valves marked red at the same time After using the emergency control it is necessary to re lock the valves Emergency Control 39 gt Z K ie G N Power regulati on valve 40 General Maintenance Instructions 8 General maintenance instructions After first commissioning aerial work platforms must be inspected by an ac credited expert at intervals of one year 8 1 Lubrication Plan 1 Lubrication grease Fuchs Renolit MP 2 Spray grease Optimol White T 3 Motor oil Titan 15 W 40 Lubrication all lubriction nipples weekly with 1 all articul
15. nd the platform func tion selector switch to supports Lower the supports evenly using the toggle switches and bring the aerial work plat form in working position When the supports are in place correctly the green lamps in the control panels light up continuously Bring the chassis in horizontal position by aligning the supports using the box level The bubble of the box level must be within the 1 circle The Support System 33 6 2 Bringing the Machine Transport Position The upper and the lower arm must be fully retracted in the transport support Switch on power supply see Chapter 4 At the ground control panel turn the key switch to I and the platform function selec tor switch to supports Lower the chassis using the toggle switches and bring the front and rear supports in top position Loosen the locking pins of the front and rear supports move the supports to trans port position and lock them properly using the locking pins Interrupt power supply 34 Operation of Aerial Work Platform 7 Operation of Aerial Work Platform Control from work cage To enable a perfect operation of the lifting platform a proper working position of the machine and power supply are required necessary to protect the control panel against water moisture paint etc by means of the provided protection cover O In order to maintain a perfect function of the control elements it is absolutely Procedure Turn key swi
16. re in any case that the supports are locked correctly Drive motor case OPTION Fuel refill cutout in lid filling level indica tor on opposite side Position of Control Elements 21 Hydraulic tank 230 V connection and control box Manual pumps for emergency control of platform and supports Cable remote control for chain functions with fast slow change over if not used insert jumper in any case 22 Electric Power Supply 4 Electric Power Supply Power is supplied either via the local mains network using an extension cable 230 V or by the mains 230 Volt independent drive motor 2 5 mm max 40 m 84 0 mm max 80 m As an alternative a battery drive is also possible If an extension cable is used connect the plug to the socket of the extension cable Length of cable max 40 m with 3 x 2 5 mm max 80 m with 3 x 4 0 mm Electric Power Supply 23 To start the drive motor press the pushbutton with the spiral symbol until the preheating indicator yellow spiral symbol goes out comply with operating instructions of engine manufacturer Start power supply by drive engine Start of drive engine at electric control box or in work cage X Turn key switch to the right until the engine starts Avoid unnecessary starting Voltage drop of starter battery Stop power supply by drive engine Stop of drive engine at electric control box or in work cage Tu
17. rn key switch to the left until the drive engine stops 24 Electric Power Supply 48 V battery drive If the machine is equipped with a battery drive the operating and maintenance instructions of the manufacturer of the battery and battery charger must also be complied with Continuous operation via the electric motor is not permissible danger of over heating Daily charging of the batteries is recommended if the platform is battery driven In the case of a connection to 230 V charger the batteries are charged during opera tion Thus the service time of the machine is increased Indicator lamps for battery operation Red lights in work cage ground control panel flashing battery discharged Yellow light in ground control panel battery mode switched on When the red light is flashing bring machine in transport position immediately Indicator lamp at battery case Red battery is being charged Green battery full The Hydraulic Rubber Chain Drive 25 5 The Hydraulic Rubber Chain Drive amax 14 5 26 Bmax 17 30 amax 14 5 26 Bmax 14 5 26 gt gt battery mode enly 8 ig When driving on slopes make sure that the specified slope angles are not ex ceeded Permissible slope transverse to driving direction max 26 in driving direction max 30 26 in battery mode 26 The Hydraulic Rubber Chain Drive The hydr travel drive controlled via two control levers on the cable remote contro
