Avantco 225 Operating manual

Operator and service manual

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LEGUAN 225 OPERATOR AND SERVICE MANUAL
This operator and service manual is valid on serial numbers:
0080100 ->
Version history
Date
Change
22.11.2022
Original document
15.12.2022
Pictures updated
13.1.2023
Drive motor gear oil change
10.2.2023
Technical specification and decals updated
14.4.2023
Added track tightening instructions

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Table of contents
INTRODUCTION AND WARRANTY CONDITIONS 6
1.1 Introduction 6
1.2 Display of safety instructions 6
1.3 Warranty conditions 7
1.4 Example of the EC declaration of conformity 8
GENERAL INFORMATION 9
2.1 Technical specifications 11
2.2 Main dimensions and outreach diagram 12
2.3 Signs and decals 14
SAFETY INSTRUCTIONS 17
3.1 Before starting operation 17
3.2 Risk of tipping over 18
3.3 Risk of falling 18
3.4 Risk of collision 19
3.5 Risk of electric shock 19
3.6 Risk of explosion/fire 20
3.7 Daily inspection before starting operation 20
3.8 Use of emergency stop switches 20
3.9 Safety instructions for drive control 21
3.10 Defining the gradient of the slope 21
CONTROLS AND SWITCHES 22
4.1 Controls in platform 22
4.1.1 Platform overload indicator light 23
4.1.2 Dynamic outreach control indicator light 23
4.1.3 Fault light 23
4.1.4 Inclination indicator light 24
4.1.5 Boom center position indicator light 24
4.1.6 Boom transport position indicator light 24
4.1.7 Low fuel indicator light 25
4.2 Lower control panel 25
4.3 Wireless remote control (option) 26
4.4 230 V connection and switches 27
OPERATION 28
5.1 Starting the combustion engine / electric motor 28
5.1.1 Combustion engine 28
5.1.2 Electric motor 28
5.1.3 Start-stop function 29
5.2 Speed selection switch 29
5.3 Drive control 29
5.3.1 Features of tracked access platform 30
5.4 Operation of the outriggers 31
5.4.1 Automatic leveling 31
5.4.2 Outrigger manual drive 32
5.5 Operation of the booms 32
5.5.1 Home function 33
5.5.2 Back to work position 33
5.6 Platform safety pedal (option) 33
5.7 Remote control (option) 34
5.8 Ending the operation 34
5.9 Additional instructions for winter use 35

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EMERGENCY LOWERING AND EMERGENCY BYPASS 36
6.1 Emergency lowering 36
6.2 Backup operation 36
6.3 Platform load control and platform emergency stop button override 37
6.4 Safety function override button 38
TRANSPORTATION 39
SERVICE, MAINTENANCE AND INSPECTION REGULATIONS 40
8.1 General instructions 40
SERVICE INSTRUCTIONS 41
9.1 Service and checks, maintenance schedule 41
9.1.1 General service info 42
9.1.2 Major inspection 42
9.1.3 Crawler track sprocket wheel bolts 42
9.1.4 Inspection and adjustment of the track tightness 42
9.2 Inspection of mechanical structures, hydraulic and electric systems 43
9.3 Telescope boom 44
9.4 Slew ring bolts 44
9.5 Greasing 45
9.5.1 Greasing diagram 45
9.5.2 Greasing of the slew ring 46
9.5.3 Greasing the telescope boom chain pulley and inspection of the chain 47
9.5.4 Greasing of telescope booms 47
9.6 Handling of fuel and refueling 48
9.7 Hydraulic oil and hydraulic oil filter replacement 48
9.8 Hydraulic oil level 49
9.9 Hydraulic system adjustments 49
9.10 Drive motor gear oil change 49
9.11 Diagnostics and checking the error codes 50
9.12 Outrigger set up control 51
9.13 Overload control components 52
9.14 Access platform position monitoring 53
9.15 Boom movement speeds 54
9.16 Testing of safety valves 55
9.17 Service reminder 56
9.18 Fuses 57
9.19 Battery check 57
9.20 Battery handling 58
9.21 Handling of fuel and oil products 58
REPAIR INSTRUCTIONS 59
10.1 Welding 59
INSTRUCTIONS FOR TEMPORARY STORAGE 60
INSTRUCTIONS FOR DISPOSING THE ACCESS PLATFORM 61
TROUBLESHOOTING 62
PERFORMED SERVICE 66
Attachments:
Hydraulic schematic
Electric schematic
Engine manual

