operators manual 2015-€¦ · 7 2. general information leguan 135 is a self propelled mobile...

Operators Manual 2015-

Edited: 26.1.2016

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TABLE OF CONTENTS

1. INTRODUCTION AND WARRANTY CONDITIONS 4 1.1. INTRODUCTION 4 1.2. WARRANTY CONDITIONS 4

2. GENERAL INFORMATION 7

3. TECHNICAL SPECIFICATION, LEGUAN 135 8 3.1. REACH DIAGRAM 11 3.2. SET UP DIAGRAM 12

4. SIGNS AND STICKERS 13

5. SAFETY INSTRUCTIONS 14 5.1. BEFORE STARTING OPERATION 14 5.2. OVERTURNING HAZARD 15 5.3. FALLING HAZARD 15 5.4. COLLISION HAZARD 16 5.5. ELECTROCUTION HAZARD 16 5.6. EXPLOSION / FIRE HAZARD 17 5.7. DAILY INSPECTION BEFORE STARTING OPERATION 17 5.8. USING THE EMERGENCY STOP SWITCHES 17

6. CONTROLS 18 6.1. CONTROLS AT PLATFORM 18

6.1.1 Remote control switches 18 6.1.2 Pairing of remote control unit 18 6.1.3 Remote control display 19 6.1.4 Switches at platform control panel 21

6.2. CONTROLS AT GROUND LEVEL 22 6.2.1 Battery disconnect switch 22 6.2.2 Controls on the connection box at ground level 22 6.2.3 Switches at lower controls (option) 22 6.2.4 Override of safety functions in emergency situations 23 6.2.5 230V – connection and switches 24 6.2.6 Manual pump at pedestal 24

7. STARTING THE ENGINE / ELECTRIC MOTOR 25 7.1. ADDITIONAL INSTRUCTIONS FOR WINTER USE 25

8. DRIVE CONTROL 26 8.1. DRIVE SPEED SELECTION 27 8.2. ELECTRIC DRIVE RAMP ADJUSTMENT 27 8.3. DEFINING THE GRADIENT OF THE SLOPE 27 8.4. DRIVING THE LIFT ON TRAILER 28 8.5. CRAWLER TRACK CHASSIS 28

9. OPERATION OF THE OUTRIGGERS 30

10. OPERATION OF THE BOOMS 32

11. EMERGENCY LOWERING 33

12. ENDING THE OPERATION 34

13. TRANSPORTING INSTRUCTIONS 35

14. SERVICE, MAINTENANCE AND INSPECTION INSTRUCTIONS 36 14.1. GENERAL INSTRUCTIONS 36 14.2. SERVICES AND CHECKS, MAINTENANCE SCHEDULE 38

15. SERVICE INSTRUCTIONS 40 15.1. GREASING OF THE MACHINE 40 15.2. HANDLING OF FUEL AND REFUELING 40 15.3. HYDRAULIC OIL AND FILTER CHANGE 40 15.4. HYDRAULIC OIL LEVEL 40 15.5. BATTERY CHECK 41 15.6. CHECK OF SET UP OUTRIGGER CONTROL SYSTEM 41

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15.7. WATER LEVEL CHECK 41 15.8. ADJUSTMENTS IN HYDRAULIC SYSTEM 42 15.9. COMPONENTS IN OVERLOAD CONTROL SYSTEM 45 15.10. ELECTRIC SENSORS 46 15.11. CHECK AND ADJUSTMENT OF TRACK TENSION 48

16. REPAIR INSTRUCTIONS 49 16.1. WELDING 49

17. INSTRUCTIONS FOR TEMPORARY STORAGE 49

18. DISPOSAL INSTRUCTIONS 49

19. TROUBLESHOOTING 50

20. SERVICE HISTORY 53

Attachments: Hydraulic schematic Electric schematic Parameter list and application specific error code list Error code list of IFM safety logic Error code list of Scanreco Safety functions evaluation chart Honda iGX390 Owner’s manual

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1. 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 contents of this manual completely before operating the access platform. This will improve your operating and maintenance efficiency, help avoid breakdowns and damage and extend your machine’s life.

Pay special attention to this symbol. It indicates 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 he or she familiarizes himself or herself 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. The manufacturer does not warrant any damages which are the result of using the access platform.

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 lifespan of the crawler track system of an access platform on rubber tracks is heavily dependent on the working environment and the way of working. If the access platform is being used in terrains with stones or gravel, on demolition sites where there is concrete, or in an environment with scrap metal, the lifespan of the track system can be significantly reduced. Because of this, damages on the tracks, track rollers or crawler track chassis, caused by operation in such environments, are not covered by warranty. The operator has a good possibility to increase the lifespan of the crawler track system by following the operating and maintenance instructions of the track system.

1.2. Warranty conditions

This product is warranted for a period of twenty-four (24) months, with unlimited operating hours.

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.

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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. 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:

- damages caused by wrong or negligent use of this product, or mischief - any repairs or modifications to the product, performed without the prior

authorization of the manufacturer

- damages caused by not following service and maintenance instructions

- breakdowns, unless caused by manufacturing fault

- adjustments, repairs and spare parts replacements caused by normal wear

- damages caused by excessive loads on the access platform, sudden unexpected incident, natural disaster

- damages caused by external mechanical or chemical reasons (paint

damages, especially caused by stone chips, air and environmental pollution and strong cleaning agents)

- any repairs, modifications or reassemblies performed without the prior

authorization of the manufacturer or importer - eventual visible patterns or unevenness of painted surfaces

- warranty claims that haven’t been sent to the manufacturer within 14 days

from the date the buyer has noticed the defect. In all conditions the buyer shall act so that his action doesn’t make the eventual 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 which is attributable to manufacturing or assembly defect, contact the dealer without delay.

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ALKUPERÄINEN EY-VAATIMUSTENMUKAISUUSVAKUUTUS ORIGINAL EC DECLARATION OF CONFORMITY FOR MACHINERY

TÄTEN VAKUUTAMME, ETTÄ HEREWITH DECLARES THAT

HENKILÖNOSTIN NIMELLISKUORMA AERIAL PLATFORM NOMINAL LOAD MALLI NOSTOKORKEUS MODEL PLATFORM HEIGHT SARJANUMERO VALMISTUSVUOSI SERIAL NR YEAR OF CONSTRUCTION

ON KONEDIREKTIIVIN 2006/42/EY ASIAAN KUUULUVIEN SÄÄNNÖSTEN MUKAINEN IS IN ACCORDANCE WITH THE REGULATIONS LAID OUT IN THE MACHINERY DIRECTIVE: 2006/42 / EC

KONE TÄYTTÄÄ LISÄKSI MUIDEN EY-DIREKTIIVIN VAATIMUKSET: 2004/108/EY THE MACHINE ALSO FULFILLS THE REQUIREMENTS LAID OUT IN THE DIRECTIVES 2004/108/EY SEURAAVIA EUROOPPALAISIA YHDENMUKAISIA STANDARDEJA ON SOVELLETTU SUUNNITTELUSSA: EN280:2013 FOLLOWING EUROPEAN HARMONIZED STANDARDS ARE USED WHEN THE MACHINERY WAS DESIGNED: EN280:2013 Teknisen tiedoston on valtuutettu kokoamaan: LEGUAN LIFTS OY Storage address of original documents: Ylötie 10, FI-33470 Ylöjärvi, Finland Ilmoitettu laitos / Notified Body INSPECTA TARKASTUS OY,

NB0424 Testausraportti / Test Report No. 14633-02/2015 Paikka / Place Päiväys / Date Ylöjärvi, FINLAND Valmistaja / Manufacturer:

LEGUAN LIFTS OY

Ylötie 10, FI-33470 Ylöjärvi, Finland Allekirjoitus / Signature: ____________________________________

LEGUAN

L135

230 KG

11,2 M

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2. GENERAL INFORMATION

LEGUAN 135 is a self propelled Mobile Elevating Work Platform – or commonly called access platform, designed for indoor and outdoor use. An access platform is destined for lifting of persons and their equipment only. It is not allowed to use an access platform as a crane. LEGUAN 135 access platform has two nominal loads and two working areas. With max. 140 kg load on the platform the machine can be operated over the whole working area. If the load on the platform exceeds 140 kg, the working area is restricted up to max. 230 kg load on the platform. LEGUAN is designed and built in accordance with the international safety standards and MEWP (Mobile Elevating Work Platform) standards.

The picture below shows the main parts of this access platform. Leguan 135 on wheels is identical to the machine with tracks, except for the crawler track system. 1. Chassis 2. Transmission, either with

wheels or with crawler tracks 3. Outrigger 4. Outrigger cylinder 5. Transport support 6. Electric motor 7. Connection box of control

system with emergency lowering buttons

8. Pedestal 9. Valve box at ground level

10. Lower boom cylinder 11. Lower boom 12. Self leveling bar 13. Linkage piece 14. Upper boom cylinder 15. Telescoping cylinder

16. Upper boom 17. Telescoping boom 18. Jib boom cylinder 19. Jib boom 20. Platform 21. Controls box at platform

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3. TECHNICAL SPECIFICATION, LEGUAN 135

Working height, safe working load <140 kg 13,2 m

SWL 140 - 230 kg 12,2 m

Max. platform height, SWL <140 kg 11,2 m

SWL 140 – 230 kg 10,2 m

Max. outreach, SWL <140 kg 6,8 m

SWL 140 – 230 kg 5,8 m

Safe working load, max. 230 kg

Transport length 4474 mm

Transport length without platform 3754 mm

Transport height 23” tyres 2067 mm

20” tyres 2020 mm

Tracks 2052 mm

Width 23x8,5-12” tyres 1000 mm

20x8,0-10” tyres 1000 mm

Tracks 1000 mm

Platform dimensions, W x L, 2 persons 1330 x 750

Slewing 360º

Gradeability 35 % (20,5°)

Support dimensions (outrigger spread) 3130 x 3050 mm

Max. unevenness of set up 1,5º

Max. gradient of slope for set up 19 % (11º)

Weight, depending on equipment 1700 kg (tyres) - 1850 kg (tracks)

Drive system 4WD or rubber tracks

Drive speed 3,5 km/h / 3,0 km/h

Lowest operating temperature - 20 °C

Starter battery / Electric system 12V

Sound power level at platform controls, LWA 75 dB

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3.1. Reach diagram

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3.2. Set up diagram

The minimum distances between support points are shown in the picture below.

The minimum dimensions needed to set the outriggers with small outrigger pads are 3650 x 3700 mm (length x width). With large outrigger pads the dimensions are 3800 x 3850 mm (length x width).

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4. SIGNS AND STICKERS

1. Type plate and CE marking 2. Reach diagram 3. Safe working load (SWL) and reach diagram

4. Max. horizontal force and wind speed 5. General user instructions 6. Daily inspection 7. Always use outriggers 8. Symbol stickers (pictograms) of controls 9. Emergency lowering 10. Residual current device 11. Voltage of electric motor 12. Max. support force

13. Distance from energized electric wires 14. Tie down points

15. Tyre pressure 16. LEGUAN 135 sticker

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5. 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. ATTENTION ! In order to prevent unpermitted use of the access platform, take the main battery disconnect key that is located on ground level and the engine ignition key, if fitted, with you after ending operation.

CAUTION! DANGER!

THE ACCESS PLATFORM IS NOT VOLTAGE INSULATED. NEVER USE IT NEAR ANY VOLTAGE CARRYING PARTS OR DEVICES. DO NOT DRIVE ANY PART OF THE ACCESS

PLATFORM OR 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.

5.1. Before starting operation

- 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

Safe Working 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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5.2. Overturning hazard

- Safe working load, number of persons and additional load on the platform must

never be exceeded. - When wind speed is equal to 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, level ground only. The ground is solid enough if it can carry min. 3 kg/cm2. On softer grounds use extra support plates under the outriggers (plate dimensions 400 x 400 mm).

- 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 try to 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.

- Check and make sure that all tyres are in good condition. If the tyres are air filled make sure that there is correct pressure in the tyres.

- In order to ensure the safe operation of this access platform the manufacturer has conducted approved tests for the LEGUAN 135 in accordance with the standard EN280:2013 : static stability test in accordance with paragraph 6.1.4.2.1 and dynamic overload tests in accordance with paragraph 6.1.4.3 of the EN280:2013.

5.3. 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.

- Keep platform floor clean. - Always close the platform gate before starting operation. - Do not drop or throw any material down from platform. - It is not allowed to go to or step out from the platform when the booms are lifted.

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5.4. Collision hazard

- Adjust the drive speed so that it is safe with regard to the ground conditions. - The operator must follow all regulations concerning the use of safety equipment

on the work site. - 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 an eventual collision situation.

- When operating the machine beware of eventual limited visibility and trapping hazard.

5.5. 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.

The minimum safety clearances to voltage carrying electric lines are shown in the following table. These clearances must be respected. VOLTAGE

MIN. DISTANCE

0 – 1000V 2 m 1- 45 kV 3 m 110 kV 5 m 220 kV 5 m 400 kV 5 m

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5.6. Explosion / fire hazard

- It is not allowed to start the motor/engine 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 a carbon dioxide (CO2) fire extinguisher. A dry chemical extinguisher can also be used to put out a fire, but in this case the access platform must be cleaned and checked carefully and thoroughly, because the dry chemicals are abrasive.

5.7. Daily inspection before starting operation

- ground - controls - supports - driving area - horizontal leveling - platform - emergency stop button - oil leakages - emergency lowering - working area

ATTENTION! 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.

ATTENTION! If the access platform has been in an accident/has broken down, the operation must be stopped immediately. The functions of the access platform must be

checked by Leguan service to make sure that they work properly before starting operation again.

5.8. Using the emergency stop switches

The emergency stop switches are used by pushing them all the way down in emergency situations, where there is no time to use the normal stopping of the access platform. Such emergency situations are for instance the hazards or accidents caused to the operator or to the access platform. The emergency stop switches stop the engine/electric motor, but the logic of the access platform remains active. The emergency stop switches at ground level and at platform (see 6.1.4 and 6.2.2) are always operational. The emergency stop switch of remote control can be used in emergency only if the remote control unit has been selected as active control station. Emergency stop switch is released by turning it.

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6. CONTROLS

6.1. Controls at platform

6.1.1 Remote control switches

Function of the remote control switches at platform varies somewhat, depending on model. Functions marked as “option” are not available for all models.

1. Control lever, drive, left side 2. Control lever, slewing 3. Control lever, platform rotation (option) 4. Control lever, jib boom 5. Control lever, telescoping boom 6. Control lever, upper boom 7. Control lever, lower boom 8. Control lever, drive, right side 9. Platform self leveling switch 10. Drive speed selector switch 11. Drive mode selector switch 12. Engine/electric motor start/stop switch 13. Deceleration switch 14. Remote controllers combined turn off and EMERGENCY STOP switch

15. Remote control start switch 16. Left front outrigger switch 17. Left rear outrigger switch 18. Right front outrigger switch 19. Right rear outrigger switch 20. Automatic outrigger set up switch

6.1.2 Pairing of remote control unit

If the wireless controlling isn’t working it is possible to pair the remote control with the receiver in the following way. 1. Connect the remote control to the cable. 2. Switch on battery disconnect switch of the machine. 3. Switch on the remote control unit by pushing on its start button and keep the button pushed down until you hear an audible signal from the remote control. After that the remote control goes off. 4. Restart the remote control unit. It is now paired with the receiver and the wireless control also works. Attention! The time between switching on the battery disconnect switch and starting of the remote control unit must not exceed 10 seconds. If the interval is longer, the pairing cannot be done. The remote control unit is equipped with a time-out function. If the remote control is not connected to the cable and the levers nos. 1-8 are not operated during a period of 10 minutes, the remote control will go off, in order to save the battery.

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6.1.3 Remote control display

The symbols and indicators on the remote control display at platform can vary somewhat, depending on model. Symbols that are marked as option are not available for all models.

First main page 1. Working area symbol 2. Boom operation allowed symbol 3. Combustion engine symbol 4. Machine is set up within allowed inclination 5. Symbols for outriggers touching the ground. In this field are shown also eventual malfunction codes. 6. Drive speed area (1-4) 7. Drive / outrigger operation allowed symbol 8. Electric motor symbol (option)

The first main page also shows inclination of the chassis (1) as warning, if it is more than the max. allowed set up inclination. This function is available as an option. This field also shows a STOP sign if one of the emergency stop switches is pushed down. In addition, this field warns about low battery level of remote control unit.

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1. Boom operation indicator (green) 2. Inclination warning indicator (orange)

(option) 3. Machine battery charge level indicator

(orange) 4. Fuel level warning indicator (orange) 5. Overload indicator (red) 6. Main pages browsing upwards / parameter

browsing on settings pages 7. Main pages browsing downwards /

parameter browsing on settings pages 8. In use only on login and settings pages 9. In use only on login and settings pages 10. In use only on login and settings pages 11. Backlight switch on main pages /

otherwise in use on login and settings pages

12. Moving from main pages to login page / page change on settings pages

13. Return to first main page from any page

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Second main page 1. Voltage of the battery of the machine 2. Ambient temperature sensor reading (option) 3. P1 = pump pressure, P2 = boom pressure (option), P3 = drive pressure (option), P4 = outrigger pressure (option) 4. Radio remote control symbol 5. Remote control unit battery charge 6. Chassis inclination, 1/10 degrees (at the

picture on left +0,5° and +0,2°) 7. Software version of logic 8. Parameter list version Third main page 1. Basket load, two channels (in the example picture remote controller is out of the basket) 2. Operating hours, electric motor 3. Operating hours, combustion engine 4. Operating hours, total electric motor + combustion engine

Going to login page happens by pressing on the Enter button (1) on any main page. PIN code is given with the F1-F4 buttons and login is confirmed with Enter button. It is possible to change certain parameters on the first service page. The amount of allowed parameter changes depends on the level of the password. Browsing of parameters happens by pressing on the arrow buttons and the active parameters are changed with F1 and F2 buttons. New value is confirmed by pressing on the F3 button. Logout from service page happens by pressing on the F4 button. Return to main page without logging out from service

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page happens by pressing on the ESC button. In this case the return to service page happens with the Enter button without the need to give PIN code again. Browsing of service pages happens with Enter button. User level password (1201) allows changing the parameters of automatic outrigger set up, reaction time of combustion engine for going to idle speed and the temperature unit on the second main page.

On the second service page, with user level password, it is possible to change the password (F1) or reset to factory default values (F4). After resetting to factory default values the platform load must always be calibrated which can be done by Leguan service. The third service page, with user level password, shows engine/electric motor operating hours, number of using of safety functions override switch, and the date of last operation in relation to total operating hours.

6.1.4 Switches at platform control panel

The switches at platform control panel may vary depending on model. Switches marked as option are not available on all models.

1. Emergency lowering, jib boom 2. Emergency lowering, telescoping boom 3. Emergency lowering, upper boom 4. Emergency lowering, lower boom 5. 12 V outlet 6. EMERGENCY STOP switch 7. Work light switch (option)

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6.2. Controls at ground level

6.2.1 Battery disconnect switch

Battery disconnect switch disconnects the circuit from plus line of the battery. When battery disconnect switch is switched off, all low voltage functions except for emergency lowering and GPS device (option) are switched off. The battery charger charges the battery also when battery disconnect switch is switched off.

6.2.2 Controls on the connection box at ground level

1. Outrigger blinker indicators switch (option) 2. Emergency lowering, jib boom 3. Emergency lowering, telescoping boom 4. Emergency lowering, upper boom 5. Emergency lowering, lower boom 6. Hour meter 7. EMERGENCY STOP switch 8. Ignition switch, remote controls – 0 – lower

controls 9. Overload indicator 10. Lower controls (option) 11. Override switch of safety functions (option,

included in lower controls)

6.2.3 Switches at lower controls (option)

1. Slewing 2. Jib boom up/down 3. Telescoping boom out/in 4. Upper boom up/down 5. Lower boom up/down 6. Hold to run switch, ”dead man” switch 7. Speed selector switch, the LEDs on the switch indicate the selected speed area 8. Engine preheater switch (not on petrol engine) 9. Electric motor start/stop (option) 10. Combustion engine start/stop

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Operating the lower controls: 1. Turn the ignition switch to lower controls position. 2. When lower controls have been chosen, the engine/electric motor can be

started and stopped with the buttons on the lower controls panel 3. Boom movement speed can be selected with the 4-stage switch 4. Boom movements can now be operated – except for platform self leveling

and rotating – with the switches on lower controls panel. The “dead man” switch must be pressed down before boom movement switches will work.

ATTENTION! The EMERGENCY STOP switches at platform and lower controls work always, regardless of the position of the selector switch of lower/upper controls.

6.2.4 Override of safety functions in emergency situations

With the override switch of safety functions the emergency stop switch at platform and platform load control can be bypassed. The switch is functional only when lower controls have been chosen. The switch must be kept pressed down all the time. After that lower controls will work normally. The override switch is intended for extreme emergency situations only, for instance: the operator at platform has passed out and pressed down the emergency stop switch and he must be brought back to ground level immediately for his own safety. When using the override switch it is possible to drive the booms outside the safe stability area, which means risk of overturning of the machine. The manufacturer is not responsible for overturning of the access platform caused by use of the override switch.

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6.2.5 230V – connection and switches

1. 230 V, 50 Hz, 16 A connecting cable. 2. Switch of residual current device. The switch must be in ”ON” position in order that any 230 V device will work, including the 230 V outlets. With the TEST button one can test the function of the residual current device, and also if there is 230V current coming from the network. If the residual current does not go off when pushing the TEST button, it is either defect or then there is no current coming from the network (the connecting cable must be connected of course). 3. Battery charger. There are two indicators on the charger which show the charge level of the battery: Yellow indicator on = low charge; Yellow and green indicator on = battery almost fully charged; Green indicator on = battery fully charged / trickle charge 4. Service operation switch. The switch is intended for the use of Leguan service only. It switches on electric motor, when the switch is being pushed down. Allows operation of movements by using the manual control of the valves. A more detailed description on the operation of the switch can be found in the service manual.

6.2.6 Manual pump at pedestal

1. Manual pump and shaft 2. Control valve, platform self leveling 3. Control valve, jib boom 4. Control valve, telescoping boom 5. Control valve, slewing 6. Control valve, upper boom 7. Control valve, lower boom

Function of the manual pump is explained in chapter 11.

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7. STARTING THE ENGINE / ELECTRIC MOTOR

Read carefully this Operators Manual and also the Operators Manual for the engine before starting operation. Read and understand all safety instructions before starting operation. It is the operator’s responsibility to follow all operating and safety instructions. This access platform is destined for lifting of persons and additional load only. Lifting of materials is unsafe and not allowed.

If several persons are operating this machine during the same work shift, all of them must be trained and they must follow all operating and safety instructions.

1. Turn the ignition switch to desired controls position (at platform/ground level). 2. Switch on the battery disconnect switch. 3. When using the electric motor connect the 230 V cable and check also function

of residual current device. With the TEST button you can also check that there comes 230 V to the machine.

4. Make sure that the booms are down in transport position. If necessary, press on the emergency lowering buttons one by one.

5. Check emergency stop switches; release by turning the switch if it is switched on 6. If you are in the basket fasten safety harnesses on the fastening points at

platform mounting bracket and close the gate. 7. Start the engine/motor with the switch on the remote control or with the start

button at lower controls.

ATTENTION! The engine must always be stopped with the lever on the remote control or with the button at lower controls.

7.1. Additional instructions for winter use

The minimum allowed operating temperature for the lifter is -20 °C. Do the actions listed

below when the temperature is below 0 °C in addition to the normal actions when starting

to use the lifter. 1. Check that the limit switches are free from snow, ice and dirt. 2. If ambient temperature is very low, it may be necessary to use the choke of the

combustion engine (manual lever) when starting the engine. 3. Let the engine run for a few minutes before moving the machine. 4. First use driving in full speed with speed selection 1 or 2. After this use outriggers and

lastly use boom movements. This way the hydraulic oil circulates through the entire system and warm oil gets to the cylinders.

5. Cover the remote controller from snow and ice when it isn’t used. Remote controller should be stored indoors when ending the use of the lifter.

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8. DRIVE CONTROL

ATTENTION! The machine can only be moved when the booms are down in transport position!

When driving with the machine special attention must be paid to the following things:

1. Drive on solid and level grounds only, with sufficient carrying capacity. 2. Working materials and tools must be fastened and secured against rolling

and/or sliding. 3. Safety harnesses must always be attached to the fastening points at

platform mounting bracket when the engine or electric motor is running if the operator is in the basket.

4. Operate the control levers smoothly, avoid jerky movements. 5. Primary operating position is at the side of the machine. 6. Make sure that booms are in transport position. If the booms aren’t firmly on

transport support it isn’t possible to use drive or drive will stutter. The transport position is detected with a limit switch from the end of the jib boom.

Instructions for driving: 1. Turn the ignition switch to remote control position and start the engine. 2. Make sure that the drive speed area selector switch is in desired position.

Changing of drive speed area is not allowed when the machine is moving! 3. Make sure that the drive mode selector switch is in desired position (see 6.1.1).

When the switch is on the right the traditional skid steer drive is in use, when the switch is on the left the skid steer drive with turning help is in use (Easy Drive).

4. Driving forward and backward happens by moving the levers of the drive control. By pushing the left lever left side wheels turn forward; by pulling the lever left side wheels turn backward. Right side wheels turn in the same manner by pushing and pulling the right side lever. When skid steer drive with turning help (Easy Drive) is in use the right side lever controls drive speed forward/backward, and left side lever controls turning. If only the left lever is moved the machine turns on the spot. Turning of the machine is based on the skid steer principle and the steering characteristics vary depending on ground conditions. Start driving carefully and at low speed.

Transmission of the LEGUAN 135 is hydrostatic. Each wheel is equipped with a hydraulic motor - the machine is four wheel drive. If the machine is equipped with rubber tracks there are two hydraulic motors in the track system. If you want to turn the machine on the spot: with traditional skid steer system, push one side control lever and pull the other side control lever to the extreme end position.

