Leo18gt FL GB

Translation of the original oper-
ating instructions
Aerial access platform

Leo18GT-FL_GB
Manufacturer:
TEUPEN Maschinenbau GmbH
Marie-Curie-Straße 13
D-48599 Gronau
Telephone: +49 (0) 2562 8161-0
Fax: +49 (0) 2562 8161-888
email: info@teupen.com
Internet: www.teupen.com
Service:
Telephone: +49 (0) 2562 8161-313
email: service@teupen.com
© TEUPEN Maschinenbau GmbH 2010
2 Aerial access platform Leo18GT-FL 02.05.2011

Table of contents
Table of contents
1 General................................................................ 7
1.1 Information about these instructions............. 7
1.2 Explanation of symbols................................. 7
1.3 Limitation of liability....................................... 9
1.4 Copyright....................................................... 9
1.5 Warranty provisions.................................... 10
1.6 Note regarding warranty card...................... 10
1.7 Customer service........................................ 11
2 Safety................................................................. 13
2.1 Basic hazards.............................................. 13
2.1.1 General hazards in the workplace............ 13
2.1.2 Danger due to electric current.................. 15
2.1.3 Danger due to mechanism....................... 17
2.1.4 Danger due to hydraulic energies............ 18
2.1.5 Danger due to high temperatures............ 19
2.1.6 Danger due to chemicals......................... 19
2.1.7 Danger due to traffic and vehicles............ 20
2.2 Proper use................................................... 21
2.3 Responsibility of the owner......................... 21
2.4 Personnel requirements.............................. 23
2.4.1 Qualifications............................................ 23
2.4.2 Unauthorised persons.............................. 25
2.4.3 Training.................................................... 25
2.5 Personal protective equipment.................... 25
2.6 Safety equipment........................................ 26
2.6.1 Position of the safety equipment.............. 27
2.6.2 Description of the installed safety equip-
ment......................................................... 28
2.7 Symbols on the machine............................. 32
2.8 Behaviour in case of fire or accidents......... 34
2.9 Environmental protection............................ 35
3 Technical data................................................... 37
3.1 Dimension sheet......................................... 37
3.1.1 Main dimensions...................................... 37
3.1.2 Work diagram........................................... 38
3.2 Machine....................................................... 38
3.3 Bracing........................................................ 39
3.4 Platform system.......................................... 39
3.5 Chassis....................................................... 39
02.05.2011 Aerial access platform Leo18GT-FL 3

Table of contents
3.6 Drive engines.............................................. 40

3.6.1 Otto engine............................................... 40
3.6.2 Diesel engine (option).............................. 40
3.6.3 Electric motor........................................... 40
3.7 Operating conditions................................... 41
3.8 Hydraulic system......................................... 41
3.9 Lubricants.................................................... 42
3.10 Type plate................................................. 43
4 Structure and function..................................... 45
4.1 Overview..................................................... 45
4.2 Brief description.......................................... 46
4.3 Assembly description.................................. 47
4.3.1 Platform.................................................... 47
4.3.2 Outriggers................................................ 47
4.3.3 Working basket........................................ 48
4.3.4 Crawler chassis........................................ 48
4.3.5 Combustion engine.................................. 49
4.3.6 Electric motor........................................... 49
4.4 Operating elements..................................... 50
4.4.1 Control panel/remote control.................... 50
4.4.2 Emergency control................................... 51
4.4.3 Service control......................................... 52
4.4.4 Lighting..................................................... 52
4.5 Connections................................................ 52
4.6 Work areas and danger zones.................... 53
4.7 Accessories................................................. 53
4.7.1 Keys......................................................... 53
4.7.2 Safety harness (optional)......................... 54
5 Transport and storage...................................... 55
5.1 Safety instructions for transport.................. 55
5.2 Transport inspection.................................... 55
5.3 Transport..................................................... 56
5.4 Storage........................................................ 61
6 Operation........................................................... 63
6.1 Safety instructions for operation.................. 63
6.2 Switching the machine on/off...................... 64
6.2.1 Switching the machine on/off via the
mains supply............................................ 64
6.2.2 Switching the machine on/off via the Otto
engine...................................................... 65
6.2.3 Switching the machine on/off via diesel
engine (option)......................................... 66

Table of contents
6.3 Shutting down in case of emergency.......... 67

6.4 Moving the machine.................................... 69
6.5 Putting the machine in working position...... 73
6.6 Operating the machine................................ 78
6.7 Putting the machine in transport position.... 81
6.8 Height and width adjustment crawler
chassis........................................................ 86
6.9 Changing the working basket...................... 89
6.10 Attaching/removing the floodlight mast
(optional)................................................... 91
6.11 Operating the floodlight mast (optional).... 95
6.12 Emergency operation................................ 96
6.13 Service operation...................................... 98
6.14 Valve settings.......................................... 102
6.14.1 Valve setting for platform..................... 102
6.14.2 Valve setting outriggers........................ 104
7 Maintenance.................................................... 105
7.1 Safety instructions for maintenance.......... 105
7.2 Maintenance plan...................................... 110
7.3 Maintenance work..................................... 112
7.3.1 Cleaning................................................. 112
7.3.2 Tensioning the chain.............................. 113
7.3.3 Lubricating the rotating assembly.......... 115
7.3.4 Greasing the transport........................... 116
7.3.5 Checking the hydraulic oil level.............. 118
7.3.6 Checking the gearbox oil level of the
chain drive.............................................. 120
7.3.7 Replacing the hydraulic filter.................. 122
7.3.8 Lubrication plan...................................... 123
7.3.9 Rotating assembly tightening torques.... 125
8 Faults............................................................... 127
8.1 Safety instructions for fault repair.............. 127
8.2 Fault table................................................. 132
8.3 Notes about the rubber track..................... 136
8.4 Work for fault repair................................... 138
8.4.1 Changing fuses...................................... 138
8.4.2 Switching the circuit breaker on/off........ 140
8.5 Fuses........................................................ 141
8.5.1 Fuzzy control card.................................. 141
8.5.2 Working basket fuse and FI circuit
breaker................................................... 142