18. s carefully until the chain running gear looses ground contact and is pushed out 2 person When the required position is reached allow the locks to engage again Important Before subjecting the chain running gear to load check if the locks have engaged properly Both levers must have returned to the mark red arrow automatically 30 The Support System 6 The Support System In addition to the standard support the following support variants are available Narrow support on one side Limited turning range 192 Narrow support on both sides Limited turning range 2 x 15 The Support System 31 Make sure that the ground is firm if necessary increase the support area by means of planks All supports must be loaded the rubber chain running gears must be free LA In order to increase the safety of the aerial work Ke platform in slopes skidding stability the ground disks must be aligned horizontally see sketch This is also important in view of their limited ability to adapt to the environment Anchoring the supports by means of chains ropes m ground anchors etc is not permissible max 26 32 The Support System 6 1 Bringing the Machine in Working Position IN Observe the supports while they are extended and retracted To support the machine position the supports at the required position and lock them properly At the ground control panel turn the key switch to I a
19. tch to platform symbol Lift up telescope from transport support The function extend lower arm is only possible if the lower arm is lifted up completely To extend the lower arm keep actuated the lower arm control ele ment switch over is effected automatically after approx 10 sec Control the aerial work platform by means of the corresponding pushbuttons and speed selector switches Operation of Aerial Work Platform 35 In case the movement stops during a travel to the transport position the upper arm must be lifted up first in order to turn to the transport position If it is positioned correctly the green lamp is flashing quickly and you can approach the transport position lowering 36 Ground Control 7 1 Ground Control Panel IN Ground control is only permissible if nobody is in the working cage Ground control may only be used if the required accident prevention measures are taken The ground control enables the user to transport loads e g billboards advertising banners light or loudspeaker equipment up to max permissible cage load to cer tain heights These loads must not exceed a size of 1 4 m and must be properly protected against falling out Ground Control 37 For ground control make sure that the work cage is unmanned and the toggle switch on the front left of the control panel of the work cage is in position 0 Additionally the key switch in the ground control panel must be in position 1 p
20. wed joints marked yellow and limit switch fixtures must not be loosened IN The valve settings may only be modified by qualified staff Any non compliance will result in the warranty becoming null and void 10 Safety Instructions and Warnings amax 14 5 26 Bmax 17 30 amax 14 5 26 Bmax 14 5 26 gt gt Battery operation only Fig 2 If the machine is used transverse to a slope nobody may stay downhill of the aerial work platform It is also dangerous to stay downhill behind the aerial work platform while the ma chine is moving uphill In order to prevent the aerial work platform from falling over it is necessary to let down the sup port until they almost touch the ground Safety Instructions and Warnings Jahre min 18 years ann e Note minimum age Do not climb on the cage railings 11 max 400 N Maximum side force 400 N No vibrations or jerky ig 3 movements Safety Instructions and Warnings High Voltage Danger Note the flowing traffic Secure parts projecting in the traffic area aa max 12 5 m sec 6 Bft Immediately stop using the aerial work platform if the wind speed exceeds 12 5 m sec wind force 6 The machine must not be used as a Crane hoist or lateral pull Technical Data 13 3 Particular Features of the Aeri
21. ymbols are used in these operating instructions for highlighting important in formation Warning This symbol indicates CAUTION This symbol information the non compliance indicates information the with which may result in serious non compliance with injuries or even death which may result in the machine being damaged Fig 1 8 Safety Instructions and Warnings 2 Safety Instructions and Warnings The machine is produced according to the state of the art and the generally recog nized safety regulations However the use of the machine involves certain hazards which may result in serious injuries or even death as well as material damage of the machine or other property The machine may only be used e for the specified purpose e when it is in a perfect technical condition in particular as regards the safety equipment Any defects affecting the safety must be repaired immediately Safety Instructions and Warnings Before commissioning the aerial work platform please read these operating instruc tions carefully and comply with the following safety instructions and warnings Any non compliance with these instructions and warnings may result in serious personal and material damage In addition to these operating instructions also comply with the enclosed op erating and maintenance instructions of the manufacturers of the motor and the chain running gear IN Safety devices e g limit switches must not be made ineffective Scre
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