ATTENTION! Learn how to drive with the machine at a low speed. Operate the drive control levers with ease in order to avoid abrupt and jerky movements. When driving

pay special attention to stability and the dimensions, especially length, of the machine. Do not stand very close to the machine.

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8.1. Drive speed selection

The machine is equipped with four different drive speeds. Drive speed is selected with the switch on the remote control (see 6.1.1). Selected speed is shown on the display (see 6.1.3). The values are as follows:

Engine rpm Pumps in use Value 1 2350 1 Value 2 3600 1 Value 3 2350 2 Value 4 3600 2

In addition, drive speed can be slowed with the deceleration switch (see 6.1.1). The switch is equipped with four positions: full speed and three decelerations. The active deceleration mode is shown with the green LED above the switch. The blinking frequency of the LED indicates the progressivity of deceleration. If the LED does not blink, full speed is selected. The more frequently the LED blinks the slower speed is selected. Slowing down the speed happens by restricting the maximum values of the control levers – that is the logic scales the signal of control lever output to smaller value if the deceleration is in use. The deceleration switch has an effect on drive and boom movement speeds.

8.2. Electric drive ramp adjustment

Drive and boom movements are equipped with electric ramps with which the movements start and stop (progressivity of acceleration and deceleration). The ramps can be adjusted by Leguan service at the service page of the remote control. The ramps are intended to make starting and stopping of the movements smoother.

8.3. Defining the gradient of the slope

Measure the slope with a digital inclinometer, or do as follows: Take a water level, a straight piece of wood at least 1 m long, and a pocket tape measure. Put the wood stick on the gradient. Put the water level on the lower edge of the stick and lift the stick until it is in horizontal position. Keep the stick level and measure the distance from the lower end of the stick to the ground. Divide the distance (height) by the length of the wood stick (distance) and multiply the result by 100. Example: Wood stick length = 2 m Height = 0,5 m (0,5 ÷ 2) x 100 = 25 % slope

ATTENTION! When crossing slopes always drive up or down the slope, not sideways. If you have to drive sideways on a slope, lower the downhill side outriggers so that

they are close to the ground. This prevents the machine from tipping over.

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8.4. Driving the lift on trailer

There is a trailer available, specifically designed to transport the Leguan. The trailer must be fastened to the tow car when loading the machine on the trailer. Drive the machine on trailer with nose first with remote control from the side of the machine and make sure that the lift is in the middle of the trailer in lateral direction. The rear of the lift is tied down with chains (picture on the right). The chains are tightened by driving the lift forward and by ensuring that the front of the lift doesn’t rise up. The height from ground to the top of the tow hitch should be about 410 mm while loaded so that the trailer tongue weight is correct. Drive the machine a bit so that the chains are tight, this way the machine settles in right position on the trailer. Tie down the front with belts in cross (picture on the right).

As the rear of the lift extends over 1 m over the rear of the trailer, a reflector and red light must be mounted on the platform (picture on the left). The reflector is sufficient on daylight, but the red light is mandatory when it is dark.

8.5. Crawler track chassis

General information and lifespan of rubber tracks An access platform with skid steer chassis, equipped with crawler track chassis, offers many advantages compared when driving on soft terrain. However, certain things regarding working and working environment must be taken into account with an access platform on tracks. In order to secure the maximum life expectancy for the rubber tracks and crawler track chassis follow the instructions below. The lifespan of the track system of an access platform on rubber tracks is heavily dependent on the working environment and the way of working. The operator can increase the lifespan by following the below mentioned operating and maintenance instructions. If the access platform is being used in terrains with stones or gravel, on demolition sites where there is concrete, or in an environment with scrap metal, the lifespan of the track system can be significantly reduced. Because of this damages

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on the tracks, track rollers or crawler track chassis, caused by operation in such environments, are not covered by warranty. Bolts of the rear sprocket It is important to check tightening of bolts on the rear sprocket about 2 days after putting the access platform into operation. When driving with a new machine the parts in the track system adapt to each other and ”find their place” so to say. Because of this it is possible that the bolts loosen during operation. Loose bolts can cause serious damage to the crawler track chassis.

Tighten the bolts first to 300 Nm diagonally opposite.

After that retighten immediately to 355 Nm final torque diagonally opposite.

It is recommended to check tightness of bolts once a week.

8.5.1 Instructions for working environment In order to increase 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 this kind of environments.

Daily / continuous driving on asphalt or concrete. Continuous operation on these surfaces will shorten the lifespan of rubber tracks.

Work sites with sharp objects, like broken stones or concrete waste. This kind of sharp objects can cut or damage the rubber tracks permanently. Conditions which can damage tyres can also damage rubber tracks. Damaged tracks can normally not be repaired, they must be replaced. Warranty doesn’t cover tracks that get damaged in this kind of conditions.

Work sites with corrosive substances (fuels, oil, salt or fertilizers). Corrosive substances can oxidize the metal parts in rubber tracks. If such substances come in contact with the surface of the rubber track, the tracks must be flushed with water immediately after ending operation.

8.5.2 Operating instructions

Check track tension regularly. Too loose tension can make tracks jump off the sprockets. Do not over-tension the tracks, because this causes big power loss and excessive wear on the sprockets and tracks.

Change turning direction as often as possible. Turning continuously only in one direction will cause uneven wear of the sprocket and the rubber track.

Check condition of the track system regularly. Excessive wear on the rollers, idlers, sprockets and bearings can damage the tracks.

Avoid driving sideways on a gradient. Always drive the slopes straight up and down, and turn on flat even surface only. Continuous operation on uneven terrains or driving sideways on a gradient causes wear in the track guides and rollers and makes tracks jump off the sprockets.

Avoid continuous sharp turns. By making wider and more gentle turns you can avoid unnecessary wear of the tracks and/or tracks jumping off the sprockets.

Avoid driving with one track on level surface and one track on a gradient. Always drive on an even surface. If the tracks bend continuously from the inside or from the outside during operation, the metal structure of the tracks can break.

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9. OPERATION OF THE OUTRIGGERS

Lifting of the booms without setting down the outriggers is never allowed!

When setting down the outriggers the maximum allowed inclination of the chassis is

1,5°. With automatic leveling it is possible to level the machine within one degree. With

the water level it is possible to level the machine within 0,5°. Drive the outriggers down to support position with automatic leveling as follows: 1. Turn the ignition key to remote control position and start the engine. 2. Outriggers are deployed and the machine is leveled with the automatic leveling

switch. Automatic leveling system drives the outriggers down two at a time. Make sure that the ground under all four outriggers is solid enough – put extra plates on the ground under the outrigger feet if necessary. When all four outriggers are on the ground, the system reduces engine revs and starts leveling. The logic deploys all four outriggers first, in order that the wheels (or tracks) lift off the ground. After that the logic checks inclinations and deploys the outriggers more if necessary so that the chassis becomes level. When the logic detects that the chassis is level, it stops deploying the outriggers and sets engine revs to idle.

3. The operator must always make sure that all four wheels (or both tracks) are lifted off the ground! If all four wheels are not lifted off the ground, the outriggers can be deployed further with the automatic leveling switch.

4. The horizontal position of the lift must also be double checked with the water level which is mounted on the pedestal on the left side. It is not allowed to lift the boom if the machine is not level!

5. After the machine has been leveled correctly, there will be the ”Leveling OK” text on the first page of the display.

6. If the leveling wasn’t successful lower down the machine and start automatic leveling from the beginning or alternately use manual leveling.

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Drive the outriggers down to support position manually as follows: 1. Turn the ignition key to remote control position and start the engine. 2. Deploy the outriggers by using the outrigger control levers on the remote control. It is

possible to deploy only one outrigger at the time but it is recommended to deploy two outriggers (front or rear) at the same time. Make sure that the ground under every outrigger is solid enough – put extra plates on the ground under the outrigger feet if necessary.

3. Drive the outriggers down on the ground firmly enough. They must be driven down so much that all wheels/tracks lift off the ground! (Usually it is not necessary to push the outriggers further unless it is necessary to reach higher). Make sure that the wheels do not touch the ground before starting to lift the booms.

4. When all outriggers are firmly on the ground and wheels lifted off the ground, check the horizontal position of the lift with the water level which is mounted on the pedestal on the left side. It is not allowed to lift the booms if the machine is not level!

5. After the machine has been leveled correctly, there will be the “Leveling OK” text on the first page of the display.

The set up diagram can be seen on chapter 3.2.

Setting the outriggers towards a vertical wall is strictly forbidden!

The booms must be in transport position before driving the outriggers up!

ATTENTION! If there is the text “Leveling OK” on the display when the outriggers are not correctly deployed, the operation of this access platform is not allowed! Contact

nearest Leguan service!

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10. OPERATION OF THE BOOMS

Before starting to lift the booms:

1. Make sure that all four outriggers are on solid ground, wheels/tracks are lifted off the ground, the machine has been leveled correctly and there is the text “Leveling OK” on the display.

2. When using the remote control, the control unit should be put on its place at platform. The control unit can also be connected to the cable and then it doesn’t have to be in its place, even though it is recommended.

3. Boom movements are operated with the control levers on the remote control unit. 4. When the symbol “230 kg” is on the display, the telescopic boom is within the

restricted outreach area. Thus the telescopic boom hasn’t come out more than about one meter. If the ”140 kg” symbol is on the display, the telescopic boom is on the full outreach area – in this case the telescopic boom is out more than one meter. LEGUAN 135 is also equipped with an overload control system which prevents boom movements in case the 230 kg safe working load is exceeded, or in case the telescopic boom comes out more than allowed when load on the platform is over 140 kg. Should this happen, there is an audible warning signal, a red blinking LED and a symbol on the display. The booms can be operated again after the overload has been removed from the platform.

5. Boom slewing is disabled when the booms are in transport position.

ATTENTION! If there is more than 140 kg load in the basket and the green strip on the telescopic boom comes out more than 200 mm, operation must be stopped

immediately and Leguan service must be contacted. RISK OF TIPPING OVER!

Thanks to the electric controls boom movements are very smooth, exact and stepless. Operate the control levers with ease and without hesitation – learn to operate the booms precisely.

Platform self leveling system keeps the bottom of the platform automatically level. ATTENTION! If the level position of the platform must be adjusted – for instance in case the machine has not been used for a long time and the platform has tilted – operate the control lever of platform self leveling carefully, especially when the booms are up.

ATTENTION! Always lift the lower boom first from transport support before operating other movements. When lowering the booms make sure to drive them straight down to

transport supports. It is possible to damage the machine with the jib boom if the booms aren’t lowered straight down to transport supports. It is recommended to use the lower boom as the last movement when lowering the booms to transport position.

Boom movement speed can be slowed with the deceleration switch (see 6.1.1). The switch is equipped with four positions: full speed and three decelerations. The active deceleration mode is shown with the green LED above the switch. The blinking frequency of the LED indicates the progressivity of deceleration. If the LED does not blink, full speed is selected. The more frequently the LED blinks the slower speed is selected. Slowing down the speed happens by restricting the maximum values of the control levers – that is the machine scales the signal of control lever output to smaller value if the deceleration is in use. At lower controls the deceleration mode is shown with the LED indicators of the deceleration switch (see 6.2.3). The deceleration switch has an effect on all movement speeds.

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11. EMERGENCY LOWERING

If the power supply for some reason cuts off (e.g. no fuel or electricity cuts off, or connecting cable fails) the booms can be lowered as follows.

1. The lift is equipped with an electric emergency lowering system. There are

emergency lowering buttons both on the platform and at ground level. By pushing the button the selected boom comes slowly down as long as the button is being pushed. Emergency lowering takes it power directly from the battery – it is not dependent on the position of the main switch. Emergency lowering valves are protected with a 10 A fuse which is located in the connection box at ground level.

2. Use the telescopic boom emergency lowering first. The telescopic boom emergency lowering works only if the upper boom is in upright position. Having the jib boom in upright position also helps the use of telescopic boom emergency lowering. After the telescopic boom emergency lowering use the jib boom emergency lowering. After this use lower boom emergency lowering and last the upper boom emergency lowering. Before lowering the booms to transport supports always make sure that they are properly aligned and going straight down to transport supports. If necessary, the booms can be rotated by using the manual pump mentioned in paragraph 6.2.6.

Always check function of emergency lowering before starting operation.

All hydraulic functions of the access platform can be operated with the manual pump, which works as follows:

1. Remove the plastic cover panel on the right side of the pedestal. 2. Mount the shaft on the pump. 3. All hydraulic functions of the machine can be operated by using the manual

pump and the control levers of the valves. 4. When operating the outriggers see to it that their common proportional valve

(picture below) is moved in closed position in order that the outriggers can be moved. Remember to return the valve to open position after use.

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12. ENDING THE OPERATION

When ending operation:

1. Lower the booms down to transport position. 2. Lift the outriggers completely up to transport position. 3. Stop the engine/motor with the remote control start/stop switch. Turn off the

remote control from its emergency stop switch. Lock the control unit in its place on the platform or take the unit with you. In cold conditions take the remote control to a warm and dry storage.

4. Remove safety harnesses from the platform and take them with you (harnesses must be kept in their place and in their box/package).

5. Move the ignition switch to 0 position and take the key with you. Move the main disconnect switch to vertical position and take the key with you or lock it in its position.

6. Close fuel valve (see also engine operator’s manual). 7. If the machine stays in a place where it can be connected to 230 VAC mains

current, it is recommended to connect it, in order to charge the battery (e.g. overnight).

ATTENTION! Prevent unauthorized use of the access platform!

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13. TRANSPORTING INSTRUCTIONS

Lower the booms down to transport position and lift the outriggers completely up to transport position.

ATTENTION! Transporting of the access platform is allowed in transport position only. No persons or materials are allowed to be transported on the platform.

There are lifting holes for a forklift on the chassis. The outriggers are equipped with lifting points from which the machine can be lifted if necessary. When lifting, it is advisable to use a lifting beam where the ropes are mounted, in order that the outriggers will not get damaged. There is an automatic hydraulic brake in the rear axle which engages automatically when the engine/motor is not running. If the machine is transported on a trailer or on a lorry or similar vehicle, it must be tied down properly. There are four tie-down points marked on the corners of the chassis which make it easy to tie down the machine. Always tie the machine down diagonally from every corner. The tie-down to Leguan trailer is shown in the paragraph 8.4.

ATTENTION! It is not allowed to tie down the machine so that the ropes go over the booms. Only marked tie-down points can be used!

ATTENTION! Before longer transports close the fuel valve of the petrol engine in order that engine oil and petrol can not mix and cause misfiring of the engine.

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14. SERVICE, MAINTENANCE AND INSPECTION INSTRUCTIONS

This access platform must be inspected once a year. The inspection can be done by a qualified person only. Persons who conduct periodical services shall familiarize themselves with the operation and technical features of this access platform before doing any service operations. All service and maintenance operations must be made in accordance with the instructions in this manual. If the access platform has not been used for a longer period of time, oil levels must be checked first and made sure that the machine functions correctly before starting operation.

14.1. General instructions

It is not allowed to make any changes on the construction of the machine without written permission from the manufacturer.

All defects that may have an effect on the safe use of this access platform must be repaired before starting operation.

Only professional persons are allowed to open the covers and handle the electric etc. components. Risk of serious injury!

Make sure that services are made in accordance with this Operators Manual and with the Service Manual of the engine manufacturer.

Stop the engine before starting any service or inspection operation, DISCONNECT ALSO THE 230 V MAINS CURRENT.

Do not smoke during service and inspection operations.

Keep the machine and especially the platform clean.

Make sure that the operating instructions are complete, readable and in their place in the box at the platform.

Make sure that all stickers are in their place and readable.

Make sure that the access platform is serviced.

Make sure that the checks according to the local regulations are done.

ATTENTION! All spare parts – especially electric components and sensors – must be original Leguan parts.

Always remember when handling the battery:

Battery contains corrosive sulfuric acid – handle the battery with care! When handling the battery wear protective clothing and eyewear.

Avoid contact with clothes or skin; if electrolyte gets on your skin or clothes flush with a lot of water.

In case of contact with eyes, flush with a lot of water for at least 15 minutes and call a doctor immediately.

Do not smoke when handling the battery.

Do not touch the battery terminals or cables with tools that may cause spark emissions.

In order to avoid spark emissions always disconnect the (-) cable first and connect it last.

Handling of fuel and oil products:

Do not let any oil leak on the ground.

Use oil qualities recommended by the manufacturer. Do not mix different oil types and/or brands with each other.

When handling oil always wear appropriate protective equipment.

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Before refueling always stop the engine/electric motor and disconnect from mains current.

Only use fuels recommended by the engine manufacturer. Do not mix any additives with the fuel.

If fuel or oil gets into eyes, mouth or open wound, clean immediately with a lot of water or designated fluid and call a doctor.

Check hydraulic hoses and components only when the engine is stopped and with pressure released from the hydraulic system. Do not operate the machine if you have noticed faults or leaks in hydraulic system. Ejection of hydraulic fluid can cause burns or penetrate the skin and cause serious injuries. Consult a doctor immediately if hydraulic fluid penetrates your skin. Wash carefully with water and soap any body part that has come in contact with hydraulic oil. Hydraulic oil is also harmful to the environment – prevent oil leakages. Only use hydraulic oil type approved by the manufacturer. Never handle pressurized hydraulic components, because in case of failure of a fitting or component ejection of high pressure hydraulic fluid can cause tipping over of the machine and serious injuries. Do not operate the machine if you have noticed a fault in the hydraulic system.

Check hydraulic hoses for eventual cracks and wear. Follow the wear of the hoses and stop operation if the outer layer of any hose has worn out. Check routing of the hoses and adjust the hose clamps if necessary in order to prevent chafing. If there are signs of oil leakage, put a piece of cardboard under the probable leakage place in order to find the leakage. If you find a fault, operation of the access platform must be stopped immediately and the hose or the component must be replaced. Contact Leguan service.

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14.2. Services and checks, maintenance schedule

Regarding the service of the engine see also engine manufacturer’s Operators Manual = EM. CH = Check CL= Clean R = Replace A = Adjust F = First service at 50 h

Operation day month 100 h 200 h / 12 months

400 h / 24 months

1000 h

Engine oil, EM FR CH R

Air filter, EM CH /CL R

Fuel sediment cup CH /CL

Spark plug, EM CH R

Valve clearance, EM A

Fuel tank and strainer CL

Fastening of platform F CH

Hydraulic oil FR R

Hydraulic oil level CH

Hydraulic oil suction filter CL

Hydraulic oil filters FR R

Breather cap of the oil tank CL

Condition and mounting of the battery CH

Locking of bearings and pivot pins FCH CH

Electric wires CH

Function of residual current device CH

Hydraulic fittings and hoses F CH

Cylinders, load holding & check valves F CH

Function of emergency lowering F CH

Function of emergency stop circuit F CH

Function of set up system F CH

Function of safety devices CH

Hydraulic pressure adjustments FCH CH

Function of control valves F CH

Mounting of booms on the chassis CH

Condition of steel construction CH

Movement speeds of booms F CH A

Greasing of the machine R

Function of load control system F CH A

Level position of water level F CH

Hydraulic oil: Statoil Hydraulic Oil 131, (Mineral based hydraulic oil, made for Nordic conditions. Without zinc. Operating temperature -45

0 – 65 °C. Vickers 104 C IP 281/80, FSD 8401)

Hydraulic system oil volume: oil tank about 25 l, complete system about 40 l Engine : See engine manufacturer’s manual Grease: Litium NLGI 2 grease ( not MoS2 ), slewing ring with

grease containing EP (extreme pressure) additive

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Hydraulic pressure settings: drive 275 bar outriggers 200 bar booms 200 bar boom slewing 120 bar double pump 110 bar electric motor 210 bar brake release 30 bar

Tyre pressure: 20*8.00-10 grass profile 3,0 bar (43 PSI) 23*10.50-12 grass profile 3,0 bar (43 PSI)

23*10.50-12 TR profile 3,0 bar (43 PSI) Leguan TeHo 2014 -trailer 3,5 bar (51 PSI)

Wear pads on the telescopic boom must be checked every 5 years max.

Tightening torque of the M16 fastening bolts of the slewing ring is 210 Nm – torque must be checked once a year and bolts must be changed every 10 years.

Above mentioned service intervals are recommendations. If the operating conditions are very hard and/or the machine is in heavy duty use the service and change intervals must be shortened.

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15. SERVICE INSTRUCTIONS

15.1. Greasing of the machine

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

15.2. Handling of fuel and refueling

Check fuel level and refuel if necessary (fuel tank, no. 1). Before refueling check which engine: petrol or diesel. In petrol engine use only fuel defined by the engine manufacturer in the engine Operators Manual. ATTENTION! Engine ignition switch (2) must be in position “1” in order that the engine will start.

15.3. Hydraulic oil and filter change

Hydraulic return oil filter (no. 2) is located in the chassis next to the combustion engine. Replace the filter by twisting off the filter cartridge and replacing the filter cartridge with a new one. When changing hydraulic oil, the oil can be removed with a suction pump from the opening of the cork (no. 3), or by opening the drain plug. In both cases it is important to clean the magnetic drain plug. Hydraulic pressure filter cartridge (no. 1) must be changed always when return filter is changed.

15.4. Hydraulic oil level

Hydraulic oil level can be checked from the visual level indicator on the side of the oil tank (no. 4). Oil level should be in the middle of the indicator when outriggers are completely up and booms down in transport position.

2

1

2

1

4

3

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15.5. Battery check

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

15.6. Check of set up outrigger control system

Always check the function of the set up outrigger control system when starting operation. When the outriggers are lifted up off the ground, this should also be shown with the symbols of outriggers ground contact, on the first page of the remote control display. That is: all four squares empty. When all four outriggers are on the ground, the squares are black.

ATTENTION! If the set up control system doesn’t work correctly, contact Leguan service. It is not allowed to use this access platform, and the failure/defect must be

repaired before starting operation.

15.7. Water level check

Correct position of the water level (on the left side of the pedestal) in relation to the upper surface of the slewing ring must be checked in accordance with the maintenance schedule, or if there is reason to believe that the position of the water level has changed. Make sure that the booms are in transport position and put a water level on the slewing ring. Compare the position of this water level to the position of the water level on the left side of the pedestal. If the positions are different, adjust the water level on the side of the pedestal with the adjustment screws so that both levels are in the same position. Do the adjustment both lengthwise and sideways.

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15.8. Adjustments in hydraulic system

All settings of the hydraulic system have been made at the factory and normally there is no need to adjust them.

Picture above shows the components next to the combustion engine:

1. Main hydraulic pressure sensor (the reading is shown on the remote control display)

2. Dump valve, solenoid K2 3. Double pump valve, solenoid K30 4. Pump block 5. Tank block 6. Main pressure adjustment of electric propelling, 210 bar 7. Double pump pressure adjustment, 110 bar 8. Double pump pressure check fitting 9. Selector valve, drive / outrigger operation, solenoid K9 10. Selector valve, boom operation, solenoid K1

2

1

3

4

5

7

6

9 10

8

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Picture above shows the components next to the platform: 1. Drive pressure adjustment point, 275 bar 2. Outrigger pressure adjustment point, 200 bar 3. Drive pressure check fitting 4. Outrigger pressure check fitting

The picture on left shows the brake release block. Brake release can be adjusted by removing the bottom plate of the frame on the platform side.

1. Brake release pressure adjustment point, 30 bar

2. Brake release pressure check fitting

2 1

3

4

1 2

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Picture on the left shows the components on the right side of the pedestal: 1. Boom pressure adjustment point, 200 bar 2. Boom pressure check fitting Picture on the left shows the boom slewing pressure adjustments: 1. Slewing counterclockwise, 120 bar 2. Slewing clockwise, 120 bar

All cylinders – except for the self leveling ”master” cylinder – are equipped with load holding valves (no. 1 in the picture left), which prevent cylinder movements in case e.g. a hydraulic hose fails. When using emergency lowering of the booms, the electric solenoid valve in the cylinder (no. 2) opens and oil flows through the flow restrictors into the tank and the boom(s) come down. The restrictors can not be adjusted, they have fixed setting for slowing down the boom movements correctly.

1 2

2 1

1

2

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15.9. Components in overload control system

Overload control system has been set to correct values at the factory. Changing of the settings without permission and instructions from the manufacturer is strictly

forbidden. RISK OF TIPPING OVER!

Overload control mechanism is located between the platform and platform mounting bracket. Load on the platform is measured with a strain gauge (no. 1) which is equipped with two channel measuring. The tare weight of both channels is set following no load on the platform (see service manual). Readings of both channels are compared with the settings of the load control system, 140 kg and 230 kg. When load on any of the two channels exceeds 140 kg, movement of the telescopic boom is being restricted. The position of the telescopic

boom is indicated on the remote control display, on the first main page in the top left corner. The symbol “230 kg” is shown when the telescopic boom is on the 230 kg working area. When the telescopic boom is extended out to the 140 kg working area the symbol will change to “140 kg”. If the telescopic boom has been extended and more load is added on the platform so that it exceeds the allowed load, all boom movements are prevented. When load on any of the two channels exceeds 230 kg, there is an audible warning signal and a red indicator blinks on top of the control display, and also a weight symbol on the top left corner of the display main page is shown. In this situation all boom movements of the machine are prevented. In order to continue operation, remove overload from the platform. After that operation can be continued normally. If the values in the two channels differ more than 30 kg, boom movements are prevented. In this case contact Leguan service. If the sensor needs to be replaced the tightening torque for the screws is 150 Nm. The values of the overload control, in relation to no load on the platform, can be checked from the third main page of the display. Both should be about 0 kg when the platform is empty. If the value on one or both channels differs over 10 kg from 0 kg, or if the difference between the channels is over 10 kg, contact Leguan service. The platform no-load must be calibrated.

NEVER EXCEED SAFE WORKING LOAD!