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INTRODUCTION AND WARRANTY CONDITIONS
1.1 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 that you read and understand the contexts of this manual completely before operating the access
platform. This will improve your operating and maintenance efficiency, help avoid breakdowns, damage and
extend the life of your machine.
1.2 Display of safety instructions
Safety sign, signal word
Meaning
Identifies a dangerous situation that will result in
death or serious injuries if not avoided.
Identifies a dangerous situation that may result in
death or serious injuries if not avoided.
Identifies a dangerous situation that will result in
moderate or minor injuries if not avoided.
Damage to equipment: the product or the
environment risks damage.
Pay special attention to these symbols. They indicate important safety factors that require special attention.
Every operator must read and understand this manual before starting operation, and the instructions in this
manual must be followed. If you are lending the access platform out to somebody, make sure that they
familiarize themselves with and understands these instructions. If there is anything unclear with the operation,
please contact your Leguan dealer.
If spare parts are needed, use only original LEGUAN parts. They will provide your machine with the maximum
life expectancy and ensure optimum safety.
It is not possible to give explicit operating instructions 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 the working
environment and work methods. If the access platform is being used on terrain with stones or gravel, on
demolition sites with concrete, or in an environment with scrap metal, the lifespan of the track system may be
significantly reduced. Therefore, damage to the tracks, track rollers or crawler track chassis, caused by
operation in such environments, is not covered by warranty.
The machine operator can influence the service life of the tracks by complying with instructions for their use
and maintenance.

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1.3 Warranty conditions
This product is warranted for a period of twenty-four (24) months without hour limit. In the event a fault
occurs which is attributable to manufacturing or assembly defect, contact the dealer without delay.
Warranty covers manufacturing and material defects. All warranty obligations end when the warranty period
ends. Warranty repair that has been started will be completed regardless of the ending date of warranty
period.
A condition for the warranty is that both the buyer and the seller have accepted the delivery. If the buyer is
not present when the delivery takes place and doesn’t make a complaint within 14 days of delivery of this
access platform, it is considered that the sale is closed and the warranty period has started.
Warranty is limited to the repair of a faulty access platform without cost at an authorized 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’ property without compensation.
Warranty does not cover the following situations:
-Wrong or negligent use of this product, or mischief.
-Acts of vandalism.
-Any repairs or modifications to the product, performed without the prior authorization of the
manufacturer.
-Not following service and maintenance instructions.
-Machine breakdowns due to causes other than a manufacturing error.
-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 flying stones, pollution and environmental impurities, strong detergents, or by lifting
operations or lifting equipment).
-Any patterns or uneven patches on the paintwork.
-if the warranty claim is not submitted within reasonable time of the buyer observing the flaw or when
the flaw should have been noticed. Notification must always be submitted within two (2) weeks of the
buyer noticing the defect. - under all circumstances, the buyer must act so that his action does not
make the defect(s) worse.
-The manufacturer does not accept any responsibility for consequential losses resulting from the use of
this access platform.
In the event a fault occurs that is attributable to manufacturing or assembly defect, contact the dealer without
delay.

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1.4 Example of the EC declaration of conformity

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GENERAL INFORMATION
LEGUAN 225 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.
LEGUAN access platforms are designed and built in accordance with the international safety standards and
MEWP (Mobile Elevating Work Platform) standards.
The main parts of the machine are shown in figure 1. The numbered parts in the figure:
1. Chassis
2. Transmission (tracks)
3. Outrigger
4. Outrigger cylinder
5. Slewing ring
6. Lower control box
7. Pedestal
8. Lower boom cylinder
9. Self levelling bar 1
10. Lower boom 1
11. Linkage piece 1
12. Self levelling bar 2
13. Lower boom 2
14. Linkage piece 2
15. Upper boom cylinder
16. Self levelling cylinder (primary cylinder)
17. Telescope cylinder
18. Upper boom
19. Telescope boom 1
20. Telescope boom 2
21. Jib boom
22. Self levelling bar 3
23. Jib boom cylinder
24. Platform control box
25. Platform
26. Self levelling cylinder (secondary cylinder)