Table of contents
9 Disposal........................................................... 143
10 Index................................................................ 145
Appendix......................................................... 147
A Circuit diagram............................................... 149

B Hydraulic plan................................................. 151
C Honda Otto engine.......................................... 153
D Kubota diesel engine....................................... 

General
1 General
1.1 Information about these instructions
These instructions enable the safe and efficient han-
dling of the machine. These instructions are a compo-
nent of the machine and must be kept in the immediate
vicinity of the machine so that they are accessible to the
personnel at any time.
Before beginning any work, the trained personnel must
have read through these instructions carefully and
understood them. The basic requirement for safe
working is adherence to all the specified safety instruc-
tions and operating instructions in these instructions.
In addition, the local accident prevention regulations
and general safety provisions for the area of application
of the machine apply.
Figures in these instructions serve the purpose of basic
understanding and can deviate from the actual model.
1.2 Explanation of symbols

Safety instructions Safety instructions are marked with symbols in these
instructions. The safety instructions are always intro-
duced by signal words which express the extent of the
danger.
DANGER!
This combination of symbol and signal word
indicates an immediately-dangerous situation
which could cause death or severe injuries if
not avoided.
WARNING!
indicates a possibly-dangerous situation
which could cause death or severe injuries if
it is not avoided.

General
CAUTION!
which could cause slight injuries if it is not
avoided.
NOTICE!
which could cause property and environ-
mental damage if it is not avoided.
Tips and recommendations

This symbol highlights useful tips and recom-
mendations as well as information designed
to ensure efficient and smooth operation.
Special safety instructions The following symbols are used in the safety instruc-
tions to draw attention to specific dangers:
DANGER!
indicates an immediately-dangerous situation
due to electric shock. If an instruction so
marked is not heeded, severe or even fatal
injuries can be the consequence.
Additional markings To emphasise instructions, results, lists, references and

other elements, the following markings are used in
these instructions:
Marking Explanation
Step-by-step instructions
ð Results of action steps
References to sections of these
instructions and to other relevant
documents

General
Marking Explanation
Listing without fixed sequence
[Buttons] Operating elements (e.g. buttons,
switches), display elements (e.g.
signal lamps)
„Display“ Screen elements (e.g. buttons, pro-
gramming of function keys)
1.3 Limitation of liability

All details and instructions in these instructions were
compiled taking into account the applicable standards
and regulations, the state of technology, as well as our
many years of knowledge and experience.
In the following cases, the manufacturer assumes no
liability for damage:
n Failure to follow these instructions
n Use deviating from the proper use
n Use of untrained personnel
n Unauthorised changes
n Technical alterations
n Use of non-approved spare parts
For special models, with the usage of additional order
options or due to the latest technical changes, the
actual scope of delivery can deviate from the explana-
tions and depictions provided here.
Applicable are the obligations agreed upon in the
delivery contract, the general terms and conditions, as
well as the delivery conditions of the manufacturer and
the legal regulations valid at the time the contract was
concluded.
1.4 Copyright
The contents of these instructions are copyrighted.
Their use is permitted in the context of using the
machine. Any use extending beyond this is not allowed
without written permission from the manufacturer.

General
1.5 Warranty provisions

The warranty provisions are contained in the manufac-
turer's general terms and conditions.
1.6 Note regarding warranty card

In order to be able to process warranty applications
between the customer, service partner, and Teupen as
quickly as possible, it is absolutely necessary to fill out
the warranty card that is at the front of the machine
record and send it back to Teupen directly after hand-
over of the machine to the owner. If the warranty card is
not filled out properly, we cannot process the warranty
application since important data that is necessary for
the processing has not been made available to us.

General
Please send the warranty card to:

Teupen Maschinenbau GmbH
Service Point
Marie-Curie-Straße 13
D-48599 Gronau
Sample of a properly filled-out warranty card:
Fig. 1: Sample warranty card
1.7 Customer service

Our customer service division is available to provide
technical information. See page 2 for contact details.
In addition, our employees are always interested in
acquiring new information and experience gained from
practical application; such information and experience
may help improve our products.