1

46

15.10. Electric sensors

Transport position sensor S4 is located inside the transport support for the jib boom, see picture on the left. All the booms must be lowered down to transport supports in order that the sensor accepts that the booms are in transport position.

Limit switches that are monitoring the stroke of telescoping cylinder are mounted at the end of upper boom. Primary limit switch S5 (1) stops telescoping movement – if load on platform exceeds 140 kg – the movement sensing rail activates the sensor. If the telescoping movement didn’t stop for some reason, limit switch S6 (2) secures the function by stopping all boom movements.

At the end of the outriggers there are the limit switches S7-S10, which detect the ground contact of the outriggers. Ground contact of each outrigger is shown on the first main page of the remote control display.

1

2

47

The inclination sensor is located on the chassis next to the drive control valve. Readings of the inclination sensor are used in the automatic leveling of the machine. In addition, it prevents lifting of the booms if the inclination of the chassis exceeds the allowed value. Inclination sensor transmits information through CAN bus.

There are two limit switches at platform which detect if the remote control unit is properly fastened in its place. The remote control unit must be in its place and the two limit switches in correct mode in order that booms can be operated without connecting the cable to the remote control unit.

A chart of all safety functions of this access platform is attached.

48

15.11. Check and adjustment of track tension

Check and adjust track tension with the outriggers deployed and tracks lifted off the ground. First track tension check and eventual adjustment shall be made after first hour of operation. After that track tension shall be checked, and adjusted if needed, once a week. Check also tightness of the bolts and nuts of the sprockets. See to it that track tension is always correct. It has a direct effect on the wear of the tracks and eventual derailing of the tracks.

1. Lift the tracks off the ground by deploying the outriggers. 2. Move the tracks a bit forward and backward by moving the drive control

levers. Check track tension by measuring the slack between the track rollers and inside of the track, no. 1 in the picture above. The slack should be 15-35 mm. If it is more than 35 mm, tighten the track.

Adjust track tension Start adjusting by opening locking nut no. 2. After that tighten the tracks with the tightening nut no. 3 until the slack between the roller and inside of the track is about 15 mm. Finally retighten locking nut no. 2. The width across flats of the tightening and locking nuts is 36 mm and recommended tightening torque 350-400 Nm. The nut at the end plate shall not be tightened when adjusting track tension.

1

2 3

49

16. REPAIR INSTRUCTIONS

16.1. Welding

All load carrying steel parts are manufactured from S420MC EN10149-2 / S650MC EN10149-2 sheet and S355J2H EN10219 tube.

Welding repairs are only allowed to be carried out by professional welders. When welding, use only methods and additives suited for above mentioned steel qualities. SFS EN-ISO 5817 quality level D of imperfections in welding is suitable for all weldings, except for load carrying parts. On load carrying parts the damaged part should in principle always be replaced with a new one (instead of welding), and even the smallest repair welding can be performed only by permission from the manufacturer.

ATTENTION! It is not allowed to change the construction and structure of this access platform without written permission from the manufacturer.

17. 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 1 month - The machine shall be covered and, if possible, stored inside or under roof in

a place where unauthorized persons don’t have access. - Make sure that eventual leaks during storage will not cause waste water or

similar environmental problems.

ATTENTION! See also engine manufacturer’s instructions for the storage of the engine.

18. DISPOSAL INSTRUCTIONS

When the lifespan of the access platform has come to an end, it must be dismantled and disposed of in an environmental friendly way.

- Battery and other electric components must be recycled or disposed of, in accordance with the national regulations.

- Oils must be collected and recycled following national regulations. - Plastics must be recycled following national regulations. - Metals must be recycled following national regulations.

50

19. TROUBLESHOOTING

Following table shows possible failures and malfunctions of the access platform and the ways how to repair them.

PROBLEM REASON CORRECTIVE ACTION

Engine/electric motor does not start when START lever is being moved. Engine and electric propelling

Remote control is not in connection with receiver.

Turn off remote control and restart.

Combustion engine does not start when START lever is being moved. (See also engine manufacturer’s Operators Manual).

Battery disconnect switch is in “OFF” position. Ignition switch at lower controls is in “OFF” position. Petrol engine ignition switch is in ”OFF” position Emergency stop switch is pushed down. Fuel valve is closed. Fuel tank is empty. Empty start battery. Fuse inside petrol engine ignition switch is broken. Fuse inside the connection box is broken. The fuses are inside the connection box.

Move the switch to ON position. Move the switch to lower controls position or remote control position. Move to correct position. Release emergency stop by turning it counterclockwise. Open fuel valve by moving lever to the right (petrol engine). Refuel. Charge by connecting to 230 V or change battery if necessary. Replace fuse (see engine manual). Replace fuse.

Combustion engine does not start when START lever is being moved. (See also engine manufacturer’s Operators Manual).

Faulty contacts in electric wires.

Check wires and terminals; and voltages with a voltage meter.

51


Electric motor does not start when START lever is being moved.

Mains 230 V cable is not connected to network. Emergency stop switch is pushed down. Battery disconnect switch is in “OFF” position. Empty start battery. Fuse inside the connection box is broken. The fuses are inside the connection box.

Connect 230 V mains, min. 16A wall socket fuse. Make sure that the socket is electrified. Release emergency stop by turning it counterclockwise. Move to ON position. Charge by connecting the cable to 230 V mains, or change battery if necessary. Replace fuse – if the fuse blows again, find out the reason.

Electric motor stops suddenly during operation.

Power failure. Emergency stop button has been accidentally pushed down. Electric motor thermal overload relay (F41) in 230 V box of the machine has gone off. Connection fault in mains or 12 V wiring.

Lower the booms by using emergency lowering. Check that there is current in mains. Release emergency stop and restart. Wait for approx. 2 min. and start the motor – the relay will return to ON automatically. Find out the reason for overload. Check voltages and wirings.

Movements don’t work even though the engine/electric motor is running.

Boom has lifted off the transport support even though the outriggers are not deployed. Failure in hydraulic system – e.g. hydraulic pump broken. Overload on platform.

Lower down the boom to transport support. Check hydraulic pressure. If there is no pressure check function of hydraulic pump and the coupling between engine and pump. Remove overload.

Boom(s) come down by itself. Dirt in load control valve or faulty valve. Dirt in emergency lowering valve or faulty valve. Emergency lowering valve(s) don’t work when emergency lowering button is pushed. Lift cylinder seals are faulty.

Clean valve with compressed air, if that doesn’t help change valve. Clean valve with compressed air, if that doesn’t help change valve. Check emergency lowering fuse, if all right check also emergency lowering valve(s) separately. Change lift cylinder seals.

52


Outrigger gives in.

Make sure that the ground doesn’t give in. Air in outrigger cylinder(s). Dirt in outrigger cylinder check valve. Faulty check valve. Faulty outrigger cylinder seals.

Put extra support plates under the outriggers or move to another place. Drive outriggers completely up and down a couple of times. Clean valve with compressed air. Change valve. Change outrigger cylinder seals.

Platform tilts backwards by itself when booms are down on transport supports.

Air in hydraulic system. Dirt in load control valve of self leveling cylinder or faulty valve. Faulty self leveling cylinder seals.

Start the engine/motor, drive the platform to extreme end positions. If this doesn’t help, do the air bleeding of the platform self leveling system (there are bleeding screws in the self leveling master cylinder). Clean valve with compressed air. If that doesn’t help, change the valve. Change cylinder seals.

53

20. SERVICE HISTORY

It is advisable to write down all service operations that are included in the periodical service. All services that have been made during the warranty period must be noted on the list below, otherwise the manufacturer’s warranty will expire. The service operations mentioned in the maintenance schedule on chapter 14.2 shall be noted as follows: FIRST SERVICE, 1 MONTH SERVICE, 6 MONTHS SERVICE etc.

Date Operating hours Remarks / Information

1. _______________ _________________ _________________________________ 2. _______________ _________________ _________________________________ 3. _______________ _________________ _________________________________ 4. _______________ _________________ _________________________________ 5. _______________ _________________ _________________________________ 6. _______________ _________________ _________________________________ 7. _______________ _________________ _________________________________ 8. _______________ _________________ _________________________________ 9. _______________ _________________ _________________________________ 10. ______________ _________________ _________________________________ 11. ______________ _________________ _________________________________ 12. ______________ _________________ _________________________________ 13. ______________ _________________ _________________________________ 14. ______________ _________________ _________________________________

Outrigger BR (4) Outrigger BL (3) Outrigger FR (2) Outrigger FL (1)

Track motor (right) Track motor (left)

6 bar

275 bar

6.3 cc4.0 cc 2.0 cc

8.7 kW @3500 rpm26.4 Nm @2500 rpm

PI

2nd drive speed

Safety valve

Safety valves must comply with ISO 13849-1: Appendix C2nd speed pump is used only for driving functions

Hand pump

2.2 kW 230 V / 50 Hz2850 rpm

P P

T T

X1 X2 X3

Safety valve

200 bar110 bar

-04 -04 -04 -04 -04-04 -04 -04-06 -06 -06 -06

M M

A B A BPT

M

A B A B A B A BM

200 bar

A B

P

T

20 cc

1

3

2.2

4

6

5

78

25

910

26

27 27

11

23 23

13 13

2428 28 28 28

29 29 29 29

16 16 16 16

7.17.5

7.17.3

7.1

7.4

7.2

32

2.1

-08-08-08-08

-08

-08

-04

-06

-04

-04

-04

-K23-K22-K25-K24-K26-K26-K27-K28-K16 -K17 -K18 -K19

-K30

-K31

-K1

-K2

-K9

-P2

30 bar

A416373A416373A416373A416373A410082A410082A410092A410092A419063A419063A419064A419064

A414566

A419133

A419056

A46247

A46247

A46247A46247 A416373

A47729

A46247

A47729-08

-08

-06

-06

A416373

A410450

A416373

A414918

A410487

A410451

-04 -04

-04

-04

-04-06-06

A419068A419068 A419068 A419068

A419014 A419014

A419080

A44559

A44559

A419113 A419113 A419113 A419113-04 -04 -04 -04

-06

id. 25 mm

id. 25 mmA419078

A419078

id. 19 mm A419791

1.75 bar

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SFS 3393 BSFS 4011 Keski

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© This drawing is the property of Avant Tecno Oy.


Boom 1 (lift) Boom 2 (folding)

Slewing Telescopic boom (zoom) Jib boomBasket levelling

Master Levelling / slave

OPTION: Wheels

Wheel motor (left) Wheel motor (right)

A B A BPT

M

200 bar

275 bar

PT

M

A B A B A B A B A B A B

0.4

P

T

-04 -04

-04 -04

-04 -04

-04 -04

-04 -04

-04

-04

120 bar

120 bar

0.9 0.9 0.9

12

11

24

15 1514 14

2323

30

17 18 19 21 22

23

33

2929 29

35

-K3 -K4 -K5 -K6 -K7 -K8-K10 -K11 -K12 -K13 -K14 -K15

-K19-K18-K17-K16

-K94 -K95-K96-K97

3134

0.9

0.9 0.9

A416485 A416485 A410051 A410051 A410051 A410051 A410051 A410051 A410051 A410051

A410176 A410176

A416485 A416485

A410958 A410958

-06 -06 -06 -06 -06 -06 -06 -06

A411684 A411684A411684+A46265

A411684+A46265

A410479 A410479

A419014

A419014

A415353 A415353 A415353 A415353

A419068 A419068A419066 A419066-08 -08 -08 -08

A415353

A419056A419056-08 -08

A410450-04

-04 -04

30

17

292930 29 29

20

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(10) 4/3 SUUNTAVENTTIILI, ARON ADC 3 E 04 CL P2 1 + NG06 single subplate side entry 3/8 (OPTIO)

(7.2) 2/2 SUUNTAVENTTIILI, Sun Hydraulics 2/2 spool valve, DLDA-LHN-212 (OPTIO)

64736 Kuormanlaskuventtiili, Oleostar CA-10-A/8-S-2-B 270 bar, PIL 1:8

NO OSANUMERO NIMI TYYPPI KPL

1 A36258/A36509 Hydrauliöljysäiliö 25-30 litraa 12.1 A419282 Imusuodatin R3/4 - 25 mm, 150 µm 12.2 A419292 Imusuodatin R3/4 - 19 mm, 150 µm 13 65219 Pumppu Hammaspyörpumppu, Casappa polaris PLP20-6.3-4.0 14 66123 Polttomoottori Honda iGX 390 15 65231 Pumppu Hammaspyörpumppu, Casappa polaris PLP10-2.0 (OPTION) 16 65191 Sähkömoottori Grundfos 2.2kw/ 1-phase (OPTION) 17 66115 Venttiililohko Bosch Rexroth OFE20806BS0101 17.1 66209 Venttiili Vastaventtiili, Oil Control VUH1-G38 (3)7.2 66211 Venttiili 2/2 Suuntaventtiili, Oil Control OD1506181CS100 (1)7.3 66210 Venttiili 2/2 Suuntaventtiili, Oil Control OD1506181AS000 (1)7.4 66208 Venttiili Paineennrajoitusventtiili, Oil Control VSBN-10A-35 (1)7.5 65745 Venttiili Paineennrajoitusventtiili, Oil Control VSBN-10A-10 (1)8 66039 Painelähetin IFM PT3550 (PT-400-SBG14-A-ZVG/US/ /W) 19 65269 Painesuodatin MP Filtri FMM 050 2-B-A-D-A10-N-P01 19.1 65393 Suodatinpanos MP FILTRI HP050-2-A10-A-N/P01 10 mikr. abs (1)10 66042 Venttiili 4/3 Suuntaventtiili, LF1 22 A201 0B 01 0F 111 66113 Venttiililohko Bosch Rexroth ED-series (L9300860062AA00) Ajo & tukijalat 112 66114 Venttiililohko Bosch Rexroth ED-series (L9300860054AA00) Puomi 113 66047 Hydraulimoottori Poclain MKD04 214 65376 Hydraulimoottori M+S MT/B500KP/2 (Jarru) 215 64698 Hydraulimoottori OMT 500 151B3017 216 A36330/A36312 Hydraulisylinteri 63/45-520 A785 (Tukijalka) 417 A36193/A417522 Hydraulisylinteri 70/40-500 A794 (Nosto/Taitto) 218 64959 Hydraulimoottori M+S MR50CD (Kääntö) 119 A36187/A417518 Hydraulisylinteri 50/35-2000 A2345 (Teleskooppi) 120 A36180/A417508 Hydraulisylinteri 70/40-387 A610 (Jib) 121 A36209 Hydraulisylinteri 50/32-205 A401 (Vakaaja, isäntä) 122 A36196/A417529 Hydraulisylinteri 50/32-205 A401 (Vakaaja, orja) 123 65829 Venttiili Kuormanlaskuventtiili, Oil Control 05.42.47.03.02.35.000, PIL 1:6.6 324 65864 Venttiili Paineenalennusventtiili, Sun Hydraulics PBDB-LAN 125 66043 Paluusuodatin MP Filtri MPS050-C-G1-P10-A-T (55L/min. 2*R3/4) 125.1 64499 Suodatinpanos MP Filtri CS-050-P10-A (1)26 66183 Käsipumppu Badenost PRBC 20E 127 64065 Venttiili Vastaventtiili, Oil Control VUC 20 (R 3/8" - R 3/8") 228 65115 Venttiili Ohjattu vastaventtiili, Delta Power Company, DF-CPB-00-0050 429 65147 Venttiili Kuormanlaskuventtiili, Oil Control VBSN-08AA 02.52.20.03.56.35, Pil 1:4 1130 65377 Venttiili 2/2 Suuntaventtiili, Oil Control OD.11.03.18.31.00 331 64598 Venttiili 2/2 Suuntaventtiili, Oil Control OD.15.31.18.37 132 63879 Venttiili Säädettävä kuristin, Parker 9N400S R1/4"-R1/4" 133 64736 Venttiili Kuormanlaskuventtiili, Oleostar CA-10-A/8-S-2-B 270 bar, PIL 1:8 134 66207 Venttiili Kuormanlaskuventtiili, Walvoil CC10A/4S2B 180-350 bar, PIL 1:4 135 65675 Venttiili Vaihtovastaventtiili, VU/SF 01 1

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NO PART NUMBER NAME TYPE PCS

1 A36258/A36509 Hydraulic tank 25-30 litre 12.1 A419282 Suction filter R3/4 - 25 mm, 150 µm 12.2 A419292 Suction filter R3/4 - 19 mm, 150 µm 13 64153 Pump Gear pump, Casappa polaris PLP20-6.3-4.0 14 66123 Combustion

engine Honda iGX 390 15 65219 Pump Gear pump, Casappa polaris PLP10-2.0 (OPTION) 16 65191 Electric motor Grundfos 2.2kw/ 1-phase (OPTION) 17 66115 Valve block Bosch Rexroth OFE20806BS0101 17.1 66209 Valve Check valve, Oil Control VUH1-G38 (3)7.2 66211 Valve 2/2 Directional valve, Oil Control OD1506181CS100 (1)7.3 66210 Valve 2/2 Directional valve, Oil Control OD1506181AS000 (1)7.4 66208 Valve Pressure relief valve, Oil Control VSBN-10A-35 (1)7.5 65745 Valve Pressure relief valve, Oil Control VSBN-10A-10 (1)8 66039 Pressure sensor IFM PT3550 (PT-400-SBG14-A-ZVG/US/ /W) 19 65269 Pressure filter MP Filtri FMM 050 2-B-A-D-A10-N-P01 19.1 65393 Filter cartridge MP FILTRI HP050-2-A10-A-N/P01 10 mikr. abs (1)10 66042 Valve 4/3 Directional valve, LF1 22 A201 0B 01 0F 111 66113 Valve block Bosch Rexroth ED-series (L9300860062AA00) Drive & Outriggers 112 66114 Valve block Bosch Rexroth ED-series (L9300860054AA00) Boom control 113 66047 Hydraulic motor Poclain MKD04 214 65376 Hydraulic motor M+S MT/B500KP/2 (Brake) 215 64698 Hydraulic motor OMT 500 151B3017 216 A36330/A36312 Hydraulic cylinder 63/45-520 A785 (Outrigger) 417 A36193/A417522 Hydraulic cylinder 70/40-500 A794 (Lift/folding) 218 64959 Hydraulic motor M+S MR50CD (slewing) 119 A36187/A417518 Hydraulic cylinder 50/35-2000 A2345 (Telescope) 120 A36180/A417508 Hydraulic cylinder 70/40-387 A610 (Jib) 121 A36209 Hydraulic cylinder 50/32-205 A401 (Leveling master) 122 A36196/A417529 Hydraulic cylinder 50/32-205 A401 (Leveling slave) 123 65829 Valve Counterbalance valve, Oil Control 05.42.47.03.02.35.000, PIL 1:6.6 324 65864 Valve Pressure reducing valve, Sun Hydraulics PBDB-LAN 125 66043 Return line filter MP Filtri MPS050-C-G1-P10-A-T (55L/min. 2*R3/4) 125.1 64499 Filter cartridge MP Filtri CS-050-P10-A (1)26 66183 Hand pump Badenost PRBC 20E 127 64065 Valve Check valve, Oil Control VUC 20 (R 3/8" - R 3/8") 228 65115 Valve Pilot operated check valve, Delta Power Company, DF-CPB-00-0050 429 65147 Valve Counterbalance valve, Oil Control VBSN-08AA 02.52.20.03.56.35, Pil 1:4 1130 65377 Valve 2/2 Directional valve, Oil Control OD.11.03.18.31.00 331 64598 Valve 2/2 Directional valve, Oil Control OD.15.31.18.37 132 63879 Valve Flow control valve, Parker 9N400S R1/4"-R1/4" 133 64736 Valve Counterbalance valve, Oleostar CA-10-A/8-S-2-B 270 bar, PIL 1:8 134 66207 Valve Counterbalance valve, Walvoil CC10A/4S2B 180-350 bar, PIL 1:4 135 65675 Valve Shuttle valve, VU/SF 01 1

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PÄÄPIIRIKAAVIO ELECTRIC DIAGRAM

A36359 A

M

1 ~

A2 149698

97 95

L

N

PE

Ird < 30mA

RCx

L

Cx

Cy Cy

-M1

1

2

3

4

5

6

13

14

Sähkömoottorin start/stopElectric motor start/stop

A1

A2-K41

-F412 4 6

230V/50Hz16A

PE

-+

-G1

-FT110A

PE

-F0-T1

-S22

12VDC C

12VDC

EX27Sähkömoottorin start/stopElectric motor start/stop

Sheet 8

A1

A2

11

14-K44

-

AkkuliitäntäBattery in/output

+

EX41Sähkömoottorin tilaElectric motor status

Sheet 5

-F12

5A

-F130A

-S24

Sähkömoottorin pakko-ohjausElectric motor´s forced control

6A100-D1

ENGINE START

Sheet 2

-E6

Sheet 1: 230V supply and electric motor

OPTION

OPTION

OPTION

ELECTRIC MOTOR

SOCKET

A VJRI 15.06.2015 S4 connector modified, cable lengths modified, connector types modified, K16-K19 ground points changed

