TEUPEN LEO 21GT Quick guide

Aerial access platform
Translation of the original oper-
ating instructions
Serial number: _______________

© TEUPEN Maschinenbau GmbH 2013
Manufacturer:
TEUPEN Maschinenbau GmbH
Marie-Curie-Straße 13
48599 Gronau, Germany
Telephone: [phone]
Fax: [phone]
email: [email protected]
Internet: www.teupen.com
Service:
Telephone: [phone]
email: [email protected]
LEO21GT_GB
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Table of contents
1 General................................................................ 9
1.1 Information about these instructions............. 9
1.2 Explanation of symbols................................. 9
1.3 Limitation of liability..................................... 11
1.4 Copyright..................................................... 12
1.5 Warranty provisions.................................... 12
1.6 Note regarding warranty card:..................... 12
1.7 Customer service........................................ 13
2 Safety................................................................. 15
2.1 Basic hazards.............................................. 15
2.1.1 General hazards in the work station......... 15
2.1.2 Hazards due to electric energies.............. 17
2.1.3 Hazards due to mechanical elements...... 19
2.1.4 Hazards due to hydraulic energies........... 20
2.1.5 Hazards due to high temperatures........... 21
2.1.6 Hazards due to chemical substances...... 21
2.1.7 Hazards due to traffic and vehicles.......... 22
2.2 Proper use................................................... 23
2.3 Responsibility of the owner......................... 24
2.4 Personnel requirements.............................. 25
2.4.1 Qualifications............................................ 25
2.4.2 Unauthorised persons.............................. 27
2.4.3 Training.................................................... 27
2.5 Personal protective equipment.................... 28
2.6 Safety devices............................................. 29
2.6.1 Position of the safety devices................... 30
2.6.2 Description of the installed safety
devices..................................................... 31
2.7 Symbols on the machine............................. 34
2.8 How to act in case of fire or accidents........ 35
2.9 Environmental protection............................ 36
3 Technical data................................................... 39
3.1 Dimensions................................................. 39
3.2 Work diagram.............................................. 40
3.3 Productivity.................................................. 40
3.4 Weight and loads........................................ 41
3.5 Drives.......................................................... 41
3.5.1 Combustion engines................................ 41
3.5.2 Electric motor........................................... 41
3.6 Emissions.................................................... 42
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3.7 Operating conditions................................... 42
3.8 Hydraulic system......................................... 42
3.9 Consumables.............................................. 43
3.10 Type plate................................................. 43
4 Structure and function..................................... 45
4.1 Overview..................................................... 45
4.1.1 Brief description....................................... 46
4.2 Assembly description.................................. 47
4.2.1 Platform.................................................... 47
4.2.2 Outriggers................................................ 48
4.2.3 Working basket........................................ 48
4.2.4 Crawler chassis........................................ 49
4.2.5 Combustion engine.................................. 49
4.2.6 Electric motor........................................... 49
4.3 Operating elements and displays................ 50
4.3.1 Outrigger latching..................................... 50
4.3.2 Cable remote control................................ 50
4.3.3 Control panel in working basket............... 52
4.3.4 Engine controller...................................... 54
4.3.5 Display screen on the control box............ 55
4.3.6 Emergency control................................... 55
4.4 Connections................................................ 56
4.5 Work areas and danger zones.................... 56
4.6 Accessories................................................. 56
4.6.1 Keys......................................................... 56
4.6.2 Safety harness (optional)......................... 57
5 Transportation and storage............................. 59
5.1 Safety instructions for transportation........... 59
5.2 Inspection on receipt of delivery.................. 59
5.3 Transportation............................................. 60
5.4 Storage........................................................ 64
6 Operation........................................................... 67
6.1 Safety instructions for operation.................. 67
6.2 Connecting the cable remote control.......... 68
6.3 Switching the machine on/off...................... 69
6.3.1 Switching the machine on/off at the mains
supply....................................................... 69
6.3.2 Switching machine on/off using the com-
bustion engine.......................................... 72
6.4 Shutting down in case of emergency.......... 74
6.5 Principles of the graphic display.................. 75
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6.5.1 Overview.................................................. 75
6.5.2 Possible assignment of the function keys 75
6.5.3 Examples of the operating modes............ 76
6.5.4 Main menu............................................... 79
6.5.5 Machine data............................................ 80
6.5.6 Service hotline.......................................... 81
6.5.7 Settings.................................................... 81
6.5.8 Additional information messages
regarding machine status......................... 86