General

Safety
2 Safety
This section provides an overview of all safety aspects
that are essential to the best possible protection of the
personnel and the safe and trouble-free operation of the
machine. Additional safety instructions for specific work
tasks are contained in the sections regarding the indi-
vidual life stages of the machine.
2.1 Basic hazards

The following section describes remaining risks which
can arise from the machine even with proper use.
In order to reduce risks of personal injury and property
damage and avoid dangerous situations, the safety
instructions listed here and the safety instructions in the
other sections of these instructions must be followed.
2.1.1 General hazards in the workplace

Swivelling aerial access plat-
form WARNING!
Danger to life due to swivelling aerial
access platform!
During operation, the aerial access platform
can swivel out. This can cause severe injuries
or even death.
– Never step under or into the swivel range
of the aerial access platform.
– Only move the aerial access platform
under supervision.
– Always operate the aerial access platform
with at least two people.
– Always wear personal protective equip-
ment.

Safety
Work in high places

WARNING!
Danger of falling over!
During work in high places, there is a danger
of falling. This can cause severe injuries or
even death.
– While in the working basket, always wear
a safety harness (in compliance with EN
361), do not swing or move jerkily.
– Do not climb onto the safety fence around
the basket.
– Make sure that the machine is set up
properly and holds securely.
– Make sure that when moving the working
basket, no body parts are crushed, e.g.
against a wall.
– At wind speeds above 12.5 m/s (wind
strength 6 Bft), stop work immediately.
– Always wear personal protective equip-
ment.
Exhaust gases
WARNING!
Danger to life through poisoning and suf-
focation by exhaust gases!
Exhaust gases can lead to suffocation if
inhaled, as also severe poisoning and
marked damage to the respiratory system.
– While operating the machine in diesel
mode, always ensure the supply of fresh
air.
– In case of inhalation of exhaust gases,
immediately take the affected person into
fresh air. Call a doctor in.

Safety
2.1.2 Danger due to electric current

Electric current
DANGER!
Danger to life due to electric current!
Upon contact with voltage-conducting parts,
there is an immediate danger to life due to
electric shock. Damage to the insulation or
individual components can present a danger
to life.
– Do not work on or near high-voltage lines.
– Only have a trained electrician perform
work on the electrical system.
– In case of damage to the insulation, switch
off the power supply immediately and
have the machine repaired.
– Never bypass fuses or take them out of
operation. When changing fuses, adhere
to the correct amperage.
– Keep humidity away from voltage-con-
ducting parts. This can cause a short-cir-
cuit.
– Before performing work on voltage-con-
ducting parts, pull the mains plug.

Safety
Batteries
WARNING!
Danger of injury due to incorrect handling
of batteries!
In case of batteries are improperly handled,
there is the danger that the batteries can
explode or that liquids that are hazardous to
health can egress from the batteries. The
liquid egressing can cause severe burns
upon skin contact, severe poisoning upon
swallowing and blindness in case it comes in
contact with eyes.
– Never short circuit the contacts (positive
and negative poles) of the batteries!
– Never use or store batteries in places
where the atmosphere is explosive or
where temperatures can rise excessively.
– Never attempt to solder batteries, to repair
them, to change their form, to remodel
them or to dismantle them.
– Always protect batteries from access by
unauthorised persons.
– In order to avoid fires, overheating, explo-
sions or escape of fluids, do not subject
batteries to heavy vibrations or shocks,
place heavy weights on them or subject
them to other damaging exposures. Liq-
uids which emanate from batteries can get
inflamed.
– Avoid contact with escaping liquids.
Measures to be undertaken upon contact with battery

liquids:
n Wash skin with plenty of water and soap after con-
tact.
n Rinse out with clear water under the eyelids for at
least 15 minutes after contact. While doing so, do
not direct the stream of water directly on the eyes
and do not rub. Immediately summon medical assis-
tance.

Safety
2.1.3 Danger due to mechanism

Falling materials
WARNING!
Danger of injury due to falling materials!
During operation, material can fall down
uncontrolled and cause severe injuries.
– Make others aware of the danger zone
and block off the area.
– Do not enter the danger zone during
normal operation.
Supports and arms

WARNING!
Danger of crushing on supports and arms!
When bracing or swivelling the machine,
there is a danger of crushing.
– Make sure that when bracing, no people,
supply lines or other objects are in the
area around the supports.
– Make sure that no people are in the
danger zone when swivelling the machine.
– Make sure that no people are in the
danger zone when moving into transport
position.

Safety
Chain drive
WARNING!
Danger to life due to pulling in and
pinching off body parts on the chain drive!
Running chains and rotating chain wheels
can pull in pieces of clothing as well as body
parts and thus cause severe to fatal injuries.
– During operation, do not reach into run-
ning chains or chain wheels.
– Keep chain drives inaccessible during
operation. Do not open any covers.
– While in the danger zone, wear closely-fit-
ting protective clothing with low tear
strength.
– Before all work on chains or chain wheels,
switch the machine off and secure against
switching on again. Wait until all compo-
nents have come to a standstill.
– During operation, maintain a sufficient
safety distance.
– Pay attention to the change of direction.
2.1.4 Danger due to hydraulic energies

Hydraulics
WARNING!
Danger to life from hydraulic forces!
Hydraulically driven moving parts can cause
grave injuries.
– Work on the hydraulic system must only
be carried out by trained hydraulics techni-
cians.
– Before starting work on the hydraulic
system, ensure that it has been com-
pletely depressurised. The pressure accu-
mulator must be completely relieved.
– During operation, do not reach into or
handle moving parts.
– Do not open covers during operation.
– When in the danger zone, wear close-fit-
ting protective work clothing with low tear
strength.