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A36359 A

G

M

PWR1

PWR2

HONDA ECM

COM_12V

COM_TX

COM_RX

S_GND

OUTPUT

SW1

SW2

2

1

3

COMBINATION

SWITCH

LO

BAT

EXT-

EXT+

ST

IGNITION COIL

LED

OIL

_ALT

EX

T -

EX

T +

SPARK PLUG

-T20

-M20

-F22

30A

-S21

EX25Moottorin käynnistysEngine start Sheet 8

EX26Moottorin sammutusEngine stop Sheet 8

EX28HehkutusAnnealing Sheet 8

EX43Nopeusalue 2Speed level 2 Sheet 8

EX42Nopeusalue 3Speed level 3 Sheet 8

EX24Polttomoottorin tilaEngine status Sheet 5

EX40Öljynpaine varoitusOil pressure alarm Sheet 5

EX22Lämpötila varoitusTemperature alarm Sheet 5

ENGINE START

12VDC 12VDC

12VDC C 12VDC C

-G20

-H9

1

5

6

3

4

8

7

2

85

86

87

30-K46

Moottorin sammutusEngine stop

85

86

87

30-K47

Nopeusalue 2Speed level 2

85

86

87

30-K48

Nopeusalue 3Speed level 3

85

86

87

30-K45

Moottorin käynnistysEngine start

-F14

10A

1

2

HONDA

Sheet 2: Thermic motor


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A36359 A

ST VDC

VBBr

VBBs

VBBo

GND

VBB15

GND output1

GND output2

TEST

EX VDC

VBB2

VBB4

VBB1

GND

VBB3

GND output1

VBBrel

| ||1

10

19

20

32

37

42

50

1

10

19

20

32

37

51

-F4

5A

-H3

-H4

-H5

-H6

-H7

-S23

12VDC

-F3

25A-F2

5A

12VDC

12VDC C 12VDC C

ST32

Sheet 4-F8

10A

+

12VDC Ulostulo12VDC AUX

-

-S25

-H10

TyövalotWork lights

-H11

LOGICIFM CR7132

Sheet 3:Logic supply

OPTION

OPTION

OUTRIGGER LIGHTS

WORK LIGHTS

-E0


kg

1:19.1.2014 16:16:08

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9.10.2014 VMVI

LEGUAN 135


A36359 A

ST IN1

Vref I00

I01

I02

I03

I04

I05

I06

I07

ST IN2I08

I09

I10

I11

I12

I13

I14

I15

Scanrecosafety loop

DV2

LOOP1_OUT

LOOP1_IN

LOOP2_OUT

LOOP2_IN

I 0 II

mA

+ - + -

51 55

36

54

35

53

34

52

33

24

41

23

40

22

39

21

38

3

4 2

1

-S4

VDC

ST55

ST24

VDC

Puomin kuljetusasento 1Boom´s transport position 1

VDC

Sheet 5

1

2

3

4

-S1

VD

C

VD

C

Hätä-seisEmergency stop

1

2

3

4

-S2Korin hätä-seisEmergency stop basket

-F6

2A

12VDC 12VDC

12VDC C 12VDC C

1

2

3

4

5

ST32 Sheet 3

3

4 2

1

-S6

VDC

ST54

ST23

VDC

Ulottuma 2Extend 2

-F5

2A

3

4 2

1

-S7

VDC

VDC

ST53

VDC

Tukijalka 1Outrigger 1

3

4 2

1

-S8

VDC

VDC

ST34

VDC


3

4 2

1

-S10

VDC

EX38

ST33

VDC


3

4 2

1

-S9

VDC

VDC

ST52

VDC


EX38 Sheet 5

3

4 2

1

-S13

VDC

VDC

VDC

VDC

Radio-ohjauspaikanvalvontaRadio control´s position

EX33 Sheet 5

3

4 2

1

-S14

VDC

EX33

ST38

VDC

VDC

VDC

S11

S12

1

2

3

4

5

6

7

8

9

10

11

12

-S11

-S1212 22

11 21

32

311

2

VD

C

S01

ST2

1

S21

S22

S02

VD

CS

T39

-P10

ST3

6

ST4

1

21

5 6

3 4

Kuorman valvonta 1Overload control 1

-R3330 ohm

-R4330 ohm

LOGICIFM CR7132

Sheet 4:Inputs 1

Upper - OFF - Lower

OPTION

SAFETYOVERRIDE

-E0 ST


kg

1:19.1.2014 16:16:08

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9.10.2014 VMVI

LEGUAN 135


A36359 A

EX IN1I00_E

I01_E

I02_E

I03_E

I04_E

I05_E

I06_E

I07_E

EX IN2I08_E

I09_E

I10_E

I11_E

I12_E

I13_E

I14_E

I15_E

+-

P

+-

P

+-

P

+-

TE

+-

TE

+-

+-

+-

P

55

36

54

35

53

34

52

33

24

41

23

40

22

39

21

38

VDC

-S3

VD

CE

X36

Kuolleenmiehen poljinDead man´s pedal

-P8EX54 PolttoaineanturiFuel level sensor

EX41Sähkömoottorin tilaElectric motor statusSheet 1

-F7

5A

12VDC 12VDC

12VDC C 12VDC C

EX22Lämpötila varoitusTemperature alarmSheet 2

EX40Öljynpaine varoitusOil pressure alarmSheet 2

EX24Polttomoottorin tilaEngine statusSheet 2

-P2EX53 PumppupainePump pressure

-P3EX34 PuomipaineBoom pressure

-P4EX52 Tukialkojen paineOutriggers pressure

-P6EX35 IlmanlämpötilaTemperature sensor

-P7EX39 Hydrauliöljyn lämpötilaHydraulic oil temperature

3

4 2

1

-S5

EX55

VDC

Ulottuma 1Extend 1

-P9EX21 Hydrauliöljyn taso

Hydraulic oil level

EX38Sheet 4

EX33Sheet 4

-P5EX23 AjopaineDrive pressure

LOGICIFM CR7132

Sheet 5:Inputs 2

OPTION

OPTION

OPTION

OPTION

OPTION

OPTION

OPTION

-E0 EX


kg

1:19.1.2014 16:16:08

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9.10.2014 VMVI

LEGUAN 135


A36359 A

ST OUTPUT 1Q00

Q01

Q02

Q03

Q04

Q05

Q06

Q07

ST OUTPUT2Q08

Q09

Q10

Q11

Q12

Q13

Q14

Q15

A1

A2

-K2

ST17

GND

Vapaakierto 1Dump valve 1

A1

A2

-K1

ST18

GND

Valintaventtiili ASelector A

A1

A2

-K3

ST16

GND

Nosto ABoom 1 A

A1

A2

-K4

ST15

GND

Nosto BBoom 1 B

A1

A2

-K5

ST14

GND

Taitto ABoom 2 A

A1

A2

-K6

ST13

GND

Taitto BBoom 2 B

A1

A2

-K7

ST12

GND

Teleskoopppi ATelescopic A

A1

A2

-K8ST

11GN

D

Teleskoopppi BTelescopic B

A1

A2

-K10

ST4

GND

Pyöritys ASlewing A

A1

A2

-K9

ST2

GND

Valintaventtiili BSelector BA1

A2

-K11

ST5

GND

Pyöritys BSlewing B

A1

A2

-K12

ST6

GND

Jib AJib A

A1

A2

-K13

ST7

GND

Jib BJib B

A1

A2

-K14

ST8

GND

Kori tilt ABasket tilt A

A1

A2

-K15

ST9

GND

Kori tilt BBasket tilt B

2

3

4

5

6

7

8

9

18

17

16

15

14

13

12

11

12VDC 12VDC

12VDC C 12VDC C

A1

A2

-K31

ST3

GND

Tukijalkojen proportionaalinenOutriggers proportional

LOGICIFM CR7132

Sheet 6:Boom outputs

-E0 ST


kg

1:19.1.2014 16:16:08

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9.10.2014 VMVI

LEGUAN 135


A36359 A

EX OUTPUT1Q00_E

Q01_E

Q02_E

Q03_E

Q04_E

Q05_E

Q06_E

Q07_E

EX OUTPUT2Q08_EQ09_EQ10_EQ11_EQ12_EQ13_EQ14_EQ15_E

M

A1

A2

-K16

EX18

GND

Ajo O ARight track A

A1

A2

-K17

EX17

GND

Ajo O BRight track B

A1

A2

-K18

EX16

GND

Ajo V ALeft track A

A1

A2

-K19

EX15

GND

Ajo V BLeft track B

A1

A2

-K22

EX2

GND

Tukijalka 1 BOutrigger 1 B

A1

A2

-K23

EX3

GND

Tukijalka 1 AOutrigger 1 A

A1

A2

-K24

EX4

GND


A1

A2

-K25

EX5

GND


A1

A2

-K26

EX6

GND


A1

A2

-K27

EX7

GND


A1

A2

-K28

EX8

GND


A1

A2

-K29

EX9

GND


23456789

18

17

16

15

14

13

12

11

-M2

12VDC 12VDC

12VDC C 12VDC C

86

85

87a 87

30

-K70

EX

12

Korinkääntö ABasket slewing A

86

85

87a 87

30

-K71

EX

11

Korinkääntö BBasket slewing B

-F13

15A

LOGICIFM CR7132

Sheet 7: Drive outputs and basket rotate

-E0 ST


kg

1:19.1.2014 16:16:08

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14.10.2014 VMVI

LEGUAN 135


A36359 A

EX OUTPUT3Q16_E

Q17_E

Q18_E

Q19_E

Q20_E

Q21_E

Q22_E

Q23_E

EX OUTPUT4Q24_E

Q25_E

Q26_E

Q27_E

Q28_E

Q29_E

Q30_E

Q31_E

HOURS

A1

A2

-K30

EX30

GND

1/2 pumppua1/2 pumps

1

2

-H2

EX29

GND

SummeriBuzzer

25

26

27

28

29

30

31

50

EX27Sähkömoottorin start/stopElectric motor start/stopSheet 1

EX26Moottorin sammutusEngine stopSheet 2

EX25Moottorin käynnistysEngine startSheet 2

EX28HehkutusAnnealingSheet 2

12VDC 12VDC

12VDC C 12VDC C

42

43

44

45

46

47

48

49

EX43Nopeusalue 2Speed level 2Sheet 2

EX42Nopeusalue 3Speed level 3Sheet 2

EX44Moottorin käynnistyksen sallintaMotor´s starter allowedSheet 2 -P1

-H8

2

1

Radio-ohjaus merkkivaloRadio control indicator

1

2

-H1

EX31

GND

Ylikuorma merkkivaloOverload indicator

LOGICIFM CR7132

Sheet 8:Motor controls and indicators

OPTION

-E0 ST


EX50

GND

kg

1:19.1.2014 16:16:08

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14.10.2014 VMVI

LEGUAN 135


A36359 A

ST CAN

CAN1_H

CAN1_L

CAN2_H

CAN2_L

CAN3_H

CAN3_L

CAN4_H

CAN4_L

IFM JN2101Shield

Supply

GND

CAN_H

CAN_L

CAN_H

CAN_L

KEYPADPower

GND

CAN_H

CAN_L

Scanrecosupply

DV1

Supply

GND

CAN_H

CAN_L

Scanrecoremote control

connection

Data

GND

RS 232 TX

RS 232 RX

Supply

scanrecoREMOTE CONTROL

Data

GND

RS 232 TX

RS 232 RX

Supply

GPS

I/O

I/O

Power

GND

CAN_H

CAN_L

47

29

46

28

45

27

44

26

12VDC 12VDC

12VDC C 12VDC C

-F9

5A1

2

3

4

-E1

-F10

10A

1

2

3

4

5

-E3

1

2

3

4

5

-E3

1

2

3

4

5

-E4

-R2

R120

1

2

3

4

5

-E2

-R1

R120

1

2

3

4

-E5

-F16

2A

LOGICIFM CR7132

SCANRECORECEIVER

Sheet 9:CAN and remote control

4

5

OPTION

OPTION

-E0


kg

1:19.1.2014 16:16:08

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14.10.2014 VMVI

LEGUAN 135


A36359 A

13

14

-S97A

-F15

10A

13

14

-S96A13

14

-S9713

14

-S9613

14

-S95A13

14

-S9513

14

-S94A13

14

-S94

A1

A2

-K97

GND

NostoLift

A1

A2

-K95

GND

JibJib

A1

A2

-K94

GND

TeleskooppiTelescopic

A1

A2

-K96GN

D

TaittoUpper boom

12VDC 12VDC

12VDC C 12VDC C

Sheet 10:Emergency lowering


kg

1:19.1.2014 16:16:08

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LEGUAN 135

JOHDOTUSKAAVIO WIRING DIAGRAM

A36360 A

M

1 ~

A2 149698

97 95

Ird < 30mA

| ||

RCx

L

Cx

Cy Cy

-M1

PE

-+

-G1

-FT1

10A

PE

Sheet 7 and Sheet 8 12VDC C

12VDC

-

+

-F130A

-IFM EX

-S23

-H8

GND

1

2

-H2

Sheet 2ENGINE START

-H1

-F4

5A

-F12

5A

2741 50 2931

27

-E0 EX

41 50 2931

-X3 1 2

1

2

-X1 A B C

-X21

5-X

216

-X21

1-X

212

-H8

1

-H82 -X

31 2

-X1

A B C

-X21

5-X

216

-X21

1-X

212

6A100Dio

de-D

1

-E6

A1

A2-K41

13

14

5

6

3

4

1

2

-T1

-GND3 -GND4

-GND12

-S22

A1

A2

11

14-K44

-S24

L N PE

-X9

L N PE

1

-X242 3 4 5 6

7

-X24

8

-X24

9-X24

10

-X2411

-F0

-H3

-H4

-H5

-H6

-H7

-F412 4 6

-X50

.1

1

2

-X50

.2

1

2

-X50

.3

1

2

-X50

.4

1

2

-X50

.5

1

2

-X50

.6

1

2

Sheet 1: 230V supply, electric motor and beacons

OPTION

CONNECTION BOXOT3

OT4

OT1

OT2

BOOM

LNPE

KK05

1.00mm2 Brown

1.00mm2 Blue

0.75mm2 yellow

2.5mm2 Brown

2.5mm2 Blue

1.50 mm2 Green-Yellow

2.5mm2 Brown

2.5mm2 Blue

2.5mm2 GreenYellow

6.00mm2 Red

230V/50Hz16A

OPTION

OPTIONOPTION

OPTION

1.50 mm2 Green-Yellow


1.00 mm² BrownS23

S23

GND4

GND4

S23

GND4

S23

GND4

S23

GND4

1.00 mm² Blue

1.00 mm² Brown

1.00 mm² Blue

1.00 mm² Brown

1.00 mm² Blue

1.00 mm² Brown

1.00 mm² Blue

1.00 mm² Brown

1.00 mm² Blue

1.00 m

m²Br

own

1.00 m

m²Bl

ue

S23

GND4

0.75 m

m²Ye

llow

0.75 m

m²W

hite

S23

GND4

0.75 m

m²Gr

een

F40.7

5 mm²

Gree

nF4

0.75 m

m²Ye

llow

S23

0.75 mm² Yellow

0.75 m

m²Ye

llow

EX50

EX31

0.75 m

m²Ye

llow

EX31

0.75 m

m²W

hite

GND3

0.75 mm² Yellow

0.75 mm² Yellow

EX27

Ex41

F12

0.75 m

m²Gr

een

0.75 m

m²Gr

een

F12

0.75 m

m²W

hite

GND4

GND3

0.75 m

m²W

hiteG

ND3

0.75 m

m²Ye

llow

EX29

2.50 m

m²Gr

een-

Yello

w

2.50 m

m²Br

own

2.50 m

m²Bl

ue

2.50 mm² Blue

2.50 mm² Brown

2.50 mm² Green-Yellow


2.50 mm² Brown

2.50 mm² Blue

2.50 mm² Blue

2.50 mm² Brown

2.50 m

m²Gr

een-

Yello

w

2.50 mm²Green-Yellow

2.50 m

m²Br

own

2.50 m

m²Br

own

2.50 m

m²Br

own

10.00 mm² Red

10.00 mm² Black

1.50 mm² Black

1.50 m

m²Re

d

10.00

mm²

Red

10.00

mm²

Blac

k

2.50 mm² Red

10.00 mm² Red

2.50 mm² Blue

2.50 mm² Blue

1.50 mm² Brown

1.50 mm² Blue

1.50 mm² Black

10.00 mm² Red

1.50 m

m²Bl

ack

0.75 m

m²Ye

llow

1.50 mm² Black

1.50 m

m²Bl

ack

1.50 mm² White

1.50 mm² Brown

1.50 mm² Blue

kg

1:19.1.2014 16:16:08

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14.10.2014 VMVI

LEGUAN 135


A36360 A

ENGINE START

87a 87

30

86

85

87a 87

30

86

85

M

87a 87

30

86

85

87a 87

30

86

85

87a 87

30

86

85

87a 87

30

86

85

G

M

PWR1

PWR2

HONDA ECM

COM_12V

COM_TX

COM_RX

S_GND

OUTPUT

SW1

SW2

2

1

3

COMBINATION

SWITCH

LO

BAT

EXT-

EXT+

ST

IGNITION COIL

LED

OIL

_ALT

EX

T -

EX

T +

SPARK PLUG

-IFM EX/1.B5/3.A1

GND

12VDC

-M2

-G20

-M20

-F22

30A

-S21

-H9

Sheet 1

1

2

1

5

6

3

4

8

7

-F13

15A

-F14

10A

11 12 24 25 26 42 43

-E0 EX

11 12 24 25 26 42 43

-X91

.1

1 2

-X93

.1

-X91

.1

1 2

-X93

.1

-X91

1 2

-X93

-X93

-X91 1 2

-K70

-K71

-K45-K46 -K47 -K48

-X51

3

-X52

4

-X24 -X2

5

6

7

-X23

-X2 1 2-X11

1

3

-X112

4

-X46

1

-X46

2

-X111

3

-X112

4

-X24 -X2

5

6

7

-X23

-X2

1 2

-X51

3

-X52

4

-X46

1

-X46

2

-GND3-GND4

-T20

-X92

1

HONDA

Sheet 2: Thermic motor and basket rotate


1.50 mm² Black8

1.50 mm² Black12

1.50 mm² Black7

1.50 mm² Black9

F13

EX25

EX26

EX42

EX43

EX11

EX12

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

1.50 mm² GreenK70

1.50 mm² Green

K71

1.50 m

m²Gr

een

K71

0.75 m

m²Ye

llow

EX24

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²W

hite

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

1.50 m

m²Gr

een

K45

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 mm² Yellow

K46.1

K46.2

0.75 mm² Yellow

0.75 mm² YellowSW1

SW2

GND4

SW1

SW2

1.50 m

m²Gr

een

K71

0.75 m

m²W

hite

1.50 m

m²W

hite

1.50 m

m²W

hite

0.75 m

m²W

hite

GND3

0.75 mm² White

1.50 m

m²Gr

een

F14

1.50 mm² Green

1.50 mm² GreenK70

1.50 mm² Green

1.50 mm² Green

F13

1.50 mm² Green

1.50 mm² GreenK70

0.75 mm² White

0.75 mm² White

0.75 mm² White

0.75 mm² White

0.75 mm² White

0.75 mm² White

GND4

K46.1

EX24

0.75 mm²YellowK46.2

kg

1:19.1.2014 16:16:08

Pvm. Suunn.


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14.10.2014 VMVI

LEGUAN 135


A36360 A

-IFM ST-IFM EX

GND

12VDC

11121314151617182 3 4 5 6 7 8 915 16 17 182345678930

15 16 17 1823456789 -E0 EX30 1112131415161718-E0 ST 2 3 4 5 6 7 8 9

-K1 -K2 -K3 -K4 -K7 -K8

-K9 -K10 -K11 -K12 -K13 -K14 -K15

-K16-K17-K18-K19-K6-K5

-K22-K23-K24-K25-K26-K27-K28

-K29-K30

-K31

-GND5

-GND6

-GND7 -GND8 -GND9

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

Sheet 3:Valves


0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

EX30

EX9

EX8

EX7

EX6

EX5

EX4

EX3

EX2

EX15

EX16

EX17

EX18

ST5

ST6

ST7

ST8

ST9

ST4

ST18

ST17

ST16

ST15

ST14

ST13

ST12

ST11

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

GND9

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²Ye

llow

0.75 m

m²W

hite

GND7 GND5

ST3

ST2

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

GND8

kg

1:19.1.2014 16:16:08

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LEGUAN 135


A36360 A

HOURS

+-

L

+-

P

+-

P

+-

P

+-

TE

+-

TE

+-

L

+-

P

mA

+-+-

-IFM ST -IFM EX

GND

12VDC

-P1

-S25

-H10

+-

F5Sheet 5

-P8

-P9

F2Sheet 7

-H11

-F2

5A

-F3

25A

-F6

2A

-F7

5A

-F8

10A

1 10 19 20 37 42 5136 41 1 10 19 20 32 37 51 21 34 35 39 52 53 5436 55 2345

1 10 19 20 32 37 51 21 34 35 39 52 53 5436 55 23

-E0 EX

451 10 19 20 37 42 51

-E0 ST36 41

-X5 5 6 7 8

-X11

5 6 7 8

-X4 7 8

-X4 1 2 3 4

-X10

7 8

-X10

1 2 3 4

-X43

A-X

43B

-X48

1 2 3 4

-X6 1

-X6

2

-X21

7-X

218

-X11

5 6 7 8

-X5

5 6 7 8

-X10

7 8

-X10

1 2 3 4

-X4

7 8

-X4

1 2 3 4

-P6 1

2-X43

A-X

43B

-X48

1 2 3 4

-X6

1-X

6 2

-X21

7-X

218

-P10

123456

-S5

-P6

-P7

-GND2

-GND3

-GND4

-P21

2

-P31

2

-P7 1

2

-P9 1

2

21

-P4 1

2

2

-P5 1

-X1001

2

3

4

-P8 1

2

-P2

-P3

-P4

-P5

Pedal-S3

-R3

330 ohm-R4

330 ohm

-X47

12

OPTION

AUX12VDC

WORKING

OPTION

Sheet 4: Sensors

LIGHTS

OPTION

OPTION

OPTION

OPTION

OPTION

OPTION

OPTION


0.75 m

m²Ye

llow

1.50 m

m²Bl

ack4

1.50 m

m²Bl

ack3

1.50 m

m²Bl

ack2

1.50 m

m²Bl

ack1

ST41

GND4

ST36

F6

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Gr

een

1.50 m

m²Bl

ack1

1.50 m

m²Bl

ack2

0.75 mm² YellowEX55

EX55

F5

0.75 m

m²Ye

llow

EX36

1.50 mm² Black7

1.50 mm² Black8

0.75 m

m²Gr

een

F5

F5

EX36

0.75 m

m²Ye

llow

EX36

EX45

GND3

0.75 m

m²W

hite

0.75 m

m²Ye

llow

0.75 m

m²W

hite

GND3

EX45

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

EX21

EX34

EX35

EX39

EX52

EX53

EX54

1.50 m

m²W

hite

1.50 m

m²Bl

ack1

4

1.50 m

m²Bl

ack1

3

1.50 m

m²Bl

ack1

2

1.50 m

m²Bl

ack1

1

ST41

ST36

F6

1.50 m

m²Gr

een

F2

1.50 m

m²Gr

een

F2

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

0.75 m

m²W

hite

GND2

GND2

GND2

GND2

GND2

1.50 mm² Green

1.50 mm² Green

F3

F3 1.50 mm² Green

1.50 mm² Green

1.50 mm² Green

1.50 mm² GreenF3

F3

F3

F3

1.50 m

m²W

hite

GND4

GND4

1.50 m

m²Gr

een

1.50 m

m²Gr

een

F8F8F8 GN

D4

F8 GND4

1.50 m

m²Gr

een

1.50 m

m²Gr

een

1.50 m

m²Gr

een

F8F8F81.5

0 mm²

Whit

e

1.50 m

m²W

hite

1.50 m

m²W

hite

GND4

GND4

GND4

B1

1.50 mm² Green

0.75 m

m²Ye

llow

EX23

0.75 mm² Green

0.75 mm² Green

0.75 mm² Green

0.75 mm² Green

0.75 mm² Green

0.75 mm² Green

0.75 mm² Green

0.75 mm² Green

F7

F7

F7

F7

F7

F7

F7

F70.7

5 mm²

Whit

e

0.22 mm² Yellow

0.22 mm² Brown

0.75 mm² Green

0.75 mm² White

0.75 mm² Yellow

0.75 mm² Yellow

0.22 mm² Red

0.22 mm² Blue

0.22 mm² Green

0.22 mm² White

kg

1:19.1.2014 16:16:08

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LEGUAN 135


A36360 A

12VDC

F5Sheet 4 F5

-IFM ST -IFM EX

Sheet 6 F5

-F5

2A

23 24 33 34 38 52 53 54 55 33 38

-E0 EX

33 38

-E0 ST

23 24 33 34 38 52 53 54 55

-X181

2

3

4

5

6

7

8

9

10

11

-X4 5 6 9 10

-X10

5 6 9 10

-X63

4

5

6

-X171

2

3

4

5

-X181

2

3

4

5

6

7

8

9

10

11

-X10

5 6 9 10

-X4

5 6 9 10

-X63

4

5

6

-X171

2

3

4

5

3 1

-S6

4 2

3 1

-S7

4 2

3 1

-S8

4 2

3 1

-S9

4 2

3 1

-S10

4 2

3 1

-S4

4 2

3 1

-S13

4 2

3 1

-S14

4 2

-OT1

-OT1

-OT2

-OT2

-OT3

-OT3

-OT4

-OT4

Sheet 5: Limit switch

0.75mm2 Green

0.75mm2 Green


0.75 mm² YellowST38

1.50 m

m²Bl

ack5

1.50 m

m²Bl

ack6

1.50 m

m²Bl

ack9

1.50 m

m²Bl

ack1

0

F5 ST38

F5 EX33

0.75 m

m²Gr

een

0.75 m

m²Gr

een

F5 F5

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

ST24

ST55

1.50 m

m²Bl

ack6

1.50 m

m²Bl

ack4

1.50 m

m²Bl

ack5

1.50 m

m²Bl

ack3

F5 F5

ST54

ST23

0.75 mm² Yellow

0.75 mm² Yellow

ST23

ST54

0.75 mm² Yellow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

ST55

ST54

ST53

ST52

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

EX38

LS2

LS1 0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

EX33

ST38

0.50 mm² Brown

0.50 mm² Brown

0.50 mm² Brown

0.50 mm² Brown

0.50 mm² Blue

0.50 mm² White

0.50 mm² White

0.50 mm² White

0.50 mm² White

0.50 mm² Black

0.50 m

m²Bl

ue

0.50 m

m²Bl

ack

0.50 m

m²Bl

ue

0.50 m

m²Bl

ack

0.50 m

m²Bl

ack

JUMP

1

JUMP

2

JUMP

2

JUMP

3

JUMP

3

EX38

F5

F5

F5

F5

F5

ST53

ST34

ST52

ST33

JUMP1

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

ST34

ST33

0.75 m

m²Gr

een

0.75 m

m²Gr

een

F5F5

0.75 mm² Green

0.75 mm² Green

F5

F5

0.75 mm² Green

0.75 mm² Green

F5

F5

0.50 m

m²Bl

ue

0.75 mm² YellowEX33

0.75 mm² Green

0.75 mm² Green

0.75 mm² Green

0.75 mm² Green

0.75 mm² Green

F5

F5

F5

F5

F5

kg

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LEGUAN 135


A36360 A

1

2

3

41

2

3

4

I 0 II

Scanrecosafety loop

DV2

LOOP1_OUT

LOOP1_IN

LOOP2_OUT

LOOP2_IN

12VDC

-IFM ST

Sheet 5 F5

21 22 35 39 4032

1

2

3

4

5

6

7

8

9

10

11

12

-S11

-E0 ST

21 22 35 39 4032

-X5 9 10 11 12

-X23

1 2 3 4 5 6 7 8 9 10

-X11

9 10 11 12

-X22

1 2 3 4 5 6

-X11

9 10 11 12

-X23

1 2 3 4 5 6 7 8 9 10

-X5

9 10 11 12

-X22

1 2 3 4 5 6

-S1

F5 F5

S01

S02

-S2

S01

S02

S11

S12

-X161

2

3

4

5

1

2

3

4

5

-E3

-S12 12 22

11 21

32

311

2

Sheet 6: Switches

SCANRECO RECEIVER

Upper - OFF - Lower

OPTION


0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

ST35

ST40

ST35

ST22

ST32

0.75 mm² Yellow

0.75 mm² Yellow

S21

S22

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

ST40

S12

S11

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Yellow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