6.6 Moving the machine.................................... 89
6.6.1 Moving the machine via the cable remote
control...................................................... 90
6.6.2 Moving the machine via the control panel 94
6.7 Setting the working position of the outrig-
gers............................................................. 96
6.8 Putting machine in work position................. 98
6.8.1 Bracing the machine via the cable remote
control...................................................... 99
6.8.2 Bracing the machine via the control
panel...................................................... 103
6.9 Operating the machine.............................. 106
6.9.1 Operating the machine via the cable
remote control........................................ 107
6.9.2 Operating the machine via the control
panel...................................................... 108
6.9.3 Negotiating height differences on edges 111
6.10 Moving the machine into transport posi-
tion.......................................................... 113
6.10.1 Moving the machine into the transport
position via the cable remote control.... 114
6.10.2 Moving the machine into the transport
position via the control panel................ 118
6.11 Crawler chassis height and width adjust-
ment........................................................ 125
6.11.1 Mechanical height/width adjustment.... 125
6.11.2 Hydraulic height adjustment (option).... 128
6.12 Replacing the working basket................. 133
6.13 Filling the fuel tank.................................. 137
6.14 Emergency mode.................................... 138
6.14.1 Platform operation in emergency
mode.................................................... 139
6.14.2 Operate the outriggers in emergency
mode.................................................... 143
6.15 Service mode.......................................... 146
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6.15.1 Switching the machine on/off using the
engine controller................................... 146
6.15.2 Platform operation in service mode...... 148
6.15.3 Outrigger operation in service mode.... 151
6.15.4 Chain drive in service mode................. 153
6.16 Valve assignments.................................. 155
6.16.1 Valve assignment for platform.............. 155
6.16.2 Valve assignment for outriggers........... 158
6.17 Resetting the combination for the locks.. 159
6.17.1 Resetting the combination on the
shackle lock.......................................... 159
6.17.2 Resetting the combination for the combi-
nation lock on the control panel........... 160
7 Maintenance.................................................... 163
7.1 Safety instructions for maintenance.......... 163
7.2 Maintenance schedule.............................. 168
7.3 General maintenance schedule................ 169
7.4 Maintenance work..................................... 170
7.4.1 Cleaning the machine............................ 170
7.4.2 Tensioning the chain.............................. 171
7.4.3 Checking the hydraulic oil level.............. 173
7.4.4 Checking the gear oil for the chain
chassis................................................... 174
7.4.5 Replacing the hydraulic filter.................. 176
7.4.6 Lubricating the boom section and ropes 178
7.4.7 Lubricating the rotary drive..................... 181
7.4.8 Lubrication schedule.............................. 181
7.4.9 Rotating assembly tightening torques.... 182
8 Faults............................................................... 183
8.1 Safety instructions for fault clearance....... 183
8.2 Fault table................................................. 188
8.3 Fault code list............................................ 192
8.4 Notes about the rubber track..................... 199
8.5 Fuses........................................................ 201
8.5.1 Changing fuses...................................... 201
8.5.2 Fuse assignment.................................... 201
9 Disposal........................................................... 205
10 Index................................................................ 207
Appendix......................................................... 211
A Circuit diagram............................................... 213
B Hydraulic plan................................................. 215
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C Combustion engines...................................... 217
C.1 Kubota diesel engine................................. 219
DList of the stickers/symbols............................ 
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1 General
1.1 Information about these instructions
These instructions enable the safe and efficient han-
dling of the access platform (hereinafter referred to as
"machine"). These instructions are a component of the
machine and must be kept in the immediate vicinity of
the machine so that they are accessible to the per-
sonnel at any time.
Before beginning any work, the trained personnel must
have read through these instructions carefully and
understood them. The basic requirement for safe
working is adherence to all the specified safety instruc-
tions and operating instructions in these instructions.
In addition, the local accident prevention regulations
and general safety provisions for the area of application
of the machine apply.
Figures in these instructions serve the purpose of basic
understanding and can deviate from the actual model.
1.2 Explanation of symbols
Warnings are identified by symbols. These warnings
are introduced by signal words, which express the
severity of a danger.
DANGER!
This combination of symbol and signal word
indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING!
This combination of symbol and signal word
indicates a potentially hazardous situation
which, if not avoided, may result in death or
serious injury.
Warnings
General
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CAUTION!
This combination of symbol and signal word
indicates a potentially hazardous situation
which, if not avoided, may result in minor or
moderate injury.