Safety
2.1.5 Danger due to high temperatures

Hot surfaces
WARNING!
Danger of injury due to hot surfaces!
Surfaces of engine components can get
heated up considerably during operation.
Skin contact with hot surfaces causes severe
burns to the skin.
– Avoid contact with engine components
such as exhaust components, silencers,
coolers, radiators, pipes and engine
blocks.
– Check before all work on engine compo-
nents, as to whether these are hot. If nec-
essary, allow them to cool.
2.1.6 Danger due to chemicals

Anti freeze agents
WARNING!
Health danger of anti freeze agents
The coolant of the diesel engine consists of a
mixture of water and anti freeze agent. In
case of body contact, swallowing or inhalation
of aerosols, anti freeze agents can lead to
severe health hazards.
– Avoid contact with anti freeze materials.
– Do not eat, drink or smoke while handling
anti freeze materials. Wash hands before
breaks and at the end of work.
– Always wear protective gloves while
working with anti freeze agents.
Measures to be undertaken upon contact with anti

freeze agents:
n Wash skin with plenty of water after contact.
n Rinse eyes thoroughly with water for at least 15
minutes and call a doctor.
n Rinse out mouth after swallowing and drink plenty of
water afterwards. Summon a doctor.
n In case aerosols are inhaled, go out into fresh air.

Safety
Engine oil
WARNING!
Danger of injury through engine oil!
Engine oil contains poisonous substances
which can cause inflammations and / or are
carcinogenic.
– Avoid all skin contact with engine oil.
– In case of accidental skin contact, wash
the hands or affected area immediately
with soap. Do not ever use petrol, gaso-
line, solvents or other chemical cleaning
agents.
2.1.7 Danger due to traffic and vehicles

Public street traffic
WARNING!
Danger to life due to parts protruding into
the traffic area!
A failure to heed flowing traffic can cause
accidents with the most severe injuries or
even death.
– Secure the danger zone around the aerial
access platform completely and visibly
(even in case of poor visual conditions).
– Always be prepared for possible traffic
accidents, especially such kind as can be
caused by third parties.
Industrial trucks
WARNING!
Danger to life due to industrial trucks!
There is a danger that people can be over-
looked and run over by the vehicle driver.
– Only have industrial trucks operated by
trained personnel.
– Only walk past industrial trucks if the
vehicle driver has indicated that he has
seen the people.

Safety
2.2 Proper use

The machine is designed and constructed exclusively
for the proper use described here.
The machine is to be used exclusively to convey

people and tools up to the maximum allowable
working basket load to perform work in high places.
Proper use also includes adherence to all details in
these instructions.
Any use beyond or differing from the proper use counts
as a misuse.
WARNING!
Danger due to misuse!
Misuse of the aerial access platform can
create dangerous situations.
– Do not use the aerial access platform to
support loads.
– Do not use the aerial access platform as a
crane, lift or side pull.
– Do not use the aerial access platform in or
near unprotected active parts of electrical
systems.
– Do not operate the aerial access platform
in an atmosphere subject to explosion.
Claims of any type due to damage from misuse are

excluded.
2.3 Responsibility of the owner

Owner The term 'owner' refers to the person who himself oper-
ates the machine for trade or commercial purposes, or
who surrenders the machine to a third party for use/
application, and who bears the legal product liability for
protecting the user, the personnel or third parties during
the operation.
Duties of the owner The machine is used in the commercial realm. There-
fore, the owner of the machine is subject to the legal
obligations relating to occupational safety.

Safety
In addition to the safety instructions in these instruc-

tions, the valid safety, accident prevention and environ-
mental protection regulations applicable to the
machine's area of application must be adhered to.
Here, the following points apply in particular:
n The owner must inform himself about the applicable
occupational safety provisions and also determine in
a risk assessment the risks which arise due to the
specific working conditions in the place where the
machine is used. He must implement these in the
form of operating instructions for the operation of the
machine.
n The owner must check during the entire time the
machine is used whether the operating instructions
he has created correspond to the current state of
regulations; if necessary, he must adapt the oper-
ating instructions.
n The owner must clearly regulate and specify the
responsibilities for installation, operation, fault repair,
maintenance and cleaning.
n The owner must ensure that all employees who
handle the machine have read and understood
these instructions. In addition, he must train the per-
sonnel at regular intervals and inform them about
the risks.
n The owner must provide the required protective
equipment and ensure that the personnel wears the
required protective equipment.
Furthermore, the owner is responsible for ensuring that
the machine is always in technically-perfect condition.
Therefore, the following points apply:
n The owner must ensure that the maintenance inter-
vals described in these instructions are adhered to.
n The owner must check all safety equipment for per-
fect function before each start-up or have it checked
by an authorised person.