1.50 m

m²Bl

ack1

5

1.50 m

m²Bl

ack1

6

1.50 m

m²Bl

ack1

7

1.50 m

m²Bl

ack1

8

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

S01

S11

S02

S12

S01

S11

S02

S12

S01

S11

S02

S12

ST21

ST39

ST32

ST22

ST35

ST40

S11

ST35

S12

ST40

ST39

ST21

0.75 mm² Yellow

0.75 mm² YellowF5

0.75 mm² Yellow

0.75 mm² Yellow

S02

S01

0.75 mm² YellowS12

0.75 mm² YellowS11

F5

kg

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LEGUAN 135


A36360 A

Scanrecoremote control

connection

Data

GND

RS 232 TX

RS 232 RX

Supply

Scanrecosupply

DV1

Supply

GND

CAN_H

CAN_L

KEYPADPower

GND

CAN_H

CAN_L

IFM JN2101Shield

Supply

GND

CAN_H

CAN_L

CAN_H

CAN_L

scanrecoREMOTE CONTROL

Data

GND

RS 232 TX

RS 232 RX

Supply

GPSPower

GND

CAN_H

CAN_L

GND

1

2

3

4

5

-E3

1

2

3

4

5

-E3

-IFM ST

12VDC

Sheet 1 12VDC C

Sheet 4 F2

1

2

3

4 -E5

-F9

5A

-F10

10A

-F16

2A

26 27 28 29 44 45 46 475030 31 2548 43

26 27 28 29 44 45 46 475025

-E0 ST

30 31 4348

-X151

2

3

4

5

-X131

2

3

4

5

-X941

2

3

4

5

6

7

8-X20

1

2

3

4

-X951

2

3

4

-X941

2

3

4

5

6

7

DT06-8SA

8

1

2

3

4

5 -E2

1

2

3

4

-E1

-GND2

1 -GND3 -GND4

-X441

2

3

4

5

-X451

2

3

4

5

-X81

2

3

4

5

-X441

2

3

4

5

1

2

3

4

5

-E4

-R2

R120

-R1

R120

-R5

R120

Sheet 7: CAN

SCANRECO RECEIVER

4

5

0.75mm2 Green

OPTION

OPTION


0.50 mm² Yellow

0.50 mm² White

0.50 mm² Brown

0.50 mm² White

0.50 mm² Brown

0.75 mm² Yellow

0.75 mm² Yellow

0.75 mm² Green

0.50 mm² Green

0.75 mm² Blue


0.75 mm² Brown

1.50 mm² Black1


1.50 mm² Black2

RC1

RC2

RC5

RC1

RC2

RC5

GND3

ST46

ST28

F9

ST45

ST27

F10

ST47

ST29

0.50 mm² YellowGND3

0.75 mm² WhiteGND3

SilverGND3

0.50 mm² GreenF9

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

0.75 m

m²Ye

llow

USB_

P

USB_

N

USB_

5V

RxD

ST50

TxD

0.75 mm²Green

0.75 mm² Yellow

0.75 mm² White

0.75 mm² Yellow

ST26

ST44

F16

GND4

kg

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22.10.2014 VMVI

LEGUAN 135


A36360 A

GND

Sheet 1 12VDC C

-F15

10A

Coil

-K94

Coil

-K95

Coil

-K96

Coil

-K97-X1081

2

-X71

2

3

4

5

6

-X121

2

3

4

5

-X611

2

3

4

5

6

-X1081

2

-X121

2

3

4

5

6

-X611

2

3

4

5

6

-X71

2

3

4

5

-GND1

2

12

12

12

Push button-S94

Push button-S94A

Push button-S95

Push button-S97A

Push button-S97

Push button-S96A

Push button-S96

Push button-S95A

-X60.21

2

3

4

5

-X60.1

1

2

3

4

5

6

-X60.31

2

-X60.41

2

-X60.51

2

-X60.61

2

Sheet 8: Emergency lowering

CONNECTION BOXKK06


1.50 mm² Black1

1.50 mm² Black2

1.50 mm² Black3

1.50 mm² Black4

1.50 mm² Black5

1.50 mm² Black6

F15

1

2

3

4

5

1.50 mm² Green

1.50 mm² Yellow

1.50 mm² Yellow

1.50 mm² Yellow

1.50 mm² Yellow

1.50 mm² Green

1.50 mm² Yellow

1.50 mm² Yellow

1.50 mm² Yellow

1.50 mm² Yellow

1.00 mm² Brown

1.00 mm² Blue

1.00 mm² Brown

1.00 mm² Blue

1.00 mm² Brown

1.00 mm² Blue

1.50 mm² Green

1.50 mm² Yellow

1.50 mm² Yellow

1.50 mm² Yellow

1.50 mm² Yellow

1.50 mm² White

F15

1

2

3

4

GND

1.50 m

m²Ye

llow

1.50 m

m²Ye

llow

1.50 m

m²Ye

llow

1.50 m

m²Ye

llow

4321

F15

1

2

3

41.5

0 mm²

Whit

eGN

D

1.50 m

m²Gr

een

F15

1.50 m

m²Gr

een

F15

1.50 mm² GreenF15

1.50 m

m²Gr

een

1.50 m

m²Gr

een

1.50 mm² Green

1.50 mm² Green

1.50 mm² Green

F15

F15

F15

F15

1.00 mm² Brown

1.00 mm² Blue

1.00 mm² Brown

1.00 mm² Blue

LEGUAN LIFTSLEGUAN LIFTSLEGUAN LIFTSLEGUAN LIFTSLeguan 135 Electrical diagram A36359A

Parts list

Name Part No. Type DescriptionD1 74949 6A100 Diode, electric motor startE0 66037 CR7132ST Safety logicE1 66148 3KYY1115-316N, Grayhill Lower control keypadE2 66038 JN2101 Inclination sensorE3 66176 G3 receiver Scanreco receiverE4 66175 G3 MAXI transmitter Scanreco remote controllerE5 GPS trackerE6 66116 FN-2030-6-06 Schaffner EMC-filterF0 65184 089-09, 25A 30mA, Legrand Residual current deviceF1 75008 30A MIDI bolt-on fuse, main fuseF2 74997 5A ATO blade fuse, safety logic supplyF3 75007 25A ATO blade fuse, safety logic supplyF4 74997 5A ATO blade fuse, flashing lightsF5 75006 2A ATO blade fuse, safety componentsF6 75006 2A ATO blade fuse, overload controlF7 74997 5A ATO blade fuse, sensorsF8 74998 10A ATO blade fuse, work lights and 12V in basketF9 74997 5A ATO blade fuse, lower controls and inclination sensorF10 74998 10A ATO blade fuse, ScanrecoF12 74997 5A ATO blade fuse, electric motor running signalF13 74602 15A ATO blade fuse, basket rotateF14 74998 10A ATO blade fuse, engine startF15 74998 10A ATO blade fuse, emergency loweringF16 75006 2A ATO blade fuse, GPSF22 75045 30A ATM blade fuse, HondaF41 65185 EATON ZB12-16 Thermal breakerFT1 74998 10A ATO blade fuse, battery chargerH1 66149 19040253 Overload LEDH2 64955 Sonitron SCI 535 A5 F2 BuzzerH3 65417 40-9811A Flashing light, outriggerH4 65417 40-9811A Flashing light, outriggerH5 65417 40-9811A Flashing light, outriggerH6 65417 40-9811A Flashing light, outriggerH7 65417 40-9811A Flashing light, boomH8 64388 40-9578A Flashing light, motion beaconH10 65450 HELLA 1G0 996.176-72 WorklightH11 65450 HELLA 1G0 996.176-72 WorklightK1 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, selector valve boomK2 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, dump valveK3 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, lower boomK4 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, lower boomK5 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, upper boomK6 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, upper boomK7 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, telescopic boomK8 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, telescopic boomK9 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, selector valve drive-outtrigK10 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, slewingK11 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, slewingK12 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, jib boomK13 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, jib boomK14 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, basket levelK15 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, basket levelK16 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, drive right

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Parts list

Name Part No. Type DescriptionK17 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, drive rightK18 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, drive leftK19 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, drive leftK22 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, outtrigger 1K23 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, outtrigger 1K24 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, outtrigger 2K25 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, outtrigger 2K26 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, outtrigger 3K27 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, outtrigger 3K28 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, outtrigger 4K29 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, outtrigger 4K30 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, double pumpK31 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, outtrigger proportionalK41 65186 DILM 15-10 12VDC ContactorK44 65867 Releco C10-A10230AC Relay, electric motor runningK45 Bosch 0 332 209 152 / Wehrle 20 201 103 Automotive relay with diode, engine startK46 Bosch 0 332 209 152 / Wehrle 20 201 103 Automotive relay with diode, engine stopK47 Bosch 0 332 209 152 / Wehrle 20 201 103 Automotive relay with diode, engine speed 2K48 Bosch 0 332 209 152 / Wehrle 20 201 103 Automotive relay with diode, engine speed 3K70 Bosch 0 332 209 152 / Wehrle 20 201 103 Automotive relay with diode, basket rotateK71 Bosch 0 332 209 152 / Wehrle 20 201 103 Automotive relay with diode, basket rotateK94 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, emerg. lowering telescopeK95 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, emerg. lowering jibK96 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, emerg. lowering upper boomK97 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diode coil, emerg. lowering lower boomM1 65191 MG90LC2-24FF165B Electric motorM2 66036 Linak 301200-00150225 Linear motor, basket rotateP1 64152 Unideck 06200001 HourmeterP2 66039 PT3550 Pressure sensor, pumpP3 66039 PT3550 Pressure sensor, boomP4 66039 PT3550 Pressure sensor, outtriggersP5 66039 PT3550 Pressure sensor, driveP6 A419941 W-M-6/60-3-A-TR / 5333A Air temperature sensorP7 Hydraulic oil temperature switchP8 66119 S1.B45.3.0140.O.FOPX.S1.L.1.I2 Fuel level switchP9 Hydraulic oil level switchP10 66033 MRW-500, Moba Overload sensorR1 66136 1507816 Termination Resistor, 120ohmR2 75009 R120 Resistor, lower control keypad CAN-terminationR3 75005 R330 Resistor, overload controlR4 75005 R330 Resistor, overload controlS1 A419326 A-B 800FP-MT443LX11 Emergency stop, lowerS2 A419326 A-B 800FP-MT443LX11 Emergency stop, upperS3 66102 XPE-A110 Foot switchS4 66069 EM1G12ZM COMEPI Limit switch, boom transport positionS5 66069 EM1G12ZM COMEPI Limit switch, telescopic extendS6 66069 EM1G12ZM COMEPI Limit switch, telescopic extendS7 66069 EM1G12ZM COMEPI Limit switch, outtrigger ground contactS8 66069 EM1G12ZM COMEPI Limit switch, outtrigger ground contactS9 66069 EM1G12ZM COMEPI Limit switch, outtrigger ground contactS10 66069 EM1G12ZM COMEPI Limit switch, outtrigger ground contactS11 66127 CG 4 SF6788 *FS1 / S00 V750D/2C/11 Key switch, control position selectorS12 A419638 A-B 800FP-F1PX104 Push button, emergency use

2 / 3Mikko Toivanen

18.11.2015


Parts list

Name Part No. Type DescriptionS13 66069 EM1G12ZM COMEPI Limit switch, remote controller positionS14 66069 EM1G12ZM COMEPI Limit switch, remote controller positionS22 64141 Member´s 080987.00 Main switchS23 A419327 A-B 800FP-SM22PX10 Switch, flashing lightsS24 A419324 A-B 800FP-F1PX10 Push button, electric motorS25 A419327 A-B 800FP-SM22PX10 Switch, work lightsS94 A419324 A-B 800FP-F1PX10 Push button, emergency landing, in basketS94A A419324 A-B 800FP-F1PX10 Push button, emergency landing, lower panelS95 A419324 A-B 800FP-F1PX10 Push button, emergency landing, in basketS95A A419324 A-B 800FP-F1PX10 Push button, emergency landing, lower panelS96 A419324 A-B 800FP-F1PX10 Push button, emergency landing, in basketS96A A419324 A-B 800FP-F1PX10 Push button, emergency landing, lower panelS97 A419324 A-B 800FP-F1PX10 Push button, emergency landing, in basketS97A A419324 A-B 800FP-F1PX10 Push button, emergency landing, lower panelT1 65183 CME 1206 Battery chargerT20 66219 Honda 31750-Z2E-803 Charge controller

3 / 3Mikko Toivanen

18.11.2015

LEGUAN LIFTSLEGUAN LIFTSLEGUAN LIFTSLEGUAN LIFTSLeguan 135 Sähkökaavio A36359A

Osaluettelo

Nimi Osanumero Tyyppi KuvausD1 74949 6A100 Diodi, sähkömoottorin käynnistysE0 66037 CR7132ST TurvalogiikkaE1 66148 3KYY1115-316N, Grayhill AlaohjausnäppäimistöE2 66038 JN2101 KallistusanturiE3 66176 G3 vastaanotin Scanreco vastaanotinE4 66175 G3 MAXI lähetin Scanreco kauko-ohjainE5 GPS paikanninE6 66116 FN-2030-6-06 Schaffner EMC-suodatinF0 65184 089-09, 25A 30mA, Legrand VikavirtasuojaF1 75008 30A MIDI sulake, pääsulakeF2 74997 5A ATO lattasulake, turvalogiikka syöttöF3 75007 25A ATO lattasulake, turvalogiikka syöttöF4 74997 5A ATO lattasulake, vilkutF5 75006 2A ATO lattasulake, turvakomponentitF6 75006 2A ATO lattasulake, kuormanvalvontaF7 74997 5A ATO lattasulake, anturitF8 74998 10A ATO lattasulake, työvalot ja 12V ulostulo korissaF9 74997 5A ATO lattasulake, alaohjaus ja kallistusanturiF10 74998 10A ATO lattasulake, ScanrecoF12 74997 5A ATO lattasulake, sähkömoottorin käyntiF13 74602 15A ATO lattasulake, korin kääntöF14 74998 10A ATO lattasulake, polttomootorin käynnistysF15 74998 10A ATO lattasulake, varalaskuF16 75006 2A ATO lattasulake, GPSF22 75045 30A ATM lattasulake, HondaF41 65185 EATON ZB12-16 LämpösuojaFT1 74998 10A ATO lattasulake, akkulaturiH1 66149 19040253 Ylikuorman led-valoH2 64955 Sonitron SCI 535 A5 F2 SummeriH3 65417 40-9811A Vilkkuvalo, tukijalkaH4 65417 40-9811A Vilkkuvalo, tukijalkaH5 65417 40-9811A Vilkkuvalo, tukijalkaH6 65417 40-9811A Vilkkuvalo, tukijalkaH7 65417 40-9811A Vilkkuvalo, puomiH8 64388 40-9578A Vilkkuvalo, majakkaH10 65450 HELLA 1G0 996.176-72 TyövalaisinH11 65450 HELLA 1G0 996.176-72 TyövalaisinK1 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, valintaventtiili puomiK2 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, vapaakiertoK3 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, alapuomiK4 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, alapuomiK5 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, yläpuomiK6 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, yläpuomiK7 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, teleskooppiK8 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, teleskooppiK9 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, valintaventtiili siirto+tukiK10 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, pyöritysK11 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, pyöritysK12 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, jibK13 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, jibK14 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, korin kallistusK15 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, korin kallistusK16 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, siirtoajo oikea

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Osaluettelo

Nimi Osanumero Tyyppi KuvausK17 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, siirtoajo oikeaK18 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, siirtoajo vasenK19 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, siirtoajo vasenK22 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, tukijalka 1K23 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, tukijalka 1K24 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, tukijalka 2K25 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, tukijalka 2K26 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, tukijalka 3K27 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, tukijalka 3K28 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, tukijalka 4K29 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, tukijalka 4K30 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, tuplapumppuK31 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, tukijalkojen propoK41 65186 DILM 15-10 12VDC KontaktoriK44 65867 Releco C10-A10230AC Rele, sähkömoottorin käyntisignaaliK45 Bosch 0 332 209 152 / Wehrle 20 201 103 Rele diodilla, polttomoottorin käynnistysK46 Bosch 0 332 209 152 / Wehrle 20 201 103 Rele diodilla, polttomoottorin sammutusK47 Bosch 0 332 209 152 / Wehrle 20 201 103 Rele diodilla, polttomoottorin nopeus 2K48 Bosch 0 332 209 152 / Wehrle 20 201 103 Rele diodilla, polttomoottorin nopeus 3K70 Bosch 0 332 209 152 / Wehrle 20 201 103 Rele diodilla, korin kääntöK71 Bosch 0 332 209 152 / Wehrle 20 201 103 Rele diodilla, korin kääntöK94 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, varalasku teleskooppiK95 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, varalasku jibK96 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, varalasku yläpuomiK97 66161 Molex 121207-0082 (S28200TC310R) MPM LED+diodi kela, varalasku alapuomiM1 65191 MG90LC2-24FF165B SähkömoottoriM2 66036 Linak 301200-00150225 Karamoottori, korin kääntöP1 64152 Unideck 06200001 KäyttötuntimittariP2 66039 PT3550 Paineanturi, pumppuP3 66039 PT3550 Paineanturi, puomiP4 66039 PT3550 Paineanturi, tukijalatP5 66039 PT3550 Paineanturi, siirtoajoP6 A419941 W-M-6/60-3-A-TR / 5333A Ilman lämpötila-anturiP7 Hydrauliöljyn lämpötilakytkinP8 66119 S1.B45.3.0140.O.FOPX.S1.L.1.I2 Polttoaineen pinnankorkeuskytkinP9 Hydrauliöljyn pinnankorkeuskytkinP10 66033 MRW-500, Moba Ylikuorma-anturiR1 66136 1507816 Päätevastus, 120ohmR2 75009 R120 Vastus, alaohjausnäppäimistö CAN-päätevastusR3 75005 R330 Vastus, kuormanvalvontaR4 75005 R330 Vastus, kuormanvalvontaS1 A419326 A-B 800FP-MT443LX11 Hätäseispainike, alhaallaS2 A419326 A-B 800FP-MT443LX11 Hätäseispainike, ylhäälläS3 66102 XPE-A110 JalkapoljinS4 66069 EM1G12ZM COMEPI rajakytkin, kuljetusasennon valvontaS5 66069 EM1G12ZM COMEPI rajakytkin, teleskoopin ulottumaS6 66069 EM1G12ZM COMEPI rajakytkin, teleskoopin ulottumaS7 66069 EM1G12ZM COMEPI rajakytkin, tukijalan maakosketusS8 66069 EM1G12ZM COMEPI rajakytkin, tukijalan maakosketusS9 66069 EM1G12ZM COMEPI rajakytkin, tukijalan maakosketusS10 66069 EM1G12ZM COMEPI rajakytkin, tukijalan maakosketusS11 66127 CG 4 SF6788 *FS1 / S00 V750D/2C/11 Avainkytkin, ohjauspaikanvalintaS12 A419638 A-B 800FP-F1PX104 Hätäkäytön ohituskytkin

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Osaluettelo

Nimi Osanumero Tyyppi KuvausS13 66069 EM1G12ZM COMEPI rajakytkin, kauko-ohjaimen paikkaS14 66069 EM1G12ZM COMEPI rajakytkin, kauko-ohjaimen paikkaS22 64141 Member´s 080987.00 PääkytkinS23 A419327 A-B 800FP-SM22PX10 Vipukytkin, vilkutS24 A419324 A-B 800FP-F1PX10 Sähkömoottorin pakko-ohjauspainikeS25 A419327 A-B 800FP-SM22PX10 Vipukytkin, työvalotS94 A419324 A-B 800FP-F1PX10 Varalaskupainike, korissaS94A A419324 A-B 800FP-F1PX10 Varalaskupainike, alhaallaS95 A419324 A-B 800FP-F1PX10 Varalaskupainike, korissaS95A A419324 A-B 800FP-F1PX10 Varalaskupainike, alhaallaS96 A419324 A-B 800FP-F1PX10 Varalaskupainike, korissaS96A A419324 A-B 800FP-F1PX10 Varalaskupainike, alhaallaS97 A419324 A-B 800FP-F1PX10 Varalaskupainike, korissaS97A A419324 A-B 800FP-F1PX10 Varalaskupainike, alhaallaT1 65183 CME 1206 AkkulaturiT20 66219 Honda 31750-Z2E-803 Lataussäädin

3 / 3Mikko Toivanen

18.11.2015

Leguan 135 Parameters and error codes Version 4/2015

1 / 4 Mikko Toivanen 30.10.2015

Parameter list (user level)

Number Default setting

Description Password level

Comment

1 186 Number_Of_Parameters

2 27 Version_Of_Parameters

3 5 Time_To_Motor_Idling 1

4 20 Idling_Time_After_First_Start 1

5 10 Idling_Time_After_Restart 1

6 29 Propo_Outriggers_Up_Comb_Engine 1

7 33 Propo_Outriggers_Lifted_Up_Comb_Engine 1

8 23 Propo_Outriggers_Down_Comb_Engine 1

9 30 Propo_Outriggers_Up_Electric_Motor 1

10 35 Propo_Outriggers_Lifted_Up_Electric_Motor 1

11 30 Propo_Outriggers_Down_Electric_Motor 1

12 30 Autolevel_Lifting_Time_Start_Comb_Engine 1

13 30 Autolevel_Relifting_Time_Comb_Engine 1

14 30 Autolevel_Lifting_Time_Start_Electric_Motor 1

15 25 Autolevel_Relifting_Time_Electric_Motor 1

16 0 Temperature_Unit 1 0=°C / 1=°F

187 1012 Password_1

Parameter settings are always machine specific and thus may differ from the default settings on the list. All machines have saved correct default parameters when they are dispatched from the factory. These factory parameters are possible to reset from service page on Scanreco remote controller. After resetting to factory default values the platform load must always be calibrated. (see Leguan 135 Service manual, 5.4)



Application specific error codes

Error code Description Comment Fixing the fault

02010000 Emergency stop activated Twist all emergency stop buttons up. If the error code still exists, check the wiring and the functionality of the contact blocks on the emergency stop buttons.

01030000 Fault in the overload control Activates when the reading of the overload sensor is over 500 kg, below -100 kg or the difference of measuring channels is too high (difference over 30 kg).

Remove all load from the basket. Turn off the main power switch, wait 10 seconds and turn on the main power. Check the readings of both overload measuring channels. If the measures differ too much calibrate the platform load (see service manual 5.4). Load sensor may show over 500 kg load if the main power switch is on but the logic has been turned off from the control position switch. As the logic starts wait 10-30 seconds for the load sensor calibrates its outputs correctly. The overload alarm should then go off (assuming there isn’t overload in the basket already). Check also the condition of the cables.

01040000 Fault in the boom outreach control

Activates when the boom outreach monitoring limit switches aren’t giving expected signals to the logic.

Check that both limit switches on the boom outreach control are properly placed and activate when the telescopic boom comes out. If necessary adjust the limit switches so that they recognize the telescopic booms outreach. Check also the condition of the cables.

02050000 Fault in the outrigger control Activates when the outrigger ground touch monitoring limit switches aren’t giving expected signals to the logic.

Check the activation of all limit switches on the outriggers and the condition of the cables. If necessary replace the faulty limit switch or cable.

02060000 Fault in the boom transport position control

Actives when the boom transport position monitoring limit switch isn’t giving expected signals to the logic.

The contacts of the limit switch have to change their output signals within a very small time. Lower the boom to transport support and check the functionality of the limit switch and the condition of the cabling. If necessary replace the faulty cable or limit switch.




01080000 Fault in the control position monitoring

Activates when the control position limit switches aren’t giving expected signals to the logic and the operator tries to use boom movements in radio control mode.

Boom movements are disabled if the radio controller isn’t placed in the correct position in the platform or the controller isn’t connected to the cable. Place the remote controller to docking station on the platform or attach the cable to the controller. If the error code still exists check the condition of the cables and the functionality of the limit switches.

02090000 Fault in the safety function override system

Check that the functionality of the safety function override button matches electrical diagram. If any of the contact blocks is faulty, replace it. If the fault still exists contact nearest Leguan service.

02200000 Overload in outputs Some output is taking more current than is allowed.

Check the outputs of the safety logic. It is possible that a solenoid of some valve is broken or there is a broken cable that is grounding the output before the valve. Check the condition of the cables.

02210000 Faulty parameter Parameter value is out of setting range.

Reset the factory default parameters (see service manual, 5.4). If the fault still exists, contact the manufacturer.

01250000 Fault in CAN bus of the inclination sensor

The traffic in CAN bus is faulty.

Check the condition of the inclination sensors CAN cable. Inclination sensor also informs about CAN bus fault on its built-in led’s.

02260000 Fault in CAN bus of the lower control panel


Check the condition of the lower control panels CAN cable. The error code for the lower control panels CAN bus will disappear when remote control is selected as the active control position.

02270000 Fault in CAN bus of the remote control


Check the condition of the remote control receivers CAN cable. The error code for the lower control panels CAN bus will disappear when remote control is selected as the active control position.




01230000 Alarm for too low hydraulic oil level

In use only if the option is installed to the machine. Add more hydraulic oil according to the operators manual. (see operators manual 15.4)

01240000 Alarm for too high oil temperature

In use only if the option is installed to the machine. Turn off the machine and wait until the oil temperature has decreased enough.

IFM safety logic error codes

IFM safety logic can give its own error codes in addition to the system specific error codes listed above. These error codes are listed in another attachment.

Scanreco radio receiver error codes Scanreco radio receiver indicates its error codes on two part seven segment display (picture below). These error codes are listed in another attachment.

ifm System manual ecomatmobile SafetyController (CR7132) runtime system v01 2014-03-18

Error codes and diagnostic information Error codes

373

7.2 Error codes

Error cause (1st byte) .......................................................................................................................... 373Error source (2nd byte)........................................................................................................................ 375Application-specific error code (3rd byte)............................................................................................ 377Error class (4th byte) ........................................................................................................................... 377

12334

Overview of the error codes output by some of the function blocks. The 32-bit error code consists of four 8-bit values (DWORD).

4th byte 3rd byte 2nd byte 1st byte

Error class Application-specific error code Error source Error cause

>

7.2.1 Error cause (1st byte) 12336

Valuedec | hex

Description

0 00 No error cause or: application-specific error

1 01 Break

2 02 Short

4 04 Overload

5 05 Undervoltage

6 06 Overvoltage

7 07 Current control

8 08 Safety diagnosis on current input

9 09 Safety diagnosis on voltage input

10 0A Safety diagnosis on activated output (stuck-at-1, cross fault)

11 0B Safety diagnosis on SafetySwitch

12 0C Safety diagnosis on analogue multiplexer

13 0D Safety diagnosis on deactivated output (stuck-at-1)

24 18 Temperature

25 19 Relay contact

26 20 Memory test

27 21 Address test

48 30 Interrupt system

49 31 Time base

50 32 Command execution

51 33 Integer overflow or: division by zero

56 38 FPU underflow

57 39 FPU overflow

58 3A FPU division by zero

59 3B FPU unspecific error

374



Valuedec | hex

Description

112 70 Communication to coprocessor

128 80 CRC

129 81 Corrupt data

130 82 Memory protection

131 83 No data

144 90 Watchdog

145 91 Trap

146 92 Safety core stopped

147 93 Assertion failed

192 C0 CANsafety

194 C2 CAN bus-off

195 C3 CANsafety reception error

196 C4 CANsafety transmission error

197 C5 CANsafety configuration corrupt

224 E0 Board link warning (ExtendedController)

225 E1 Board link error (ExtendedController)

240 F0 Serial number

241 F1 Runtime system expired

248 F8 Wrong parameter



375

>

7.2.2 Error source (2nd byte) 12337

Valuedec | hex

Description

0 00 No error source or: application-specific error

1 01 CPU

2 02 Peripheral processor

3 03 Coprocessor

4 04 Safety core

5 05 Safety core (code)

6 06 Safety core (trap)

8 08 Floating point unit

16...31 10...1F Input 0...15 (standard side)

32...63 20...3F Input 0...31 (extended side)

64...79 40...4F Output 0...15 (standard side)

80..111 50...6F Output 0...31 (extended side)

128...131 80...83 CAN 1...4

144 90 Relay voltage VBBo (standard side)

145 91 Relay voltage VBBr (standard side)

146 92 VBBo (standard side)

147 93 VBBr (standard side)

148 94 VBBs (standard side)

149 95 Terminal 15

150 96 Relay voltage VBB1 (extended side)




154 9A VBBRel (extended side)

155 9B VBB1 (extended side)

156 9C VBB2 (extended side)

157 9D VBB3 (extended side)

158 9E VBB4 (extended side)

160 A0 Analogue multiplexer

161 A1 Analogue reference

176 B0 Internal flash

177 B1 External flash

178 B2 Internal RAM

179 B3 External RAM

192 C0 Code Startupper

193 C1 Code Bootloader

376



Valuedec | hex

Description

194 C2 Code runtime system

195 C3 Data peripheral processor

196 C4 Boot project

197 C5 Code application program

198 C6 Scratchpad RAM

199 C7 Code peripheral processor

224 E0 System data

225 E1 System settings

226 E2 System information

227 E3 Calibration data

228 E4 FRAM / MRAM (user's area)



377

>

7.2.3 Application-specific error code (3rd byte) 12338

In case of an application-specific error, it is requested that: ERRORCODE byte 1 = error cause = 0x00 ERRORCODE byte 2 = error source = 0x00

Signal application-specific errors to the controller using ERROR_REPORT ( page 364).