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Figure 1. Main parts

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2.1 Technical specifications
Working height
22,5 m
Max. platform height
20,5 m
Max. outreach @ 250 kg
9,1 m
Max. outreach @ 120 kg
11,2 m
Max. platform rated load
250 kg
Max. wind speed
12,5 m/s
Max. manual force
400 N
Transport length
6,03 m
Transport length without platform
5,27 m
Transport height
2,20 m
Width
1,25 m
Platform dimensions, W x L, 2 persons
1,33 x 0,75 m
Platform rotation
± 55°
Boom slewing
360° (non-continuous)
Gradeability
45 % (25°)
Gradeability sideways
45 % (25°)
Max. allowed levelling inaccuracy
1,0°
Min. required space for outrigger set up
4,26 x 4,36 m
Support dimensions
4,08 x 4,08 m
Max. gradient of slope for outrigger set up
25 % (14°)
Weight, depending on equipment
2950 kg
Drive system
Tracks
Drive speed
max. 3,1 km/h
Lowest operating temperature
-20 °C (storage -40 °C)
Starter battery / electric system
77 Ah / 12V
Sound power level, LWA
101 dB (A)
Sound pressure level at platform controls, LpA
79 dB (A)
Sound pressure level at lower controls, LpA
78 dB (A)
Max. outrigger force
22 kN
Max. load under tracks
0,2 N/mm2
Vibration emission, awmax
Less than 0,5 m/s2
MEWP group classification
Group B, type 1

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2.2 Main dimensions and outreach diagram
Figure 2. Required space for outriggers in widest position
Figure 3. Main dimensions from side
Figure 4. Main dimensions from behind

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Figure 5. Outreach diagram

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2.3 Signs and decals
1. Outrigger force and lifting points
2. Tie down points
3. Residual current device
4. Lower control panel
5. Emergency procedures
6. Daily inspection and general instructions
7. Radio controlled (option)
8. Crushing of hands hazard

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9. Type plate
10. Platform control panel
11. Maximum rated load
12. Distance from energized electric wires
13. Operator manual

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Figure 6. Signs and decals

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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 Operators Manual must always be kept in the box on
the platform.
In order to prevent unpermitted use of the access platform, the operator must take the ignition key that is
located on the ground level with them after ending the operation.
Electrocution Hazard!
Falling Hazard!
The access platform is not voltage insulated. Never use it near any voltage carrying parts of devices. Do not
move any part of the access platform close to uninsulated cables or other voltage carrying parts or devices.
When working with the access platform, the operator(s) must always wear certified safety harness which is
properly connected to the platform.
3.1 Before starting operation
Risk of serious injury!
-The operator manual, all warnings and labels must be read carefully.
-Only persons with min. 18 years of age are allowed to use the access platform. They must have
received sufficient operating instructions.
-Operator must know all the functions of this access platform as well as the maximum platform rated
load, loading instructions and safety instructions.
-If there is heavy traffic in the working area, it must be fenced off widely enough and marked with a
fence or with a line. Road traffic regulations must be followed as well.
-Make sure that there are no bystanders in the working area.
-Do not use faulty access platform. Inform about all faults and defects and make sure that they are
repaired before starting operation.
-Follow check and service instructions and intervals.
-The operator must check this access platform visually at the beginning of each work shift. This check is
necessary in order to make sure that the machine is all right before making the daily inspection prior
to starting operation.
-If combustion engine is used indoors, make sure that the ventilation is sufficient.