Safety
2.4 Personnel requirements

2.4.1 Qualifications
WARNING!
Danger of injury in case of insufficient
qualification of the personnel!
If unqualified personnel undertakes work on
the machine or is in the machine's danger
zone, dangers arise which can cause severe
injuries and significant property damage.
– Only have all activities performed by quali-
fied personnel.
– Keep unqualified personnel away from the
danger zones.
In these instructions, the qualifications listed below are

named for the personnel for the various areas of
activity:
Expert
An expert is somebody who, based on his professional
training and experience, has sufficient knowledge of
aerial platforms and is sufficiently familiar with the appli-
cable state regulations, accident prevention regulations
and generally-recognised rules of technology (e.g.
employer's liability insurance rules, DIN standards, VDE
regulations, technical rules of other member states of
the European Union or other treaty states of the agree-
ment about the European Economic Community) that
he can assess the safe operational state of aerial plat-
forms.
Hydraulics Specialist
The Hydraulics Specialist is trained for the special area
of responsibility he is involved with and knows the rele-
vant standards and regulations.
Based on his technical training and experience, the
Hydraulics Specialist can perform work on hydraulic
systems and can recognise and avoid potential hazards
himself.

Safety
Qualified Electrician
Based on his technical training, knowledge, experience
and knowledge of the applicable standards and regula-
tions, the Qualified Electrician is able to perform work
on electrical systems and recognise and avoid potential
hazards himself.
The Qualified Electrician is specially trained for the area
of responsibility he is involved with and knows the rele-
vant standards and regulations.
The Qualified Electrician must comply with the require-
ments of the applicable legal regulations for accident
prevention.
Qualified personnel
Qualified personnel is able to carry out assigned work
and to recognize and prevent possible dangers self-reli-
antly due to its professional training, knowledge and
experience as well as profound knowledge of applicable
regulations.
Trained people
The trained people have been trained in demonstrable
fashion in a training session by the owner about the
proper use without additional prior knowledge of the
method of functioning and possible hazards which can
arise from the aerial access platform.
Personnel may only include people who are at least 18

years of age and of whom it can be expected that they
perform their work reliably. People whose reactions are
influenced, e.g. by drugs, alcohol or medications, are
not permitted.

Safety
2.4.2 Unauthorised persons
WARNING!
Risk to life for unauthorised persons due
to hazards in the danger and working
zone!
Unauthorised persons who do not meet the
requirements described here will not be
familiar with the dangers in the working zone.
Therefore, unauthorised persons face the risk
of serious injury or death.
– Unauthorised persons must be kept away
from the danger and working zone.
– If in doubt, address the persons in ques-
tion and ask them to leave the danger and
working zone.
– Cease work while unauthorised persons
are in the danger and working zone.
2.4.3 Training
The customer has been trained by the owner. The per-
sonnel must be trained by the owner accordingly.
2.5 Personal protective equipment

Personal protective equipment serves to protect people
against hazards to their safety and health while
working.
The personnel must wear the personal protective equip-
ment while working on and with the machine which is
referred specially to in the individual sections of these
instructions.
Description of the personal pro- The personal protective equipment is explained below:
tective equipment
Harness
The harness provides protection against falling in the
case of increased risk of falling. This is the case if
specified height differences are exceeded and the work
location is not protected by a railing.

Safety
Wear the harness so that the safety rope is attached to

the harness and a fixed attachment point; provide a fall
arrester if necessary.
Harnesses must only be used by persons specially
trained for their use.
Protective clothing
Protective clothing are tight fitting working clothes with
low tear resistance, with tight sleeves and without any
parts sticking out. These clothes primarily protect
against getting caught by moving machine parts. Do not
wear rings, chains, necklaces, and other jewellery.
Protective helmet
The protective helmet provides protection against falling
and flying parts and materials.
Safety boots
Safety boots are intended to protect against slipping
hazards or foot hazards like heavy gear.
2.6 Safety equipment
WARNING!
Danger to life from nonfunctional safety
devices!
If safety devices are not functioning or are
disabled, there is a danger of grave injury or
death.
– Check that all safety devices are fully
functional and correctly installed before
starting work.
– Never disable or bypass safety devices.
– Ensure that all safety devices are always
accessible.

Safety
2.6.1 Position of the safety equipment

View from the right side
Fig. 2: Position of the safety equipment

1 Emergency Stop button on the control 3 Valves for platform
panel/remote control 4 Valves for outriggers and emergency
2 Limit switch outriggers (4x) operation

Safety
View from the left side
Fig. 3: Position of the safety equipment

5 Limit switch upper boom extension 9 Tilt sensor (covered)
6 Limit switch upper boom transport lock 10 Limit switch lower boom transport lock
7 Circular level 11 Limit switch lower boom extension
8 Mechanical stop
2.6.2 Description of the installed safety equipment

Emergency Stop button
By pressing the Emergency Stop button, the machine is
stopped due to immediate switching off of the power
supply. After the Emergency Stop button has been
pressed, it must be unlocked by turning it in order to
switch the machine on again.
Fig. 4: Emergency Stop button

Safety
WARNING!
Danger to life due to uncontrolled
switching on again!
Uncontrolled switching on again of the
machine can cause severe injuries or even
death.
– Ensure before switching on again that the
cause of the emergency stop has been
eliminated and all safety equipment is
mounted and functioning properly.
– Only unlock the Emergency Stop button if
there is no more danger.
Limit switch
Limit switches find out the correct position of definite
components. Thus they can, for example prevent unin-
tended movement of the machine.
Fig. 5: Limit switch
Battery main switch

The battery main switch is always near the battery. The
batteries can be disconnected from the vehicle's elec-
trical system by means of the main battery switch. This
is recommended, for example before longer duration
storage of the machine.
Fig. 6: Battery main switch