Valuedec | hex

Description

0 00 No application-specific error

> 0 > 00 Application-specific error

>

7.2.4 Error class (4th byte)

Error codes: general errors (standard side) ........................................................................................ 378Error codes: general errors (extended side)........................................................................................ 382Error codes: serious errors .................................................................................................................. 386Error codes: Fatal errors...................................................................................................................... 391

12339

Value

dec | hexDescription

0 00 no error

1 01 general error

2 02 serious error

3 03 critical error

4 04 fatal error

378



>

Error codes: general errors (standard side)

13737

The following general errors have been defined: ERRORCODE byte 3 = application-specific error = 0x00 ERRORCODE byte 4 = error class = 0x01

Byte 1 Byte 2

Error cause [hex] Error source [hex] Description Function block

01 10 Wire break I00 INPUT_ANALOG










01 1A Wire break I10 INPUT_ANALOG

01 1B Wire break I11 INPUT_ANALOG

01 1C Wire break I12 INPUT_ANALOG

01 1D Wire break I13 INPUT_ANALOG

01 1E Wire break I14 INPUT_ANALOG

01 1F Wire break I15 INPUT_ANALOG

01 40 Wire break Q00










01 4A Wire break Q10

01 4B Wire break Q11

01 4C Wire break Q12

01 4D Wire break Q13

01 4E Wire break Q14

01 4F Wire break Q15

02 10 Short circuit I00 INPUT_ANALOG





379

Byte 1 Byte 2









02 1A Short circuit I10 INPUT_ANALOG

02 1B Short circuit I11 INPUT_ANALOG

02 1C Short circuit I12 INPUT_ANALOG

02 1D Short circuit I13 INPUT_ANALOG

02 1E Short circuit I14 INPUT_ANALOG

02 1F Short circuit I15 INPUT_ANALOG

02 40 Short circuit Q00










02 4A Short circuit Q10

02 4B Short circuit Q11

02 4C Short circuit Q12

02 4D Short circuit Q13

02 4E Short circuit Q14

02 4F Short circuit Q15

04 10 Overcurrent I00 INPUT_ANALOG










04 1A Overcurrent I10 INPUT_ANALOG

04 1B Overcurrent I11 INPUT_ANALOG

380



Byte 1 Byte 2


04 1C Overcurrent I12 INPUT_ANALOG

04 1D Overcurrent I13 INPUT_ANALOG

04 1E Overcurrent I14 INPUT_ANALOG

04 1F Overcurrent I15 INPUT_ANALOG

04 40 Overload Q00

04 41 Overload Q01

04 42 Overload Q02

04 43 Overload Q03

04 44 Overload Q04

04 45 Overload Q05

04 46 Overload Q06

04 47 Overload Q07

04 48 Overload Q08

04 49 Overload Q09

04 4A Overload Q10

04 4B Overload Q11

04 4C Overload Q12

04 4D Overload Q13

04 4E Overload Q14

04 4F Overload Q15

05 9B Undervoltage VBB1

05 9C Undervoltage VBB2

05 9D Undervoltage VBB3

05 9E Undervoltage VBB4

05 9A Undervoltage VBBrel

06 9B Overvoltage VBB1

06 9C Overvoltage VBB2

06 9D Overvoltage VBB3

06 9E Overvoltage VBB4

06 9A Overvoltage VBBRel

07 40 Current Control Q00










07 4A Current Control Q10



381

Byte 1 Byte 2


07 4B Current Control Q11

07 4C Current Control Q12

07 4D Current Control Q13

07 4E Current Control Q14

07 4F Current Control Q15

C2 80 CAN1 bus-off

C2 81 CAN2 bus-off

C2 82 CAN3 bus-off

C2 83 CAN4 bus-off

F8 10 Parameter error I00 SET_INPUT_MODE










F8 1A Parameter error I10 SET_INPUT_MODE

F8 1B Parameter error I11 SET_INPUT_MODE

F8 1C Parameter error I12 SET_INPUT_MODE

F8 1D Parameter error I13 SET_INPUT_MODE

F8 1E Parameter error I14 SET_INPUT_MODE

F8 1F Parameter error I15 SET_INPUT_MODE

382



>

Error codes: general errors (extended side)

13778

The following general errors have been defined: ERRORCODE byte 3 = application-specific error = 0x00 ERRORCODE byte 4 = error class = 0x01

Byte 1 Byte 2


01 20 Wire break I00_E INPUT_ANALOG_E










01 2A Wire break I10_E INPUT_ANALOG_E

01 2B Wire break I11_E INPUT_ANALOG_E

01 2C Wire break I12_E INPUT_ANALOG_E

01 2D Wire break I13_E INPUT_ANALOG_E

01 2E Wire break I14_E INPUT_ANALOG_E

01 2F Wire break I15_E INPUT_ANALOG_E

01 50 Wire break Q00_E










01 5A Wire break Q10_E

01 5B Wire break Q11_E

01 5C Wire break Q12_E

01 5D Wire break Q13_E

01 5E Wire break Q14_E

01 5F Wire break Q15_E






383

Byte 1 Byte 2









01 6A Wire break Q26_E

01 6B Wire break Q27_E

01 6C Wire break Q28_E

01 6D Wire break Q29_E

01 6E Wire break Q30_E

01 6F Wire break Q31_E

02 20 Short circuit I00_E INPUT_ANALOG_E










02 2A Short circuit I10_E INPUT_ANALOG_E

02 2B Short circuit I11_E INPUT_ANALOG_E

02 2C Short circuit I12_E INPUT_ANALOG_E

02 2D Short circuit I13_E INPUT_ANALOG_E

02 2E Short circuit I14_E INPUT_ANALOG_E

02 2F Short circuit I15_E INPUT_ANALOG_E

02 50 Short circuit Q00_E










02 5A Short circuit Q10_E

02 5B Short circuit Q11_E

384



Byte 1 Byte 2


02 5C Short circuit Q12_E

02 5D Short circuit Q13_E

02 5E Short circuit Q14_E

02 5F Short circuit Q15_E











02 6A Short circuit Q26_E

02 6B Short circuit Q27_E

02 6C Short circuit Q28_E

02 6D Short circuit Q29_E

02 6E Short circuit Q30_E

02 6F Short circuit Q31_E

04 20 Overcurrent I00_E INPUT_ANALOG_E










04 2A Overcurrent I10_E INPUT_ANALOG_E

04 2B Overcurrent I11_E INPUT_ANALOG_E

04 2C Overcurrent I12_E INPUT_ANALOG_E

04 2D Overcurrent I13_E INPUT_ANALOG_E

04 2E Overcurrent I14_E INPUT_ANALOG_E

04 2F Overcurrent I15_E INPUT_ANALOG_E

04 50 Overload Q00_E







385

Byte 1 Byte 2







04 5A Overload Q10_E

04 5B Overload Q11_E

04 5C Overload Q12_E

04 5D Overload Q13_E

04 5E Overload Q14_E

04 5F Overload Q15_E

05 9B Undervoltage VBB1

05 9C Undervoltage VBB2

05 9D Undervoltage VBB3

05 9E Undervoltage VBB4

05 9A Undervoltage VBBrel

06 9B Overvoltage VBB1

06 9C Overvoltage VBB2

06 9D Overvoltage VBB3

06 9E Overvoltage VBB4

06 9A Overvoltage VBBRel

07 50 Current Control Q00_E










07 5A Current Control Q10_E

07 5B Current Control Q11_E

07 5C Current Control Q12_E

07 5D Current Control Q13_E

07 5E Current Control Q14_E

07 5F Current Control Q15_E

E1 00 Board link error (only CR7132)

386



Error codes: serious errors

13738

The following serious errors have been defined: ERRORCODE byte 3 = application-specific error = 0x00 ERRORCODE byte 4 = error class = 0x02

Byte 1 Byte 2












01 1A Wire break I10 INPUT_ANALOG

01 1B Wire break I11 INPUT_ANALOG

01 1C Wire break I12 INPUT_ANALOG

01 1D Wire break I13 INPUT_ANALOG

01 1E Wire break I14 INPUT_ANALOG

01 1F Wire break I15 INPUT_ANALOG











01 4A Wire break Q10

01 4B Wire break Q11

01 4C Wire break Q12

01 4D Wire break Q13

01 4E Wire break Q14

01 4F Wire break Q15






387

Byte 1 Byte 2









02 1A Short circuit I10 INPUT_ANALOG

02 1B Short circuit I11 INPUT_ANALOG

02 1C Short circuit I12 INPUT_ANALOG

02 1D Short circuit I13 INPUT_ANALOG

02 1E Short circuit I14 INPUT_ANALOG

02 1F Short circuit I15 INPUT_ANALOG











02 4A Short circuit Q10

02 4B Short circuit Q11

02 4C Short circuit Q12

02 4D Short circuit Q13

02 4E Short circuit Q14

02 4F Short circuit Q15











04 1A Overcurrent I10 INPUT_ANALOG

04 1B Overcurrent I11 INPUT_ANALOG

388



Byte 1 Byte 2


04 1C Overcurrent I12 INPUT_ANALOG

04 1D Overcurrent I13 INPUT_ANALOG

04 1E Overcurrent I14 INPUT_ANALOG

04 1F Overcurrent I15 INPUT_ANALOG

04 40 Overload Q00

04 41 Overload Q01

04 42 Overload Q02

04 43 Overload Q03

04 44 Overload Q04

04 45 Overload Q05

04 46 Overload Q06

04 47 Overload Q07

04 48 Overload Q08

04 49 Overload Q09

04 4A Overload Q10

04 4B Overload Q11

04 4C Overload Q12

04 4D Overload Q13

04 4E Overload Q14

04 4F Overload Q15

05 90 Undervoltage VBBO

05 91 Undervoltage VBBR

06 94 Overvoltage VBBS (> 32 V)

06 90 Overvoltage VBBO

06 91 Overvoltage VBBR

08 10 Safety diagnosis I00 (current)










08 1A Safety diagnosis I10 (current)

08 1B Safety diagnosis I11 (current)

08 1C Safety diagnosis I12 (current)

08 1D Safety diagnosis I13 (current)

08 1E Safety diagnosis I14 (current)

08 1F Safety diagnosis I15 (current)



389

Byte 1 Byte 2


09 10 Safety diagnosis I00 (voltage)










09 1A Safety diagnosis I10 (voltage)

09 1B Safety diagnosis I11 (voltage)

09 1C Safety diagnosis I12 (voltage)

09 1D Safety diagnosis I13 (voltage)

09 1E Safety diagnosis I14 (voltage)

09 1F Safety diagnosis I15 (voltage)

0A 40 Safety diagnosis Q00










0A 4A Safety Diagnose Q10

0A 4B Safety diagnosis Q11

0A 4C Safety diagnosis Q12

0A 4D Safety diagnosis Q13

0A 4E Safety diagnosis Q14

0A 4F Safety diagnosis Q15

0B 10 SafetySwitch error I00 SAFETY_SWITCH








0D 40 Safety diagnosis Q00

390



Byte 1 Byte 2











0D 4A Safety Diagnose Q10

0D 4B Safety diagnosis Q11

0D 4C Safety diagnosis Q12

0D 4D Safety diagnosis Q13

0D 4E Safety diagnosis Q14

0D 4F Safety diagnosis Q15

83 E3 IOs not calibrated

C3 80 CANsafety reception error CAN1




C4 80 CANsafety transmission error CAN1




F8 00 Parameter error All function blocks with ERROR output











F8 1A Parameter error I10 SET_INPUT_MODE

F8 1B Parameter error I11 SET_INPUT_MODE

F8 1C Parameter error I12 SET_INPUT_MODE

F8 1D Parameter error I13 SET_INPUT_MODE

F8 1E Parameter error I14 SET_INPUT_MODE

F8 1F Parameter error I15 SET_INPUT_MODE



391

>

Error codes: Fatal errors

13739

The following fatal errors have been defined: ERRORCODE byte 3 = application-specific error = 0x00 ERRORCODE byte 4 = error class = 0x04

Fatal errors are only visible in the application if the TEST input was already active when the error occurred.

Fatal errors normally lead to a STOP of the controller; however, this will not be the case with an active TEST input.

Byte 1 Byte 2


06 94 Overvoltage VBBS (> 34 V)

06 95 Overvoltage terminal 15

18 00 Temperature error

19 90 Contact error relay VBBO

19 91 Contact error relay VBBR

80 E3 Corrupt calibration data

7.1 General description

7.2 Central Unit Error codes

7 Error code indications

!"#$"#%$&!'"()*%$+!,"'!*$-,."$(,/$"#%$+%,"'(*$-,."$('%$%0)%//%/$1."#$2!,3"(,"$4(5*"$0!,."!'.,67$

any errors noticed by the system will result in interruption of all operational commands.

8**$!4$"#%$+%,"'(*$-,."3$!5"95"3$('%$4(5*"$0!,."!'%/$4!'$3#!'"$2.'25."3$(,/:!'$!;%'*!(/37$.,$"#%$%;%,"$

of an error being detected the Central Unit will alert that an error has occurred via the external

<=>$?"("53$(,/$.,/.2("%$"#%$(99'!9'.("%$%''!'$2!/%$;.($"#%$<=>@/.39*(A7$"#%$+%,"'(*$-,."$1.**$"#%,$

reset to operational mode if possible.

%*!1$%B(09*%$C!12#('"$!,$)%#(;.!5'D

E#.3$4(5*"$3%F5%,2%$1.**$"(G%$(,$(99'!B.0("%*A$H$3%2!,/3$E#%$%B"%',(*$<=>$?E8E-?$1.**$C(3#$

'(9./*A$.,$'%/$2!*!5'$/%2*('.,6$"#("$(,$%''!'$#(3$)%%,$/%"%2"%/7$4!'$0!'%$/%"(.*%/$.,4!'0(".!,I$"#%$

LED-display must be monitored (or error code log available from diagnostics menu).

Fault detected

*Deactivate all outputs

*Alert via external LED

Status

*Declare type of error

(error code) via

LED-display

Reset system to

operational mode if pos-

sible.

Document type Document number PageRev

Service Manual S071 C 26 of 46

1/4

2nd 3rd Description Cause Action

01. 01 EEPROMfailure.

J,2!''%2"$2#%2G350$!,$==&KLM7$*(3"stored data will be set.

K%3%"$3A3"%07$.4$9%'3.3"%,"IRe-load application program.

01. 02 Flash memoryfailure.

J,2!''%2"$2#%2G350$!,$C(3#memory.

K%3%"$3A3"%07$.4$9%'3.3"%,"IRe-load application program.

01. 03 Stack memoryfailure.

Incorrect sizes of data in CANopen9'!"!2!*7$.,2!''%2"$/("(C!1$!'$3"(2G!;%'C!1N

System will self reset automatically.If persistent;Re-load application program.

01. 04 RAM memoryfailure.

Incorret RAM and/or hardware./%,".O2(".!,N

System will self reset automatically.If persistent;Re-load application program.

02. 01 Illegalvoltage; DVoutput.

DV-output error;DV-output (DV+) externally supplied

System will self reset.Check DV-output connection.Remove terminal connector and resetsystem.

02. 02 Short circuit;DV-output.

DV-output error;DV output (DV+) short circuited oroverloaded.

System will self reset.Check DV-output connection.Remove terminal connector and resetsystem.

02. 03 Safety switcherror

?(4%"A$31."2#$!5"95"$'%(/$)(2G$%''!'7incorrect voltage (High instead ofLow)

System will self reset.Remove all terminal connectors andreset system.

02. 04 Safety switcherror

?(4%"A$31."2#$!5"95"$'%(/$)(2G$%''!'7incorrect voltage (Low instead ofHigh)

System will self reset.Remove all terminal connectors andreset system.

03. 00 Illegalvoltage;Digital output

>.6."(*$!5"95"$PQ@QRS$.**%6(*$;!*"(6%7expected low signal but read as high(Could be any of the available 14

System will self reset.Check digital output connections.Remove terminal connector and reset

7.2.1 Error codes

E#%$<=>@/.39*(A$=''!'$2!/%3$('%$/.39*(A%/$.,$59$"!$T$3%F5%,2%37$"#.3$(**!13$"#%$+%,"'(*$-,."$"!$

declare exactly which output that is related to the error (where applicable).

First sequence: Letters E:r is presented declaring an error code

Second sequence: Type of error code

Third sequence: Additional information (where applicable)

In example:

The example would imply that there is an short circuit on output 1A

(Repeated 3 times)+ +



2/4

2nd 3rd Description 0utputs system

04. 00 Short circuit;Digital output

Digital output (1-14) short circuitedor overloaded (Could be any of theavailable 14 outputs)

System will self reset.Check digital output connections.Remove terminal connector and resetsystem.

05. 00 Error inputtriggered(Danfoss CUonly).

Error signal for Danfoss valvetriggered (Could be any of theavailable 8 inputs)

System will self reset.Check analogue output connections.Remove terminal connector and resetsystem.

06. x Illegal voltageanalogueoutput

Wrong voltage on analogue output(3rd sequence declares related!5"95"I$Q87Q UNSN


07. x Illegal voltageanalogueoutput

Wrong current on analogue output(3rd sequence declares related!5"95"I$Q87Q UNSN

System will self reset.Check connections.Remove terminal connector and resetsystem.

08. 01 CAN Passive CAN bus in passive mode. System will self reset.Check CAN connections.Check other nodes on bus and resetsystem.

08. 02 CAN I/OBuffer!;%'C!1

CAN overrun; either the CAN input orCAN output buffer are full

System will self reset.K%3%"$3A3"%07$'%@.,.".("%$;.($+8Vcontroller.

08. 03 CAN physicallayer error

Bad communication/transmission System will self reset.Check CAN connections.Check other nodes on bus and resetsystem.

08. 04 CAN PDOlengthexceeded

PDO length is to long System will self reset.K%3%"$3A3"%07$'%@.,.".("%$;.($+8Vcontroller.

08. 05 CAN PDOlength error

PDO length is too short System will self reset.K%3%"$3A3"%07$'%@.,.".("%$;.($+8Vcontroller.

08. 06 CAN TransmitCOB-IDcollision

To many collisions on CANbus System will self reset.Check CAN connections.Check other nodes on bus and reset3A3"%07$'%@.,.".("%$;.($+8V$2!,"'!**%'N

10. 00 PCU failure;Emergencystop

Error transmitted from PCU: Illegalsignal from PCU emergency stopswitch

System will self reset.Check emergency stop switch on PCU

11. 00 PCU failure;Analogueinput

Error transmitted from PCU:Analogue input active on start-up

System will self reset.Ensure all analogue inputs on PCU areat zero/neutral position.Restart PCU.

12 00 PCU failure;

Analogue input

Error transmitted from PCU: Signalredundancy test; illegal signal fromanalogue input.

System will self reset;Diagnose PCU via TEST MODE

13. n/a PCU failure;Analogueinput

Error transmitted from PCU: Signalredundancy test; illegal signal fromanalogue input.

System will self reset;Diagnose PCU via TEST MODE

7.2.1 Error codes (continued)



3/4

14. 01 ID programmingfailure

ID-code and/or parameter settingsnot accepted.

System will self reset.Verify ID-programming procedure.Reset application program.

14. 02 Programfailure

Programmable logic parameter error System will self reset.Reset application program.

15. x PWM outputfailure

Analogue output short circuited oroverloaded.(3rd sequence declares related!5"95"I$Q87Q UNSN


16. x PWM outputfailure

Analogue output not connected(Programmable feature).(3rd sequence declares related!5"95"I$Q87Q UNSN


17. 01 Low supplypower

<!1$9!1%'$3599*A$P %*!1$W7X$Y>+S System will self reset.Check power supply and supplyconnections.

17. 02 High supplypower

Z.6#$9!1%'$3599*A$P8)!;%$TH7[$Y>+S System will self reset.Check power supply and supplyconnections.

98. n/a -,/%O,%/$&+-error

-,/%O,%/$%''!'$.,$&+-N Diagnose PCU via TEST MODE

99. n/a -,/%O,%/$+-error

-,/%O,%/$%''!'$.,$+-N System will self reset.Remove all terminal connectorsCheck power supply and supplyconnections.Reset system.

7.2.1 Error codes (continued)

Indications Meaning

1 Analogue input 1 not at zero position during start-up








7.3 Portable Control Unit error codes

The Portable Control Unit monitors all analogue and digital inputs for faults and uses the Power-

LED and BUZZER to indicate alarms.

Below available error codes:



4/4

6/16 KÄYTTÖTAPAUKSET 7.11.2013

Vision Systems Oy PL 353, FI-40101 Jyväskylä, Finland, puhelin/tel. +358 (0)10 3227 100 , faksi/fax +358 (0)10 3227 119

Päätoimipaikka/Head Office [email protected], www.visionsystems.fi

4 TURVATOIMINTOJEN TOIMINTOKAAVIOT

4.1 SR-1 Hätäpysäytys rungossa ja työtasolla

4.2 SR-2 Hätäpysäytys kauko-ohjaimesta

deployment IOMonitor

Input and output diagnostics for wire breaks and short circuits

«error break»

Nodes::Inputs

«error break»

Nodes::Outputs

«CR7132»

Nodes::PLC

«solenoid»

Nodes:::

FreeFlowValv e

Nodes::SafeMode

«error short»

Nodes:::Inputs

«error short»

Nodes:::Outputs




deployment EmergencyStopRemote_SR-2

Emergency stop in remote controller

«CR7132»

Nodes::PLC

«safety switch»

Nodes::

EmergencyStopRemote

«solenoid»

Nodes::

FreeFlowValv e

Nodes:::SafeMode




4.3 SR-3 Korikuormanvalvonta

deployment BasketLoadMonitor_SR-3

Basket load monitor

«CR7132»

Nodes::PLC

«sensor»

Nodes::

LoadSensor

Nodes::

LoadLimitLightExceeded

Nodes::

LoadLimitHeav yExceeded

Nodes:::

SafeMode

Nodes:::

LimitTelescope

«solenoid»

Nodes::

DumpValv e

<=140kg

=>230kg




4.4 SR-4 Puomin asennonvalvonta

deployment BoomPositionMonitor_SR-4

Boom position monitor

Disabling boom control

Boom extension limitation on light load (140 kg)

«CR7132»

Nodes::PLC

Nodes:::

LoadLimitLightExceeded

Nodes:::

BoomExtensionLimit1

Nodes:::

BoomExtensionLimit2

Nodes:::

LimitTelescope

Nodes:::

DumpValv e

Nodes:::

SafeMode

Nodes:::

SafeOk




4.5 SR-5 Tukijalkavalvonta

deployment AllowBoom_SR-5

Outrigger monitor

«proximity switch»

Nodes:::

OutriggerRightFront


Nodes:::

OutriggerLeftFront


Nodes:::

OutriggerLeftRear


Nodes:::

OutriggerRightRear

«CR7132»

Nodes::PLC

«solenoid»

Nodes:::DumpValv e:

AllowBoomControl

Nodes:::SafeOk




4.6 SR-6 Puomin kuljetusasennonvalvonta

deployment AllowOutriggers_SR-6

Boom transport position monitor (allows drive and outriggers control)


Nodes::

BoomTransportPosition

«solenoid»

Nodes::Dump Valv e:

AllowDriv eAndOutriggerControl

«CR7132»

Nodes::PLC

Nodes:::SafeOk




4.7 SR-7 Koneen siirron esto

deployment AllowDriv e_SR-7

Boom transport position monitor (allows drive and outriggers control)


Nodes::

BoomTransportPosition

«CR7132»

Nodes::PLC

Nodes:::SafeOk«solenoid»

Nodes:::Dump Valv e:

AllowDriv eAndOutriggerControl




4.8 SR-8 Ohjauspaikan valvonta

deployment SelectControlLocation_SR-8

Control location monitor

«CR7132»

Nodes::PLC

«toggle switch»

Nodes::ControlLocation

«proximity sensor»

Nodes::RadioControllerPresent

«solenoid»

Nodes:::DumpValv e:

AllowBoomControl

Nodes:::SafeOk

－

INTRODUCTION

CONTENTS

SAFETY MESSAGES

EN

GLI

SH

FRA

NÇ

AIS

ES

PA

ÑO

L

ENGLISH

DAMAGE PREVENTION MESSAGES

OWNER’S MANUALMANUEL DE L’UTILISATEURMANUAL DEL PROPIETARIO

iGX240·iGX270·iGX340·iGX390

1

Thank you for purchasing a Honda engine. We want to help you to

get the best results from your new engine and to operate it safely.

This manual contains information on how to do that; please read it

carefully before operating the engine. If a problem should arise, or

if you have any questions about your engine, consult an

authorized Honda servicing dealer.