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3.2 Risk of tipping over
Tip-over Hazard!
-Maximum rated load (250 kg / 551 lbs), number of persons (2) and additional
load on the platform must never be exceeded.
-When wind speed is equal or greater than 12,5 m/s / 28 mph, the use of the
access platform must be discontinued immediately, and the platform must be
lowered down to transport position.
-Ensure that the access platform is used on dry, solid and level ground only. The
ground is solid enough if it can carry min. 3 kg/cm2/ 42 lbf/in2. On softer grounds
use extra support plates under the outriggers.
-Do not use a ladder, chair, stool, scaffolding or by any other means try to increase reach capability of
this access platform.
-In case the platform has got stuck or jammed, or it is too close to a building or a wall to be moved, do
not try to release the platform by operating the controls. All persons must leave the platform first
(with the help of a rescue service of fire brigade if necessary), only after that one can try to lower the
platform by using the emergency lowering.
-Do not increase the area of the platform or the load. Increasing of the area exposed to wind will
weaken the stability of the access platform.
-Weight must be equally distributed on the platform. Make sure that additional weight cannot shift on
the platform.
-Do not drive on gradients that are steeper than the max. values given for this access platform and for
the slope.
-Never use this access platform as a crane or an elevator. This access platform is intended for lifting of
the max. allowed number of persons and additional load only.
-In order to ensure the safe operation of this access platform the manufacturer has conducted
approved tests for the LEGUAN 225 in accordance with the standard EN 280:2022 static stability test in
accordance with paragraph 5.1.4.2.1 and dynamic overload test in accordance with paragraph 5.1.4.3.
3.3 Risk of falling
Falling Hazard!
-The operator(s) must always wear certified safety harnesses when operating this access platform. The
harnesses must be connected to the fastening point at platform mounting bracket.
-Do not stretch or reach out over the handrails. Stand steadily on the platform floor.
-It is not allowed to go to or step out from the platform when the booms are lifted.
-Always close the platform gate before starting operation.
-Keep platform floor clean.
-Do not drop or throw any material down from platform.

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3.4 Risk of collision
Collision Hazard!
-Select the drive speed so that it is safe in regard to the ground conditions.
-The operator must follow all regulations concerning the use of safety equipment on the work site.
-When operating the lift, beware that visibility may be limited and trapping hazard.
-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 possible collision situation.
3.5 Risk of electric shock
Electrocution Hazard!
-This access platform is not voltage insulated nor protected against contact
with voltage carrying parts, or when approaching them.
-Do not touch the machine if it comes in contact with voltage carrying
electric line.
-Persons on the platform or at ground level must not touch or operate the
platform before power has been cut off from the electric line.
-During welding repairs, it is not allowed to use any part of this access
platform as earth conductor.
-Do not use this access platform during thunderstorm or high winds.
-Leave clearance to electric lines taking into account movements of
platform, movements of electric line, and high winds and gusts.
For safe distance, check the national or local regulations. If no national or local regulation is available, use the
table below.
VOLTAGE
MIN DISTANCE
0 –50 kV
3 m
50 kV –200 kV
4,5 m
200 kV –350 kV
6 m
350 kV –500 kV
8 m
500 kV –750 kV
11 m
750 kV –1000 kV
14 m

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3.6 Risk of explosion/fire
Explosion Hazard!
-It is not allowed to start the combustion engine / electric motor in a place where one can smell LPG,
petrol, solvent or other flammable substance.
-Do not fill with fuel when the engine is running.
-Charge the battery only in places with sufficient ventilation, where there is no open fire or no works
which could cause spark emissions (like welding).
-In case of fire it is recommended to use carbon dioxide fire extinguisher. Dry powder extinguisher can
also be used but in this case the machine must be cleaned and inspected thoroughly because the
powder is corrosive.
3.7 Daily inspection before starting operation
- warnings and labels - personal protective devices
- platform attachment and locking - oil leakages
- operation of control elements - combustion engine oil and coolant level
- emergency stop buttons - ground capacity
- emergency lowering - chassis stabilization
- electrical cables - operating area
- loose, missing or damaged pars
If you note faults or missing equipment on this access platform, do not put it into operation 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 grounds and potholes in particular.
The operation of the access platform must be stopped if it has been in an accident or breakdown situation.
The access platform must be inspected by an authorized Leguan service workshop before taking the
machine back to operation.
3.8 Use of emergency stop switches
-Emergency stop switches are used by pressing down the red cap of the switch in emergency situations
when normal shutting down procedures are not possible. For example in accidents and other
dangerous situations involving the access platform or its user.
-Emergency stop switches shut down the engine.
-Emergency stop switches in upper (figure 7 (11)) and lower control panels (figure 8 (4)) can be used at
any time.
-Emergency stop switches can be returned to neutral position by twisting its red cap clockwise.
-The emergency stop switch on remote control unit will only operate when the remote control use is
selected.