Safety
Tilt sensor and circular level

(bubble level)
During automatic bracing, the aerial access platform is
aligned horizontally automatically with the help of the tilt
sensor (Fig. 7). The maximum permissible inclination is
1°; this must be checked visually with the circular level
(Fig. 8).
Fig. 7: Tilt sensor
Fig. 8: Circular level
Valves for emergency operation

The aerial access platform can be operated in emer-
gency mode in case of failure of energy supply or for
maintenance purposes. By means of the valves (Fig. 9),
platform or outrigger operation can be selected.
Fig. 9: Example: Valve block
Valves for outrigger function

maintenance purposes. The valves (Fig. 10) are used
for control of the outriggers.
Fig. 10: Example: Valve block

Safety
Valves platform function

maintenance purposes. The valves (Fig. 11/1) for con-
trol of the working basket and the valves (Fig. 11/2) for
control of the platform can be placed in separate valve
blocks.
Fig. 11: Example: Valve blocks
Limitation of mechanical rota-

tion area
In order to prevent an over rotation of the platform and
thus of the cables, the angle of the platform is limited by
a mechanical rotation area limitation (Fig. 12/1).
Fig. 12: Limitation of rotation

area

Safety
2.7 Symbols on the machine

The following symbols and indicator plates are on the
machine.
WARNING!
Danger of injury due to illegible symbols!
In the course of time, stickers and signs can
get soiled or become illegible in other ways,
so that hazards are not recognised and nec-
essary operating instructions cannot be fol-
lowed. This creates a danger of injury.
– Always keep all safety, warning and oper-
ating instructions in easily-legible condi-
tion.
– Replace damaged signs or stickers imme-
diately.
With specification of the item number, the

stickers can be ordered from the manufac-
turer. Please see page 2 for the contact data.

Safety
Fig. 13: Symbols on the machine

Safety
2.8 Behaviour in case of fire or accidents

Preventive measures n Be prepared for fire and accidents at all times!
n Keep first-aid equipment (first-aid kit, blankets, etc.)
and fire extinguishing devices operational and
readily available.
n Make your personnel familiar with accident reporting
equipment as well as first-aid and rescue equipment.
n Keep access paths clear for rescue vehicles.

Safety
Steps in case of fire and acci- n Immediately trigger an Emergency Stop using
dents EMERGENCY-STOP devices.
n Provided your own health is not in danger, rescue all
personnel from the danger area.
n If necessary, initiate first aid measures.
n Alert the fire department and/or emergency medical
services.
n In case of fire: provided your own health is not in
danger, extinguish the fire using fire extinguishing
equipment and continue to do so until the fire
department arrives.
n Notify the person in charge at the machine's place of
installation.
n Clear access paths for rescue vehicles.
n Wave rescue vehicles into position.
2.9 Environmental protection
NOTICE!
Danger to the environment due to incor-
rect handling of materials which can harm
the environment!
In case of incorrect handling of materials
which can harm the environment, especially
improper disposal, there can be significant
damage to the environment.
– Always heed the notes below about the
handling of materials which can harm the
environment and their disposal.
– If materials which can harm the environ-
ment accidentally escape into the environ-
ment, take suitable measures immedi-
ately. In case of doubt, inform the
responsible local authority about the
damage and ask what suitable measures
to take might be.
The following materials which might harm the envi-

ronment are used:
Cleaning liquids Cleaning liquids incorporating solvents contain toxic

substances. They must not be allowed to escape into
the environment. Disposal must be carried out by a spe-
cialist disposal company.

Safety
Lubricants Lubricants such as greases and oils contain toxic sub-

stances. They must not be allowed to escape into the
environment. Disposal must be carried out by a spe-
Hydraulic oil Hydraulic oil may not be allowed to escape into the
environment. Hydraulic oil can cause long-term damage
to bodies of water. Disposal must be handled by a pro-
fessional disposal company.
Fuels Fuels contain poisonous substances. They may not be

allowed to escape into the environment. Disposal must
be handled by a professional disposal company.
Cooling water with frost protec- Cooling water and frost guards contain toxic sub-
tion stances. They must not be allowed to escape into the
environment. Disposal must be carried out by a spe-

Technical data
3 Technical data
3.1 Dimension sheet
3.1.1 Main dimensions
Fig. 14: Main dimensions (metric)

Technical data
3.1.2 Work diagram
Fig. 15: Work diagram (metric)
3.2 Machine
Data Value Unit
Overall length with working 5,12 m
basket (min.)
Overall length without working 4,39 m
basket (min.)
Overall length without working 4,34 m
basket and rollers (min.)
Overall width (min) 0,78 m
Overall height (min) 1,99 m
Net weight approx. kg
2400
Carrying capacity while driving 5,19 kN/m2
Carrying capacity in work posi- 2,13 kN/m2
tion

Technical data
Data Value Unit

Permissible number of people 2
on the work platform
3.3 Bracing
Data Value Unit
Bracing width max./min. 3,32/3,13 m
Bracing pads Æ 0.2 m
Bracing possible up to slope of 5,7/10 °/%
Max. chassis clearance 25 cm
3.4 Platform system