This manual should be considered a permanent part of the engine

and should remain with the engine if resold.

The engine exhaust from this product

contains chemicals known to the State of

California to cause cancer, birth defects

or other reproductive harm.

All information in this publication is based on the latest product

information available at the time of printing. Honda Motor Co., Ltd.

reserves the right to make changes at any time without notice and

without incurring any obligation. No part of this publication may

be reproduced without written permission.

Review the instructions provided with the equipment powered by

this engine for any additional information regarding engine

startup, shutdown, operation, adjustments or any special

maintenance instructions.

United States, Puerto Rico, and U.S. Virgin Islands:

We suggest you read the warranty policy to fully understand its

coverage and your responsibilities of ownership. The warranty

policy is a separate document that should have been given to you

by your dealer.

The purpose of these messages is to help prevent damage to your

engine, other property, or the environment.

Your engine or other property can be damaged if you

don’t follow instructions.

This word means:

You will also see other important messages that are preceded by

the word NOTICE.

Each message tells you what the hazard is, what can happen, and

what you can do to avoid or reduce injury.

You CAN be HURT if you don’t follow

instructions.

You CAN be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

You WILL be KILLED or SERIOUSLY

HURT if you don’t follow instructions.

These signal words mean:

A safety message alerts you to potential hazards that could hurt

you or others. Each safety message is preceded by a safety alert

symbol and one of three words, DANGER, WARNING, or

CAUTION.

Your safety and the safety of others are very important. We have

provided important safety messages in this manual and on the

engine. Please read these messages carefully.

2010 Honda Motor Co., Ltd. All Rights Reserved

HELPFUL TIPS &

......................SUGGESTIONS .13

...STORING YOUR ENGINE .13

................TRANSPORTING .15

TAKING CARE OF

....UNEXPECTED PROBLEMS .15

..TECHNICAL INFORMATION .16

.....Serial Number Location .16

Battery Connections for

....................Electric Starter .16

Carburetor Modifications for

.....High Altitude Operation .17

Emission Control System

.........................Information .17

..............................Air Index .18

.....................Specifications .18

........Tuneup Specifications .19

Quick Reference

.........................Information .19

................Wiring Diagrams .19

.CONSUMER INFORMATION .20

Warranty and Distributor/

Dealer Locator

.........................Information .20

Customer Service

.........................Information .20

.......................INTRODUCTION .1

................SAFETY MESSAGES .1

..........SAFETY INFORMATION .2

.....SAFETY LABEL LOCATION .2

COMPONENT & CONTROL

..............................LOCATIONS .3

................................FEATURES .4

BEFORE OPERATION

....................................CHECKS .5

..............................OPERATION .5

SAFE OPERATING

.....................PRECAUTIONS .5

......STARTING THE ENGINE .5

......STOPPING THE ENGINE .6

.....SERVICING YOUR ENGINE .7

THE IMPORTANCE OF

....................MAINTENANCE .7

......MAINTENANCE SAFETY .7

.......SAFETY PRECAUTIONS .7

MAINTENANCE

............................SCHEDULE .7

...........................REFUELING .8

...........................ENGINE OIL .9

............Recommended Oil .9

..................Oil Level Check .9

.........................Oil Change .9

......................AIR CLEANER .10

..................SEDIMENT CUP .11

......................SPARK PLUG .12

.............SPARK ARRESTER .12

....................................FUSE .13

37Z8R801

00X37-Z8R-8010

iGX240·iGX270·iGX340·iGX390

10/09/09 19:46:29 32Z8R800_001

SAFETY INFORMATION

SAFETY LABEL LOCATION

ENGLISH

(STANDARD TYPES)

(LOW PROFILE TYPES)

For EU Except EUMUFFLER CAUTION LABEL

For EUWARNING LABEL

(STANDARD TYPES)

Except EU

(LOW PROFILE TYPES)

STANDARD TYPES

LOW PROFILE TYPES

WARNING LABEL

WARNING LABEL

MUFFLER CAUTION LABEL

2

Understand the operation of all controls and learn how to stop

the engine quickly in case of emergency. Make sure the operator

receives adequate instruction before operating the equipment.

Your engine’s exhaust contains poisonous carbon monoxide.

Do not run the engine without adequate ventilation, and never

run the engine indoors.

The engine and exhaust become very hot during operation.

Keep the engine at least 1 meter (3 feet) away from buildings

and other equipment during operation. Keep flammable

materials away, and do not place anything on the engine while it

is running.

Do not allow children to operate the engine. Keep children and

pets away from the area of operation.

These labels warn you of potential hazards that can cause serious

injury. Read them carefully.

This label warns you of potential hazards that can cause serious

injury. Read it carefully.

not

included

supplied

with product

supplied

with product

supplied

with product

attached to

product

supplied

with product

attached to

product

supplied

with product

supplied

with product

Gasoline is highly flammable and explosive.

Stop the engine and let cool before refueling.

The engine emits toxic poisonous carbon

monoxide gas. Do not run in an enclosed area.

Read Owner’s Manual before operation.

If a label comes off or becomes hard to read, contact your Honda

servicing dealer for replacement.

supplied

with product

attached to

product

supplied

with product

Gasoline is highly flammable and explosive.

Stop the engine and let cool before refueling.

The engine emits toxic poisonous carbon

monoxide gas. Do not run in an enclosed area.

Read Owner’s Manual before operation.

Hot muffler can burn you.

Stay away if engine has been running.

These labels are packed in the box.

10/09/09 19:46:57 32Z8R800_002

ENGLISH

COMPONENT & CONTROL LOCATIONS

STANDARD TYPES

LOW PROFILE TYPES

ECM

MUFFLERFUEL TANK

RECOIL STARTER(applicable types)

AIR CLEANER

FUEL FILLER CAP

STARTER GRIP(applicable types)

FUSE(applicable types)

OIL FILLERCAP/DIPSTICK

ELECTRIC STARTER(applicable types)

OIL DRAIN PLUG

FUEL VALVE LEVER

CONTROL BOX(Indicator type)

ENGINESWITCH

(Hour meter type)

ENGINESWITCH

HOUR METER

OIL ALERTINDICATOR

OIL ALERTINDICATOR

ECM

CHOKE LEVER

CHOKE LEVER

AIR CLEANER

ELECTRIC STARTER(applicable types)

RECOIL STARTER(applicable types)

STARTER GRIP(applicable types)

OIL FILLERCAP/DIPSTICK

OIL DRAIN PLUGCONTROL BOX

FUSE(applicable types)

3

10/09/09 19:47:08 32Z8R800_003

ENGLISH

FEATURES

OIL ALERT SYSTEM

Control box type Oil Alert action

AUTO CHOKE AND THROTTLE CONTROL SYSTEM

STANDARD TYPES

LOW PROFILE TYPES

CONTROL BOX(Indicator type)

INDICATOR

HOURMETER

INDICATOR

CONTROL BOX(Hour meter type)

ECM

CHOKE LEVER

ECM

CHOKE LEVER

4

The Oil Alert system is designed to prevent engine damage

caused by an insufficient amount of oil in the crankcase. Before

the oil level in the crankcase can fall below a safe limit, the Oil

Alert system will either shut off the engine or issue a warning.

Refer to the instructions provided by the equipment manufacturer.

Indicator type

Hour meter type

The indicator blinks when the

engine starts/stops.

The engine stops.

The engine will not restart.

The indicator turns on when the

engine switch is in the ON position.

The engine stops.

The engine will not restart.

If the engine stops and/or will not restart, check the oil level (see

page ) before troubleshooting in other areas.

If you continue to operate the engine after the Oil Alert system has

been activated, you can damage the engine.

The ECM of this engine controls the choke valve and throttle valve

automatically.

When starting and warming up the engine, you do not need to

operate the choke lever unless the engine is hard to start using the

normal starting procedure.

9

‘‘Oil Alert is a registered trademark in the United States’’

10/09/09 19:47:21 32Z8R800_004

ENGLISH

IS YOUR ENGINE READY TO GO?

Check the General Condition of the Engine

Check the Engine

SAFE OPERATING PRECAUTIONS

STARTING THE ENGINE

BEFORE OPERATION CHECKS OPERATION

FUEL VALVE LEVER

ON

ENGINE SWITCH

5

For your safety, to ensure compliance with environmental

regulations, and to maximize the service life of your equipment, it

is very important to take a few moments before you operate the

engine to check its condition. Be sure to take care of any problem

you find, or have your servicing dealer correct it, before you

operate the engine.

Improperly maintaining this engine, or failure to

correct a problem before operation, can cause a

malfunction in which you can be seriously hurt or

killed.

Always perform a pre-operation inspection before

each operation, and correct any problem.

Before beginning your pre-operation checks, be sure the engine is

level and the engine switch is in the OFF position.

Always check the following items before you start the engine:

Look around and underneath the engine for signs of oil or

gasoline leaks.

Remove any excessive dirt or debris, especially around the

muffler and recoil starter.

Look for signs of damage.

Check that all shields and covers are in place, and all nuts, bolts,

and screws are tightened.

Check the fuel level (see page ). Starting with a full tank will

help to eliminate or reduce operating interruptions for refueling.

Check the engine oil level (see page ). Running the engine

with a low oil level can cause engine damage.

If the oil level in the crankcase falls below a safe limit, the Oil

Alert system will either shut off the engine or issue a warning.

However, to avoid the inconvenience of an unexpected

shutdown, always check the engine oil level before startup.

Check the air filter element (see page ). A dirty air filter

element will restrict air flow to the carburetor, reducing engine

performance.

Check the equipment powered by this engine.

Review the instructions provided with the equipment powered

by this engine for any precautions and procedures that should

be followed before engine startup.

For your safety, do not operate the engine in an enclosed area

such as a garage. Your engine’s exhaust contains poisonous

carbon monoxide gas that can collect rapidly in an enclosed area

and cause illness or death.

Exhaust contains poisonous carbon monoxide gas

that can build up to dangerous levels in closed areas.

Breathing carbon monoxide can cause

unconsciousness or death.

Never run the engine in a closed, or even partly

closed area where people may be present.

WITH ELECTRIC STARTER:

Review the instructions provided with the equipment powered by

this engine for any safety precautions that should be observed

with engine startup, shutdown, or operation.

Move the fuel valve lever to

the ON position.

Turn the engine switch to the

START position, and hold it

there until the engine starts.

Some engine applications do

not include the engine-

mounted control box with

engine switch shown here.

Refer to the instructions

provided by the equipment

manufacturer.

If the engine fails to start

within 5 seconds, release the

engine switch, and wait at

least 10 seconds before

operating the starter again.

Using the electric starter for

more than 5 seconds at a time

will overheat the starter

motor and can damage it.

When the engine starts,

release the engine switch,

allowing it to return to the ON

position.

Before operating the engine for the first time, please review the

SAFETY INFORMATION section on page and the BEFORE

OPERATION CHECKS on this page.

1.

2.

3.

4.

1.

2.

3.

4.

2

1.

2.

8

9

10

10/09/09 19:47:44 32Z8R800_005

ENGLISH

STOPPING THE ENGINE

STANDARD TYPES

LOW PROFILE TYPES

ON

FUEL VALVE LEVER

DDiirreeccttiioonn ttoo ppuullll

STARTER GRIP

ENGINE SWITCH

ENGINE SWITCH

FUEL VALVE LEVER

OOFFFF

OOFFFF

STARTER GRIP

DDiirreeccttiioonn ttoo ppuullll

6

WITH RECOIL STARTER:

Move the fuel valve lever to the ON position. Turn the engine switch to the OFF position.

Turn the engine switch to the ON position.

Pull the starter grip lightly until you feel resistance, then pull

briskly in the direction of the arrow as shown below. Return the

starter grip gently.

Move the fuel valve lever to the OFF position.

Do not allow the starter grip to snap back against the engine.

Return it gently to prevent damage to the starter.

1.

2.

3.

1.

2.

10/09/09 19:47:57 32Z8R800_006

＊＊

＊＊

－

－

－

ENGLISH

MAINTENANCE SCHEDULE

THE IMPORTANCE OF MAINTENANCE

Maintenance, replacement, or repair of the emission control

devices and systems may be performed by any engine repair

establishment or individual, using parts that are ‘‘certified’’ to

EPA standards.

MAINTENANCE SAFETY

Carbon monoxide poisoning from engine exhaust.

Burns from hot parts.

Injury from moving parts.

SAFETY PRECAUTIONS

SERVICING YOUR ENGINE

7

Replace paper element type only.

Service more frequently when used in dusty areas.

These items should be serviced by your servicing dealer,

unless you have the proper tools and are mechanically

proficient. Refer to the Honda shop manual for service

procedures.

For commercial use, log hours of operation to determine

proper maintenance intervals.

In Europe and other countries where the machinery directive

2006/42/EC is enforced, this cleaning should be done by your

servicing dealer.

Failure to follow this maintenance schedule could result in non-

warrantable failures.

Good maintenance is essential for safe, economical, and trouble-

free operation. It will also help reduce pollution.

Improper maintenance, or failure to correct a

problem before operation, can cause a malfunction in

which you can be seriously hurt or killed.

Always follow the inspection and maintenance

recommendations and schedules in this owner’s

manual.

To help you properly care for your engine, the following pages

include a maintenance schedule, routine inspection procedures,

and simple maintenance procedures using basic hand tools. Other

service tasks that are more difficult, or require special tools, are

best handled by professionals and are normally performed by a

Honda technician or other qualified mechanic.

The maintenance schedule applies to normal operating conditions.

If you operate your engine under severe conditions, such as

sustained high-load or high-temperature operation, or use in

unusually wet or dusty conditions, consult your Honda servicing

dealer for recommendations applicable to your individual needs

and use.

Some of the most important safety precautions follow. However,

we cannot warn you of every conceivable hazard that can arise in

performing maintenance. Only you can decide whether or not you

should perform a given task.

To ensure the best quality and reliability, use only new Honda

Genuine parts or their equivalents for repair and replacement.

Remember that an authorized Honda servicing dealer knows your

engine best and is fully equipped to maintain and repair it.

To reduce the possibility of fire or explosion, be careful when

working around gasoline. Use only a non-flammable solvent,

not gasoline, to clean parts. Keep cigarettes, sparks and flames

away from all fuel related parts.

Read the instructions before you begin, and make sure you have

the tools and skills required.

Make sure the engine is off before you begin any maintenance

or repairs. To prevent accidental startup, disconnect the spark

plug cap. This will eliminate several potential hazards:

Be sure there is adequate ventilation whenever you operate

the engine.

Let the engine and exhaust system cool before touching.

Do not run the engine unless instructed to do so.

Failure to properly follow maintenance instructions

and precautions can cause you to be seriously hurt or

killed.

Always follow the procedures and precautions in this

owner’s manual.

(1)

(2)

(3)

(4)

REGULAR SERVICE PERIOD (3)

Perform at every indicated

month or operating hour

interval, whichever comes

first.

ITEM

Each

Use

First

Month

or

20 Hrs

Every 3

Months

or

50 Hrs

(1)

Check level

Change

Check

Clean

Replace

Check-adjust

Replace

Check-clean

Check-adjust

Clean

Clean

Clean

Check

Engine oil

Air cleaner

Spark plug

Spark arrester

( )

Valve clearance

Sediment cup

Combustion

chamber

Fuel tank &

filter

Fuel tube

Every 6

Months

or

100 Hrs

(4)

(2)

Refer

to

Page

9

9

10

10

10

12

12

Shop

manual

11

Shop

manual

Shop

manual

Shop

manual

After every 1,000 Hrs. (2)

Every 2 years

(Replace if necessary) (2)

Every

Year

or

300 Hrs

(2)

applicable types

10/09/09 19:48:20 32Z8R800_007

ENGLISH

REFUELING (LOW PROFILE TYPES)

REFUELING (STANDARD TYPES)

Recommended FuelCHAIN

FUEL FILLER CAP

MAXIMUM FUEL LEVEL

8

Add fuel to the bottom of the maximum fuel level limit of the

fuel tank. Do not overfill. Wipe up spilled fuel before starting the

engine.

Refuel carefully to avoid spilling fuel. Do not fill the fuel tank

completely. It may be necessary to lower the fuel level depending

on operating conditions. After refueling, screw the fuel filler cap

back on until it clicks.

Keep gasoline away from appliance pilot lights, barbecues,

electric appliances, power tools, etc.

Spilled fuel is not only a fire hazard, it causes environmental

damage. Wipe up spills immediately.

Follow the equipment manufacturers recommendation for

refueling.

Unleaded gasoline

U.S.

Except U.S.

Pump octane rating 86 or higher

Research octane rating 91 or higher


This engine is certified to operate on unleaded gasoline with a

pump octane rating of 86 or higher (a research octane rating of 91

or higher).

Refuel in a well ventilated area with the engine stopped. If the

engine has been running, allow it to cool first. Never refuel the

engine inside a building where gasoline fumes may reach flames

or sparks.

You may use unleaded gasoline containing no more than 10%

ethanol (E10) or 5% methanol by volume. In addition, methanol

must contain cosolvents and corrosion inhibitors. Use of fuels

with content of ethanol or methanol greater than shown above

may cause starting and/or performance problems. It may also

damage metal, rubber, and plastic parts of the fuel system. Engine

damage or performance problems that result from using a fuel

with percentages of ethanol or methanol greater than shown

above are not covered under the Warranty.

If your equipment will be used on an infrequent or intermittent

basis, please refer to the fuel section of the STORING YOUR

ENGINE chapter (see page ) for additional information

regarding fuel deterioration.

Gasoline is highly flammable and explosive, and you

can be burned or seriously injured when refueling.

Stop the engine and keep heat, sparks, and flame

away.

Refuel only outdoors.

Wipe up spills immediately.

Fuel can damage paint and some types of plastic. Be careful not to

spill fuel when filling your fuel tank. Damage caused by spilled

fuel is not covered under the Distributor’s Limited Warranty.

Never use stale or contaminated gasoline or an oil/gasoline

mixture. Avoid getting dirt or water in the fuel tank.

With the engine stopped and on a level surface, remove the fuel

filler cap and check the fuel level. Refill the tank if the fuel level

is low.

1.

2.

13

10/09/09 19:48:37 32Z8R800_008

ENGLISH

ENGINE OIL

Recommended Oil

Oil Level Check

Oil Change

UPPER LIMIT

LOWER LIMIT

OIL FILLER CAP/DIPSTICK

AMBIENT TEMPERATURE

OIL FILLER CAP/DIPSTICK

WASHER

OIL DRAIN PLUG

OIL FILL HOLE(bottom edge)

9

Oil is a major factor affecting performance and service life.

Use 4-stroke automotive detergent oil.

SAE 10W-30 is recommended for general use. Other viscosities

shown in the chart may be used when the average temperature in

your area is within the indicated range.

Check the engine oil level with the engine stopped and in a level

position.

Remove the oil filler cap/dipstick and wipe it clean.

Insert the oil filler cap/dipstick into the oil filler neck as shown,

but do not push it in, then remove it to check the oil level.

Reinstall and tighten the oil filler cap/dipstick.

Running the engine with a low oil level can cause engine damage.

This type of damage is not covered by the Distributor’s Limited

Warranty.

The Oil Alert system will stop the engine or issue a warning before

the oil level falls below a safe limit. Refer to the instructions

provided by the equipment manufacturer.

Drain the used oil when the engine is warm. Warm oil drains

quickly and completely.

Place a suitable container below the engine to catch the used oil,

then remove the oil filler cap/dipstick, oil drain plug and washer.

Allow the used oil to drain completely, then reinstall the oil drain

plug and a new washer, and tighten the oil drain plug securely.

Please dispose of used motor oil in a manner that is compatible

with the environment. We suggest you take used oil in a sealed

container to your local recycling center or service station for

reclamation. Do not throw it in the trash, pour it on the ground,

or pour it down a drain.

Running the engine with a low oil level can cause engine

damage. This type of damage is not covered by the Distributor’s

Limited Warranty.

Use 4-stroke motor oil that

meets or exceeds the

requirements for API service

category SJ or later (or

equivalent). Always check the

API service label on the oil

container to be sure it includes

the letters SJ or later (or

equivalent).

Reinstall and tighten the oil filler cap/dipstick.

If the oil level is near or below the lower limit mark on the

dipstick, fill with the recommended oil to the upper limit mark

(bottom edge of the oil fill hole). Do not overfill.

With the engine in a level position, fill with the recommended oil

to the upper limit (bottom edge of the oil fill hole).

1.

2.

3.

4.

1.

2.

3.

4.

10/09/09 19:48:54 32Z8R800_009

ENGLISH

AIR CLEANER

Inspection (standard types)

Cleaning (standard types)

Inspection (low profile types)

Cleaning (low profile types)

LOW PROFILE TYPESPAPER FILTERELEMENT

NUT

AIR CLEANERCOVER

WING NUT

FOAM FILTERELEMENT

SILENCERNOSE GASKET

Dry

Soak Squeeze Oil Squeeze

AIR CLEANER CASE

AIR CLEANER COVER

CLIP

FOAM FILTERELEMENT

10

A dirty air cleaner will restrict air flow to the carburetor, reducing

engine performance. If you operate the engine in very dusty areas,

clean or replace the air filter more often than specified in the

MAINTENANCE SCHEDULE.

Operating the engine without an air filter, or with a damaged air

filter, will allow dirt to enter the engine, causing rapid engine wear.

This type of damage is not covered by the Distributor’s Limited

Warranty.

Remove the air cleaner cover and inspect the filter elements.

Clean or replace dirty filter elements. Always replace damaged

filter elements.

Remove the nut from the air

cleaner cover, and remove

the cover.

Remove the wing nut from

the air filter, and remove the

filter.

Remove the foam filter from

the paper filter.

Inspect both air filter

elements, and replace them if

they are damaged. Always

replace the paper air filter

element at the scheduled

interval (see page ).

Clean the filter elements if they are to be reused.

Paper filter element: Tap the filter element several times on a hard

surface to remove dirt, or blow compressed air [not exceeding 207

kPa (2.1 kgf/cm , 30 psi)] through the filter element from the inside.

Never try to brush off dirt; brushing will force dirt into the fibers.

Foam filter element: Clean in warm soapy water, rinse, and allow

to dry thoroughly. Or clean in non-flammable solvent and allow to

dry. Dip the filter element in clean engine oil, and then squeeze out

all excess oil. The engine will smoke when started if too much oil

is left in the foam.

Wipe dirt from the inside of the air cleaner case and cover using

a moist rag. Be careful to prevent dirt from entering the air duct

that leads to the carburetor.

Place the foam filter element over the paper element, and

reinstall the assembled air filter. Be sure the gasket is in place

beneath the air filter. Tighten the air filter wing nut securely.

Install the air cleaner cover, and tighten the nut securely.

Remove the air cleaner cover and inspect the filter element.

Visually inspect the filter element. Clean the foam filter element.

Always replace damaged filter element.

Unsnap the air cleaner cover clips and remove the air cleaner

cover.

Remove the foam filter element from the air cleaner case.

Inspect the foam filter element, and replace it if it is damaged.

3.

4.

1.

2.

5.

6.

7.

8.

1.

2.

7

3.

10/09/09 19:49:14 32Z8R800_010

ENGLISH

SEDIMENT CUP

Cleaning

(LOW PROFILE TYPES)

(LOW PROFILE TYPES)

LOW PROFILE TYPES

Dry

Soak Squeeze Squeeze

FILTER(Viewed fromthe bottom)

AlignOil

AIR CLEANER BASE

BREATHER TUBE

5 mm FLANGE BOLTS

AIR CLEANER CASE

SEDIMENT CUP

O-RING

FILTER

5 mm FLANGEBOLTS

6 mm FLANGE BOLT

6 mm FLANGE NUTS

11

Clean the foam filter element if it is to be reused.

Wipe dirt from the inside of the air cleaner case and cover, using

a moist rag. Be careful to prevent dirt from entering the air duct

that leads to the carburetor.

Install the foam filter element to the air cleaner case.

Install the air cleaner cover and snap the air cleaner cover clips.


can be burned or seriously injured when handling

fuel.

Handle fuel only outdoors.


away.


Unsnap the air cleaner cover clips, remove the air cleaner cover,

and remove the foam filter element (see page ).

Clean in warm soapy water, rinse, and allow to dry thoroughly. Or

clean in non-flammable solvent and allow to dry.

Dip the filter element in clean engine oil, then squeeze out all

excess oil. The engine will smoke when started if too much oil is

left in the foam.

Remove the four 5 mm flange bolts, one 6 mm flange bolt, and

air cleaner case.

Remove the two 6 mm flange nuts and pull out the breather tube,

then remove the air cleaner base.

Install the air cleaner base, breather tube, air cleaner case, foam

filter element, and air cleaner cover in the reverse order of

removal.

Reinstall the sediment cup as shown. Tighten the sediment cup

securely.

Wash the sediment cup in non-flammable solvent, and dry it

thoroughly.

Remove the fuel sediment cup, O-ring and filter.

Move the fuel valve lever to the OFF position.4.

5.

6.

7.

1.

2.

4.

5.

6.

10

3.

7.

10/09/09 19:49:33 32Z8R800_011

－－

－

－－

ENGLISH

SPARK PLUG

Recommended Spark Plugs:

SPARK ARRESTER (STANDARD TYPES)

Spark Arrester Removal

SPARK PLUG WRENCH

SEALINGWASHER

SIDEELECTRODE

SPARK PLUG

0.7 0.8 mm(0.028 0.031 in)

SPARK PLUG CAP

NUT

AIR CLEANERCOVER

WING NUT

AIR CLEANERELEMENT

SILENCERNOSE

GASKET

MUFFLERPROTECTOR

6 mm SCREW

MUFFLER

SPARK ARRESTER

5 mm SCREWS

5 mm SCREWS

5 mm SCREWS

12

BPR6ES (NGK)

W20EPR-U (DENSO)

The recommended spark plug has the correct heat range for

normal engine operating temperatures.

An incorrect spark plug can cause engine damage.