NOTICE!
This combination of symbol and signal word
indicates a potentially hazardous situation
which, if not avoided, may result in property
damage.
ENVIRONMENTAL PROTECTION!
This combination of symbol and signal word
indicates potential danger to the environment.
This symbol highlights useful tips and recom-
mendations as well as information designed
to ensure efficient and smooth operation.
The following symbols are used in the safety informa-
tion in order to highlight specific dangers:
Warning signs Type of danger
Warning – high-voltage.
Warning – danger zone.
DANGER!
This combination of symbol and signal word
indicates an immediately-dangerous situation
due to electric shock. If an instruction so
marked is not heeded, severe or even fatal
injuries can be the consequence.
Tips and recommendations
Specific notes on safety
General
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To emphasise instructions, results, lists, references and
other elements, the following markings are used in
these instructions:
Marking Explanation
Step-by-step instructions
ðResults of action steps
References to sections of these
instructions and to other relevant
documents
Listing without fixed sequence
[Buttons] Operating elements (e.g. buttons,
switches), display elements (e.g.
signal lamps)
‘Display’ Screen elements (e.g. buttons, pro-
gramming of function keys)
1.3 Limitation of liability
All details and instructions in these instructions were
compiled taking into account the applicable standards
and regulations, the state of technology, as well as our
many years of knowledge and experience.
In the following cases, the manufacturer assumes no
liability for damage:
nFailure to follow these instructions
nUse deviating from the proper use
nUse of untrained personnel
nUnauthorised changes
nTechnical alterations
nUse of non-approved spare parts
For special models, with the usage of additional order
options or due to the latest technical changes, the
actual scope of delivery can deviate from the explana-
tions and depictions provided here.
Applicable are the obligations agreed upon in the
delivery contract, the general terms and conditions, as
well as the delivery conditions of the manufacturer and
the legal regulations valid at the time the contract was
concluded.
Additional markings
General
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1.4 Copyright
The contents of these instructions are copyrighted.
Their use is permitted in the context of using the
machine. Any use extending beyond this is not allowed
without written permission from the manufacturer.
1.5 Warranty provisions
The warranty provisions are contained in the manufac-
turer's general terms and conditions.
1.6 Note regarding warranty card:
In order to be able to process warranty applications
between the customer, service partner and Teupen as
quickly as possible, it is absolutely necessary to fill out
the warranty card which is at the front of the machine
record and send it back to Teupen directly after hand-
over of the machine to the customer. If the warranty
card is not filled out properly, we cannot process the
warranty application since important data which is
necessary for the processing has not been made avail-
able to us.
General
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Please send the warranty card to:
Teupen Maschinenbau GmbH
Service Point
Marie-Curie-Straße 13
D-48599 Gronau
Sample of a properly filled-out warranty card:
Fig. 1: Sample warranty card
1.7 Customer service
Our customer service division is available to provide
technical information. See page 2 for contact details.
In addition, our employees are always interested in
acquiring new information and experience gained from
practical application; such information and experience
may help improve our products.
General
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General
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2 Safety
This section provides an overview of all safety aspects
that are essential to the best possible protection of the
personnel and the safe and trouble-free operation of the
machine. Additional safety instructions for specific work
tasks are contained in the sections regarding the indi-
vidual life stages of the machine.
2.1 Basic hazards
The following section describes remaining risks which
can arise from the machine even with proper use.
In order to reduce risks of personal injury and property
damage and avoid dangerous situations, the safety
instructions listed here and the safety instructions in the
other sections of these instructions must be followed.
2.1.1 General hazards in the work station
WARNING!
Danger to life due to swivelling aerial
access platform!
During operation, the aerial access platform
can swivel out. This can cause severe injuries
or even death.
– Never step under or into the swivel range
of the aerial access platform.
– Only move the aerial access platform
under supervision.
– Always operate the aerial access platform
with at least two people.
– Always wear personal protective equip-
ment.
Swivelling aerial access plat-
form
Safety
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WARNING!
Risk of falling!
During work in high places, there is a risk of
falling. This can cause severe injuries or even
death.
– Always wear a safety harness (acc. to EN
361) when in the working basket and do
not swing or move jerk.
– Do not climb onto the safety fence around
the basket.
– Make sure that the machine is set up
properly and holds securely.
– Make sure that when moving the working
basket, no body parts are crushed, e.g.
against a wall.
– At wind speeds above 12.5 m/s (wind
strength 6 Bft), stop work immediately.