Data Value Unit
Max. work height 17,6 m
Outreach 7,4 m
Max. basket load 200 kg
Working basket (LxWxH) 1.42x0.7x m
1.1
Basket boom free to move 150 °
Max. rotation area 355 °
3.5 Chassis
Data Value Unit
Height adjustable 8 cm
Width adjustable 16 cm
Climbing ability 19,7/36 °/%
Slope angle 16/28 °/%
Chain (LxW) 145x20 cm
Travel speed 1,5 km/h

Technical data
Data Value Unit

Max. chassis clearance 18 cm
3.6 Drive engines

3.6.1 Otto engine
Otto engine Honda iGX 440 Air-cooled 1-cylinder 4-stroke Otto engine
Data Value Unit
Cylinder capacity 438 cm3
Highest performance at 3600 9,5 (12,9) kW
min-1 (PS)
Fuel type Otto fuel
type
Fill quantity approx. 5.1 l
3.6.2 Diesel engine (option)

Diesel engine Kubota Z-602 Water cooled 2 cylinder 4 stroke diesel engine
Data Value Unit
Cylinder capacity 599 cm3
Highest performance at 3600 12,5 (17) kW
min-1 (PS)
Fuel type Diesel fuel
Fill quantity approx. 12 l
Noise emission values approx. 89 dB(A)
3.6.3 Electric motor

Electric motor EBS 90 L x 4 Data Value Unit
Nominal input voltage 210–230 V
Frequency 50 Hz
Current consumption 12,9 A

Technical data
Data Value Unit

Output 2,2 kW
Cable lengths Data Value Unit

Maximum cable length with 40 m
cable diameter 3 x 2.5 mm2
Maximum cable length with 80 m
cable diameter 3 x 4.0 mm2
3.7 Operating conditions

Data Value Unit
Maximum permissible wind 12.5 (6) m/s
speed in operation (Bft)
Temperature range -15 to +40 °C
3.8 Hydraulic system

Response pressure of the pres- Data Value Unit
sure limiting valves
Platform functions (max.) 200 bar
Outrigger functions (max.) 200 bar
Crawler chassis (max.) 200 bar
Fill quantities Data Value Unit

Fill quantity of the hydraulic approx. 75 l
system
Fill quantity of the hydraulic approx. 35 l
tank
Fill quantity between min and 6 l
max

Technical data
3.9 Lubricants
Lubricant Type TEUPEN item number Fill quan- Unit
tity
Gearbox oil Gearbox oil 3917/0122 * max. 1 l
Hydraulic oil Plantohyd 32-S 3917/0066 * 75 l
Multi-purpose - 3917/0095 (cartridge) 0,5 kg
lubricant
Engine oil SAE 10W-30 - 1,1 l
(Otto engine)
Engine oil Titan 15W-40 - 2,5 l
(diesel)
Cooling water - - 2,8 l
(diesel engine)
Otto fuel type - - 5,1 l
Diesel fuel - - 12 l
* upon order, please specify order quantity in litres
Oil recommendations The hydraulic system of the aerial work platform is filled
with the abovementioned hydraulic oil at the factory. It
is recommended that you continue to use this hydraulic
oil or that you replace it with one of the following
hydraulic oils:
Operation tem- BP Esso Fuchs Shell

perature
-15 to +40 ℃ BP Energol HLPD-OEL 22 Renolin MR 5 Shell Hydrol DO
HLP-D 22 22

Technical data
3.10 Type plate
Fig. 16: Sample type plate

The type plate is located on the chassis (on the left in
the direction of travel) and includes the following details:
n Manufacturer
n Type
n Serial number
n Year of manufacture
n Net weight
n Load capacity
n Permitted number of people
n Payload
n Maximum permissible lateral force
n Maximum permissible wind speed
n Maximum electrical connection values
n Maximum permissible slope
n Time of the annual check
n CE mark

Technical data

Structure and function
4 Structure and function

4.1 Overview
View from the right side
Fig. 17: Overview

1 Outrigger 4 6 Right crawler chassis
2 Upper boom 7 Cover for platform and working basket
3 Outrigger 3 valves
4 Turning triangle 8 Hydraulic oil tank
5 Lower boom 9 Cover for valves for outriggers and
emergency operation

View from the left side
Fig. 18: Overview

10 Outrigger 2 14 Working basket
11 Lift boom holder 15 Cover for control box
12 Outrigger 1 16 Left crawler chassis
13 Control head with control panel and 17 Cover for combustion engine
230V outlet
4.2 Brief description

The aerial access platform helps to perform work in
high places. The control takes place from the working
basket (Fig. 18/14), via a control panel (Fig. 18/13),
which can also be used as a remote control. In order to
set the aerial access platform in work position, the
chassis is lifted with the help of the outriggers 1 to 4
(Fig. 17/1, 3 und Fig. 18/10 and 12) with the automatic
bracing or manually. Only when the chassis is levelled
correctly (visual check using the circular level) can plat-
form operation be started.
The left (Fig. 18/16) and right (Fig. 17/6) drives can be
moved or adjusted independent of each other and are
height-adjustable.
The working basket (Fig. 18/14) is always kept hori-
zontal by a hydrostatic balancing system. In order to
narrow down or reduce the clearance or in order to
reach places that are difficult to access, the working
basket (Fig. 18/14) can be dismantled.