For good performance, the spark plug must be properly gapped

and free of deposits.

Measure the spark plug

electrode gap with a wire-

type feeler gauge. Correct the

gap, if necessary, by carefully

bending the side electrode.

The gap should be:

0.7 0.8 mm (0.028 0.031 in)

Install the spark plug carefully,

by hand, to avoid cross-

threading.

When installing a new spark plug, tighten 1/2 turn after the spark

plug seats to compress the washer.

When reinstalling the original spark plug, tighten 1/8 1/4 turn

after the spark plug seats to compress the washer.

A loose spark plug can overheat and damage the engine.

Overtightening the spark plug can damage the threads in the

cylinder head.

Inspect the spark plug.

Replace it if damaged or

badly fouled, if the sealing

washer is in poor condition,

or if the electrode is worn.

If the engine has been running, the muffler will be hot. Allow it to

cool before servicing the spark arrester.

The spark arrester must be serviced every 6 months or 100 hours

to keep it functioning as designed.

In Europe and other countries where the machinery directive

2006/42/EC is enforced, this cleaning should be done by your

servicing dealer.

Disconnect the spark plug cap, and remove any dirt from around

the spark plug area.

Remove the spark plug with a

13/16-inch spark plug wrench.

After the spark plug is seated, tighten with a 13/16-inch spark

plug wrench to compress the sealing washer.

Attach the spark plug cap to the spark plug.

Remove the nut, air cleaner cover, wing nut, air cleaner element,

silencer nose and gasket.

Remove the four 5 mm screws and one 6 mm screw from the

muffler protector, and remove the muffler protector.

Remove the two 5 mm screws from the spark arrester, and

remove the spark arrester from the muffler.

1.

2.

4.

3.

5.

6.

1.

2.

3.

7.

10/09/09 19:49:55 32Z8R800_012

ENGLISH

Spark Arrester Cleaning & Inspection

FUSE (applicable types)

Fuse change

STORING YOUR ENGINE

Storage Preparation

Cleaning

Fuel

Adding a Gasoline Stabilizer to Extend Fuel Storage Life

HELPFUL TIPS & SUGGESTIONS

SCREEN

FUSE(30 A)

STAY

FUSE SOCKET

FUSE COVER

13

Use a brush to remove carbon

deposits from the spark arrester

screen. Be careful not to damage

the screen. Replace the spark

arrester if it has breaks or holes.

Install the spark arrester to the

muffler.

Install the muffler protector and air cleaner in the reverse order

of disassembly.

If the fuse is blown, the battery cannot be charged.

Remove the fuse socket from the stay.

Remove the fuse cover and pull the fuse out.

Replace the fuse with a fuse of the same type and rating.

Never use a fuse with different rating from that specified.

Serious damage to the electrical system or fire may result.

Install the fuse cover to the fuse socket.

Install the fuse socket to the stay.

Proper storage preparation is essential for keeping your engine

trouble-free and looking good. The following steps will help to

keep rust and corrosion from impairing your engine’s function and

appearance, and will make the engine easier to start when you use

it again.

If the engine has been running, allow it to cool for at least half an

hour before cleaning. Clean all exterior surfaces, touch up any

damaged paint, and coat other areas that may rust with a light film

of oil.

Using a garden hose or pressure washing equipment can force

water into the air cleaner or muffler opening. Water in the air

cleaner will soak the air filter, and water that passes through the

air filter or muffler can enter the cylinder, causing damage.

Depending on the region where you operate your equipment, fuel

formulations may deteriorate and oxidize rapidly. Fuel

deterioration and oxidation can occur in as little as 30 days and

may cause damage to the carburetor and/or fuel system. Please

check with your servicing dealer for local storage

recommendations.

Gasoline will oxidize and deteriorate in storage. Deteriorated

gasoline will cause hard starting, and it leaves gum deposits that

clog the fuel system. If the gasoline in your engine deteriorates

during storage, you may need to have the carburetor and other

fuel system components serviced or replaced.

The length of time that gasoline can be left in your fuel tank and

carburetor without causing functional problems will vary with

such factors as gasoline blend, your storage temperatures, and

whether the fuel tank is partially or completely filled. The air in a

partially filled fuel tank promotes fuel deterioration. Very warm

storage temperatures accelerate fuel deterioration. Fuel

deterioration problems may occur within a few months, or even

less if the gasoline was not fresh when you filled the fuel tank.

Fuel system damage or engine performance problems resulting

from neglected storage preparation are not covered under the

Distributor’s Limited Warranty.

You can extend fuel storage life by adding a gasoline stabilizer

that is formulated for that purpose, or you can avoid fuel

deterioration problems by draining the fuel tank and carburetor.

When adding a gasoline stabilizer, fill the fuel tank with fresh

gasoline. If only partially filled, air in the tank will promote fuel

deterioration during storage. If you keep a container of gasoline

for refueling, be sure that it contains only fresh gasoline.

Add gasoline stabilizer following the manufacturer’s instructions.

After adding a gasoline stabilizer, run the engine outdoors for 10

minutes to be sure that treated gasoline has replaced the

untreated gasoline in the carburetor.

Stop the engine.

1.

2.

3.

1.

2.

3.

4.

5.

1.

2.

3.

10/09/09 19:50:17 32Z8R800_013

－－

ENGLISH

Engine Oil

Draining the Carburetor

(LOW PROFILE TYPES)

(LOW PROFILE TYPES)

Storage Precautions

NOTCH

Align the notch on the pulley withthe center of the recoil starter cover.

GASKET

DRAIN BOLT

RECOIL STARTER COVER

FUEL VALVE LEVER

O-RING

SEDIMENT CUP

14

Change the engine oil (see page ).

Remove the spark plug (see page ).

Pour a teaspoon 5 10 cm (5 10 cc) of clean engine oil into the

cylinder.

Pull the starter grip several times to distribute the oil in the

cylinder.

Reinstall the spark plug.

Pull the starter rope slowly until resistance is felt and the notch

on the starter pulley aligns with the center of the recoil starter

cover. This will close the valves so moisture cannot enter the

engine cylinder. Return the starter rope gently.


can be burned or seriously injured when handling

fuel.


away.

Handle fuel only outdoors.


Unsnap the air cleaner cover clips, remove the air cleaner cover,

and remove the foam filter element (see page ).

Remove the air cleaner case and pull out the breather tube, then

remove the air cleaner base (see page ).

Move the fuel valve lever to the OFF position.

Place an approved gasoline container below the carburetor, and

use a funnel to avoid spilling fuel.

Remove the carburetor drain bolt and gasket. Remove the

sediment cup and O-ring, then move the fuel valve lever to the

ON position.

After all the fuel has drained into the container, reinstall the

drain bolt, gasket, sediment cup and O-ring. Tighten the drain

bolt and sediment cup securely.

Install the air cleaner base, breather tube, air cleaner case, foam

filter element, and air cleaner cover in the reverse order of

removal.

If your engine will be stored with gasoline in the fuel tank and

carburetor, it is important to reduce the hazard of gasoline vapor

ignition. Select a well ventilated storage area away from any

appliance that operates with a flame, such as a furnace, water

heater, or clothes dryer. Also avoid any area with a spark-

producing electric motor, or where power tools are operated.

If possible, avoid storage areas with high humidity, because that

promotes rust and corrosion.

Keep the engine level in storage. Tilting can cause fuel or oil

leakage.

With the engine and exhaust system cool, cover the engine to

keep out dust. A hot engine and exhaust system can ignite or melt

some materials. Do not use sheet plastic as a dust cover.

A nonporous cover will trap moisture around the engine,

promoting rust and corrosion.

If equipped with a battery for electric starter types, recharge the

battery once a month while the engine is in storage.

This will help to extend the service life of the battery.

1.

2.

3.

4.

5.

6.

7.

6.

1.

2.

3.

4.

5.

9

12

10

11

10/09/09 19:50:37 32Z8R800_014

ENGLISH

Removal from Storage

TRANSPORTING

ENGINE WILL

NOT START

Correction

ENGINE WILL

NOT START

Possible Cause

Possible Cause

Possible Cause

Correction

CorrectionENGINE LACKS

POWER

TAKING CARE OF UNEXPECTED PROBLEMS

CONTROL BOX:Indicator type

CONTROL BOX:Hour meter type

OIL ALERTINDICATOR

OIL ALERTINDICATOR

HOURMETER

15

Check your engine as described in the BEFORE OPERATION

CHECKS section of this manual (see page ).

If the fuel was drained during storage preparation, fill the tank with

fresh gasoline. If you keep a container of gasoline for refueling, be

sure it contains only fresh gasoline. Gasoline oxidizes and

deteriorates over time, causing hard starting.

If the cylinder was coated with oil during storage preparation, the

engine will smoke briefly at startup. This is normal.

If the engine has been running, allow it to cool for at least 15

minutes before loading the engine-powered equipment on the

transport vehicle. A hot engine and exhaust system can burn you

and can ignite some materials.

Turn the fuel valve lever to the OFF position.

Keep the engine level when transporting to reduce the possibility

of fuel leakage.

To perform the OIL ALERT indicator check, the engine must be

connected to a battery and the engine switch must be in the ON

position.

Fuse burnt out.

Fuel, engine oil,

spark plug, etc.

Engine oil level

low.

Engine oil level

low.

ECM,

sensors, etc.

INDICATOR is

not lit.

INDICATOR is

lit.

INDICATOR

blinks.

(CONTROL BOX:

Indicator type)

INDICATOR

turns on.

(CONTROL BOX:

Hour meter type)

Take engine to

an authorized

Honda servicing

dealer, or refer

to shop manual.

Battery

discharged.

Fuse burnt out.

Choke closed.

Engine switch

OFF.

Engine oil level

low.

Out of fuel.

Bad fuel; engine

stored without

treating or

draining

gasoline, or

refueled with

bad gasoline.

Spark plug faulty,

fouled, or

improperly

gapped.

Spark plug wet

with fuel

(flooded engine).

Fuel filter

restricted,

carburetor

malfunction,

ignition

malfunction,

valves stuck, etc.

Filter element(s)

restricted.

Bad fuel; engine

stored without

treating or

draining

gasoline, or

refueled with

bad gasoline.

Fuel filter

restricted,

carburetor

malfunction,

ignition

malfunction,

valves stuck, etc.

Check air filter.

Check fuel.

Take engine to

an authorized

Honda servicing

dealer, or refer

to shop manual.

Electric starting:

Check battery

and fuse.

Check control

positions.

Check engine

oil level.

Check fuel.

Remove and

inspect spark

plug.

Take engine to

an authorized

Honda servicing

dealer, or refer

to shop manual.

Replace fuse

(p. 13).

after replacing fuse,

turn the engine

switch to the ON

position once

again.

Check the BEFORE

OPERATION

CHECKS (p. 5).

Fill with the

recommended oil

to the proper level

(p. 9).

Replace or repair

faulty components

as necessary.

Recharge battery.

Replace fuse.

(p. 13).

Move choke lever

to OPEN position

unless the engine

is warm.

Turn engine switch

to ON position.

Fill with the

recommended oil

to the proper level

(p. 9).

Refuel (p. 8).

Drain fuel tank and

carburetor (p. 14).

Refuel with fresh

gasoline (p. 8).

Gap or replace

spark plug (p. 12).

Dry and reinstall

spark plug.

Replace or repair

faulty components

as necessary.

Clean or replace

filter element(s)

(p. 10).

Drain fuel tank and

carburetor (p. 14).

Refuel with fresh

gasoline (p. 8).

Replace or repair

faulty components

as necessary.

1.

2.

3.

4.

1.

2.

3.

4.

5.

6.

1.

2.

3.

5

10/09/09 19:50:58 32Z8R800_015

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＋

＋

－

＋＋

－－

－

－

＋

－

ENGLISH

TECHNICAL INFORMATION

Serial Number Location

Battery Connections for Electric Starter (applicable types)

Recommended Battery

WARNING:

Wash hands after handling.

STANDARD TYPES

LOW PROFILE TYPES

SERIAL NUMBER &ENGINE TYPE LOCATION

POSITIVE ( )BATTERY CABLE

NEGATIVE ( ) BATTERY CABLE

SERIAL NUMBER &ENGINE TYPE LOCATION

16

Record the engine serial

number, engine type, and date

of purchase in the spaces below.

You will need this information

when ordering parts and when

making technical or warranty

inquiries.

Be careful not to connect the battery in reverse polarity, as this will

short circuit the battery charging system. Always connect the

positive ( ) battery cable to the battery terminal before

connecting the negative ( ) battery cable, so your tools cannot

cause a short circuit if they touch a grounded part while tightening

the positive ( ) battery cable end.

A battery can explode if you do not follow the correct

procedure, seriously injuring anyone nearby.

Keep all sparks, open flames, and smoking materials

away from the battery.

Battery posts, terminals, and related accessories

contain lead and lead compounds.

Connect the battery positive ( ) cable to the starter solenoid

terminal as shown.

Connect the battery negative ( ) cable to an engine mounting

bolt, frame bolt, or other good engine ground connection.

Connect the battery positive ( ) cable to the battery positive ( )

terminal as shown.

Connect the battery negative ( ) cable to the battery negative

( ) terminal as shown.

Coat the terminals and cable ends with grease.

Date Purchased: ______ / ______ / ______

Engine type: ___ ___ ___ ___

Engine serial number: __ __ __ __ __ __ __ __ __ __ __

12 V 24 Ah

1.

2.

3.

4.

5.

iGX240/iGX270/iGX340/iGX390

10/09/09 19:51:13 32Z8R800_016

ENGLISH

Carburetor Modifications for High Altitude Operation Emission Control System Information

Source of Emissions

The U.S., California Clean Air Act, and Environment Canada

Tampering and Altering

Problems That May Affect Emissions

17

At high altitude, the standard carburetor air-fuel mixture will be

too rich. Performance will decrease, and fuel consumption will

increase. A very rich mixture will also foul the spark plug and

cause hard starting. Operation at an altitude that differs from that

at which this engine was certified, for extended periods of time,

may increase emissions.

High altitude performance can be improved by specific

modifications to the carburetor. If you always operate your engine

at altitudes above 1,500 meters (5,000 feet), have your servicing

dealer perform this carburetor modification. This engine, when

operated at high altitude with the carburetor modifications for

high altitude use, will meet each emission standard throughout its

useful life.

Even with carburetor modification, engine horsepower will

decrease about 3.5% for each 300 meter (1,000 foot) increase in

altitude. The effect of altitude on horsepower will be greater than

this if no carburetor modification is made.

When the carburetor has been modified for high altitude operation,

the air-fuel mixture will be too lean for low altitude use. Operation

at altitudes below 1,500 meters (5,000 feet) with a modified

carburetor may cause the engine to overheat and result in serious

engine damage. For use at low altitudes, have your servicing

dealer return the carburetor to original factory specifications.

The combustion process produces carbon monoxide, oxides of

nitrogen, and hydrocarbons. Control of hydrocarbons and oxides

of nitrogen is very important because, under certain conditions,

they react to form photochemical smog when subjected to

sunlight. Carbon monoxide does not react in the same way, but it

is toxic.

Honda utilizes appropriate air/fuel ratios and other emissions

control systems to reduce the emissions of carbon monoxide,

oxides of nitrogen, and hydrocarbons.

Additionally, Honda fuel systems utilize components and control

technologies to reduce evaporative emissions.

EPA, California, and Canadian regulations require all

manufacturers to furnish written instructions describing the

operation and maintenance of emission control systems.

The following instructions and procedures must be followed in

order to keep the emissions from your Honda engine within the

emission standards.

Removal or alteration of any part of the intake, fuel, or exhaust

systems.

Altering or defeating the governor linkage or speed-adjusting

mechanism to cause the engine to operate outside its design

parameters.

If you are aware of any of the following symptoms, have your

engine inspected and repaired by your servicing dealer.

Hard starting or stalling after starting.

Rough idle.

Misfiring or backfiring under load.

Black exhaust smoke or high fuel consumption.

Afterburning (backfiring).

Tampering with or altering the emission control system may

increase emissions beyond the legal limit. Among those acts that

constitute tampering are:

10/09/09 19:51:28 32Z8R800_017

－

－

－

× ×× ×

× ×

× × ×

× ×

× ×× ×

× ×

×

＊

＊

＊

＊

ENGLISH

Specifications (standard types)Replacement Parts

Descriptive Term Applicable to Emissions Durability Period

Air Index

Maintenance

iGX240/iGX270 (PTO shaft type S with fuel tank)

iGX340/iGX390 (PTO shaft type S with fuel tank)

18

The emission control systems on your Honda engine were

designed, built, and certified to conform with EPA, California

(models certified for sale in California), and Canadian emission

regulations. We recommend the use of Honda Genuine parts

whenever you have maintenance done. These original-design

replacement parts are manufactured to the same standards as the

original parts, so you can be confident of their performance. The

use of replacement parts that are not of the original design and

quality may impair the effectiveness of your emission control

system.

A manufacturer of an aftermarket part assumes the responsibility

that the part will not adversely affect emission performance. The

manufacturer or rebuilder of the part must certify that use of the

part will not result in a failure of the engine to comply with

emission regulations.

Follow the maintenance schedule on page . Remember that this

schedule is based on the assumption that your machine will be

used for its designed purpose. Sustained high-load or high-

temperature operation, or use in unusually wet or dusty conditions,

will require more frequent service.

An Air Index Information label is applied to engines certified to an

emission durability time period in accordance with the

requirements of the California Air Resources Board.

The bar graph is intended to provide you, our customer, the ability

to compare the emissions performance of available engines. The

lower the Air Index, the less pollution.

The durability description is intended to provide you with

information relating to the engine’s emission durability period.

The descriptive term indicates the useful life period for the engine’s

emission control system. See your Emission Control System

Warranty for additional information.

Moderate

Intermediate

Extended

50 hours (0 80 cc, inclusive)

125 hours (greater than 80 cc)





1,000 hours (225 cc and greater)

355 462 422 mm

(14.0 18.2 16.6 in)

30.3 kg (66.8 lbs)

Counterclockwise

CDI type magneto ignition

Length Width

Height

Dry mass [weight]

Engine type

Displacement

[Bore Stroke]

Net power

Max.

Net torque

Engine oil capacity

Fuel tank capacity

Cooling system

Ignition system

PTO shaft rotation Counterclockwise


Forced air

5.3 L (1.40 US gal, 1.17 lmp gal)

1.1 L (1.2 US qt, 1.0 lmp qt)

19.1 N·m (1.98 kgf·m, 14.1 lbf·ft)

at 2,500 rpm

18.3 N·m (1.86 kgf·m, 13.4 lbf·ft)

at 2,500 rpm

6.3 kW (8.6 PS, 8.4 bhp) at 3,600 rpm

5.9 kW (8.0 PS, 7.9 bhp) at 3,600 rpm

[77.0 58.0 mm (3.03 2.28 in)]

270 cm (16.5 cu-in)

4-stroke, overhead valve,

single cylinder

Forced air

6.1 L (1.61 US gal, 1.34 lmp gal)

1.1 L (1.2 US qt, 1.0 lmp qt)

26.5 N·m (2.7 kgf·m, 19.5 lbf·ft)

at 2,500 rpm

26.4 N·m (2.6 kgf·m, 19.4 lbf·ft)

at 2,500 rpm

8.7 kW (11.8 PS, 11.7 bhp) at 3,600 rpm

8.0 kW (10.8 PS, 10.7 bhp) at 3,600 rpm

[88.0 64.0 mm (3.46 2.52 in)]

389 cm (23.7 cu-in)

36.4 kg (80.2 lbs)

380 484 448 mm

(15.0 19.1 17.6 in)


single cylinder

Length Width

Height

Dry mass [weight]

Engine type

Displacement

[Bore Stroke]

Net power

Max.

Net torque

Engine oil capacity

Fuel tank capacity

Cooling system

Ignition system

PTO shaft rotation

6

iGX240

iGX270

iGX270

iGX240

iGX340

iGX390

iGX390

iGX340

(in accordance

with SAE J1349 )

(in accordance

with SAE J1349 )

(in accordance

with SAE J1349 )

(in accordance

with SAE J1349 )

10/09/09 19:51:52 32Z8R800_018

× ×× ×

－－±±

× ×

× × ×

× ×

× × ×

× ×× ×

＊

＊

＊

＊

＊

ENGLISH

Tuneup Specifications

ITEM MAINTENANCE

Quick Reference Information

Wiring Diagrams

Specifications (low profile types)

SPECIFICATION

iGX270

(iGX240/iGX270/iGX340/iGX390)

(iGX240/iGX270/iGX340/iGX390)

iGX340/iGX390

19

Spark plug gap

Valve clearance

(cold)

Other

specifications

Refer to page: 12

See your

authorized

Honda dealer

No other adjustments needed.

Fuel

Engine oil

Spark plug

Maintenance

SAE 10W-30, API SJ or later, for general use.

Refer to page 9.

Before each use:

Check engine oil level. Refer to page 9.

Check air filter. Refer to page 10.

First 20 hours:

Change engine oil. Refer to page 9.

Subsequent:

Refer to the maintenance schedule on page 7.

U.S.

Except

U.S.

Unleaded gasoline (Refer to page 8)


Research octane rating 91 or higher


BPR6ES (NGK)

W20EPR-U (DENSO)

386 468 303 mm

(15.2 18.4 11.9 in)

26.2 kg (57.8 lbs)

0.7 0.8 mm

(0.028 0.031 in)

IN: 0.15 0.02 mm

EX: 0.20 0.02 mm

Length Width

Height

Dry mass [weight]

Engine type

Displacement

[Bore Stroke]

Net power

Max.

Net torque

Engine oil capacity

Cooling system

Ignition system



Forced air

1.1 L (1.2 US qt, 1.0 lmp qt)

19.1 N·m (1.98 kgf·m, 14.1 lbf·ft)

at 2,500 rpm

6.3 kW (8.6 PS, 8.4 bhp) at 3,600 rpm

[77.0 58.0 mm (3.03 2.28 in)]

270 cm (16.5 cu-in)


single cylinder

Length Width

Height

Dry mass [weight]

Engine type

Displacement

[Bore Stroke]

Net power

Max.

Net torque

Engine oil capacity

Cooling system

Ignition system



Forced air

1.1 L (1.2 US qt, 1.0 lmp qt)

26.5 N·m (2.7 kgf·m, 19.5 lbf·ft)

at 2,500 rpm

26.4 N·m (2.6 kgf·m, 19.4 lbf·ft)

at 2,500 rpm

8.7 kW (11.8 PS, 11.7 bhp) at 3,600 rpm

8.0 kW (10.8 PS, 10.7 bhp) at 3,600 rpm

[88.0 64.0 mm (3.46 2.52 in)]

389 cm (23.7 cu-in)


single cylinder

31.4 kg (69.2 lbs)

405 484 313 mm

(15.9 19.1 12.3 in)

The power rating of the engine indicated in this document is the

net power output tested on a production engine for the engine

model and measured in accordance with SAE J1349 at 3,600

rpm (Net Power) and at 2,500 rpm (Max. Net Torque). Mass

production engines may vary from this value.

Actual power output for the engine installed in the final machine

will vary depending on numerous factors, including the

operating speed of the engine in application, environmental

conditions, maintenance, and other variables.

RECTIFIER

INDICATOR

FUSE

ENGINE SWITCH

CONTROL BOX

STARTER MOTOR

BATTERY

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

(12)

(13)

(14)

OIL LEVEL SWITCH

SPARK PLUG

IGNITION COIL

CHARGING COIL

POWER COIL

To INTERFACE

iGX340

iGX390

iGX340

iGX390

ECM

(in accordance

with SAE J1349 )

(in accordance

with SAE J1349 )

(in accordance

with SAE J1349 )

(in accordance

with SAE J1349 )

10/09/09 19:52:21 32Z8R800_019

－

《》

ENGLISH

Canada:

Honda Canada, Inc.

Australia:

Honda Australia Motorcycle and Power Equipment Pty. Ltd.

For European Area:

Honda Europe NV.

All Other Areas:

Warranty and Distributor/Dealer Locator Information


Canada:

For European Area:

Australia:

Customer Service Information


All Other Areas:

Honda’s Office


American Honda Motor Co., Inc.

CONSUMER INFORMATION

20

Please visit www.honda.ca

for address information

Telephone:

Facsimile:

(888) 9HONDA9

(888) 946-6329

(877) 939-0909

Toll free

Toll free

1954 1956 Hume Highway

Campbellfield Victoria 3061

Telephone:

Facsimile:

(03) 9270 1111

(03) 9270 1133

European Engine Center

http://www.honda-engines-eu.com

Please contact the Honda distributor in your area for assistance.

Visit our website: www.honda-engines.com

Call (888) 9HONDA9

or visit our website: www.honda.ca

Visit our website: http://www.honda-engines-eu.com

Call (03) 9270 1348

or visit our website: www.hondampe.com.au

Servicing dealership personnel are trained professionals. They

should be able to answer any question you may have. If you

encounter a problem that your dealer does not solve to your

satisfaction, please discuss it with the dealership’s management.

The Service Manager, General Manager, or Owner can help.

Almost all problems are solved in this way.

If you are dissatisfied with the decision made by the dealership’s

management, contact the Honda Regional Engine Distributor for

your area.

If you are still dissatisfied after speaking with the Regional Engine

Distributor, you may contact the Honda Office as shown.

If you are dissatisfied with the decision made by the dealership’s

management, contact the Honda Office as shown.

When you write or call, please provide this information:

Equipment manufacturer’s name and model number that the

engine is mounted on

Engine model, serial number, and type (see page )

Name of dealer who sold the engine to you

Name, address, and contact person of the dealer who services

your engine

Date of purchase

Your name, address and telephone number

A detailed description of the problem

Power Equipment Division

Customer Relations Office

4900 Marconi Drive

Alpharetta, GA 30005-8847

Or telephone: (770) 497-6400, 8:30 am - 7:00 pm ET

16

10/09/09 19:52:50 32Z8R800_020

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