– Always wear personal protective equip-
ment.
WARNING!
Danger to life from poisoning or suffoca-
tion due to exhaust gases!
When inhaled, exhaust gases can lead to suf-
focation and cause severe poisoning as well
a illness of the respiratory system.
– Always ensure fresh air supply when
working on the machine in combustion
engine mode.
– Any person inhaling exhaust gases must
be provided with fresh air immediately.
Consult a physician.
Work in high places
Exhaust gases
Safety
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2.1.2 Hazards due to electric energies
DANGER!
Danger to life due to electric current!
Upon contact with voltage-conducting parts,
there is an immediate danger to life due to
electric shock. Damage to the insulation or
individual components can present a danger
to life.
– Do not work on or near high-voltage lines.
– Only have a trained electrician perform
work on the electrical system.
– In case of damage to the insulation, switch
off the power supply immediately and
have the machine repaired.
– Never bypass fuses or take them out of
operation. When changing fuses, adhere
to the correct amperage.
– Keep humidity away from voltage-con-
ducting parts. This can cause a short-cir-
cuit.
– Before performing work on voltage-con-
ducting parts, pull the mains plug.
Electric current
Safety
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WARNING!
Danger of injury due to incorrect handling
of batteries!
In case of batteries are improperly handled,
there is the danger that the batteries can
explode or that liquids that are hazardous to
health can egress from the batteries. The
liquid egressing can cause severe burns
upon skin contact, severe poisoning upon
swallowing and blindness in case it comes in
contact with eyes.
– Never short circuit the contacts (positive
and negative poles) of the batteries!
– Never use or store batteries in places
where the atmosphere is explosive or
where temperatures can rise excessively.
– Never attempt to solder batteries, to repair
them, to change their form, to remodel
them or to dismantle them.
– Always protect batteries from access by
unauthorised persons.
– In order to avoid fires, overheating, explo-
sions or escape of fluids, do not subject
batteries to heavy vibrations or shocks,
place heavy weights on them or subject
them to other damaging exposures. Liq-
uids which emanate from batteries can get
inflamed.
– Avoid contact with escaping liquids.
Measures to be undertaken upon contact with battery
liquids:
nWash skin with plenty of water and soap after con-
tact.
nRinse out with clear water under the eyelids for at
least 15 minutes after contact. While doing so, do
not direct the stream of water directly on the eyes
and do not rub. Immediately summon medical assis-
tance.
Batteries
Safety
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2.1.3 Hazards due to mechanical elements
WARNING!
Danger of injury due to falling materials!
During operation, material can fall down
uncontrolled and cause severe injuries.
– Make others aware of the danger zone
and block off the area.
– Do not enter the danger zone during
normal operation.
– Never place objects on the working basket
safety fence.
WARNING!
Danger of crushing on supports and arms!
When bracing or swivelling the machine,
there is a danger of crushing.
– Make sure that when bracing, no people,
supply lines or other objects are in the
area around the supports.
– Make sure that no people are in the
danger zone when swivelling the machine.
– Make sure that no people are in the
danger zone when moving into transport
position.
WARNING!
Risk of injury due to insufficient stability!
Without sufficient stability, there is a risk of
the machine toppling. This can cause serious
or even fatal injuries.
– Make sure that the ground has sufficient
load bearing capacity ( Ä Chapter 3.4
‘Weight and loads’ on page 41).
– Do not exceed the maximum inclination
( Ä Chapter 3.4 ‘Weight and loads’
on page 41).
Falling materials
Supports and arms
Insufficient stability
Safety
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WARNING!
Danger of injury due to driving over body
parts!
With the crawler chassis, there is a danger of
pinching off body parts and thus causing
severe to fatal injuries.
– During operation, do not reach into run-
ning chains or chain wheels.
– During operation, maintain a sufficient
safety distance.
– Pay attention to the change of direction.
– Do not drive over power lines.
2.1.4 Hazards due to hydraulic energies
WARNING!
Danger to life from hydraulic forces!
Hydraulically driven moving parts can cause
grave injuries.
– Work on the hydraulic system must only
be carried out by trained hydraulics techni-
cians.
– Before starting work on the hydraulic
system, ensure that it has been com-
pletely depressurised. The pressure accu-
mulator must be completely relieved.
– During operation, do not reach into or
handle moving parts.
– Do not open covers during operation.
– When in the danger zone, wear close-fit-
ting protective work clothing with low tear
strength.
Crawler chassis
Hydraulics
Safety
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