The power is supplied either by the mains supply (con-

struction side feed) using an extension cable or by the
combustion engine.
4.3 Assembly description

4.3.1 Platform
Fig. 19: Platform

The working platform consists essentially of the lifting
boom holder (Fig. 19/1), the upper boom (Fig. 19/2), the
turning triangle (Fig. 19/3), the lower boom (Fig. 19/4)
and the rotating assembly (Fig. 19/5).
4.3.2 Outriggers
Fig. 20: Machine in work position

With the help of the outriggers (Fig. 20/1 to 4), the

chassis is lifted and the aerial access platform is thus
put into the work position. The outriggers are numbered
consecutively according to the position numbers listed
in Fig. 20.
4.3.3 Working basket

In the working basket there is space for a maximum of
two people. The control panel is located in the control
head (Fig. 21/1). The operating instructions with
hydraulic plan and electrical circuit diagram are located
in the document box (Fig. 21/2).
Fig. 21: Working basket
4.3.4 Crawler chassis

In the transport position, the aerial access platform can
be moved with the help of the crawler chassis. Only a
grease gun is required for the chain tensioning. The
carriage drives can be adjusted independently of each
other in 3 steps at the heights. In Fig. 22, the left car-
riage drive (1) is completely retracted and the right car-
riage drive (2) is completely extended. The height
adjustment is done mechanically.
Fig. 22: Crawler chassis

4.3.5 Combustion engine

The combustion engine (Fig. 23/1), together with the
hydraulic aggregate supplies the necessary hydraulic
pressure. In serial production, a Honda Otto engine and
optionally a Kubota diesel engine is installed.
Fig. 23: Combustion engine
4.3.6 Electric motor

Alternatively, the combustion engine can be provided
with the necessary pressure by the electric motor
(Fig. 24/1). The connection is provided by the customer
through a 230V connection.
Fig. 24: Electric motor

4.4 Operating elements

4.4.1 Control panel/remote control
The control takes place via a control panel, which can
also be used as a remote control.
Fig. 25: Control panel/remote control

1 Toggle switch 6 Pre-selection lever
2 Left control lever 7 Engine switch
3 Red light 8 Emergency Stop button
4 Green light - Pre-heating switch (no fig.)
5 Right control lever
The operating elements of the control panel are
explained in detail below.
1 - toggle switch The various operating functions are selected with the
toggle switch. The operating functions Platform, Move
and Outriggers are available for selection.
2 - Left control lever Depending on the operating function selected and the
position of the pre-selection lever, the functions marked
in colour can be executed with the left control lever.

3 - Red light After switching on the power supply, the red light blinks
until the machine is ready for operation.
4 - Green light The green light blinks in the transport position and stays
lit when the machine is braced correctly.
5 - Right control lever Depending on the operating function selected and the
position of the pre-selection lever, the functions marked
in colour can be executed with the right control lever.
6 - Pre-selection lever Various function groups are selected with the pre-selec-
tion lever. There are three function groups from which
to select; these are active depending on the position of
the toggle switch.
7 - Engine switch Starts and stops the combustion engine.
8 - Emergency Stop button An Emergency Stop button is located on the control

panel (Ä „Emergency Stop button“ on page 28). After
activation, it must be unlocked by turning it so that the
machine is ready for operation again.
Pre-heating switch (no fig.) Used for pre-heating the diesel engine (option).
4.4.2 Emergency control

In case of a power failure, the aerial access platform
can be operated with the help of the hand pump
(Fig. 26/2) using the valve groups (Fig. 26/1 and 3).
Fig. 26: Hand pump

4.4.3 Service control

For service work, the aerial access platform can be
operated with the help of the valve groups (Fig. 27/1
and 2) and the appropriate power supply (electric motor
or combustion engine).
Fig. 27: Service work
4.4.4 Lighting
The machine has two floodlights (Fig. 28/1). These are
switched on and off using the light switch on the control
box.
Fig. 28: Floodlights
4.5 Connections
The electric motor is connected by the customer to a
230V connection (Fig. 29/1).
Fig. 29: Electric motor connec-

tion

4.6 Work areas and danger zones
Fig. 30: Work area and danger zone

The work area and danger zone are within the area
marked in red (Fig. 30/1) around the machine.
4.7 Accessories
4.7.1 Keys
The included key ring contains keys for the following
components:
n Control box (double bit key)
n Base plates
n Filling necks on the hydraulic tank
n Combustion engine
n Control panel
Fig. 31: Keys

4.7.2 Safety harness (optional)

A safety harness must be worn for all work in the
working basket. This can be ordered from the manufac-
turer. Please see page 2 for the contact data.
Item no. 8300/0174

Transport and storage
5 Transport and storage

5.1 Safety instructions for transport
Improper transport
WARNING!
Danger to life due to improper transport!
Improper transport can cause severe injuries
or even death.
– During transport of the aerial access plat-
form, do not stay in the working basket.
– Heed dimensions of the aerial access plat-
form.
– Never step under or into the swivel range
of loads that are up in the air.
– Only move loads under supervision.
– Only use approved lifts and lifting acces-
sories with sufficient carrying capacity.
– Only use the attachment points provided.
5.2 Transport inspection

Check the delivery immediately upon receipt to ensure
that it is complete and there is no evidence of transport
damage.
In case of transport damage which is visible from the
outside, proceed as follows:
n Do not accept the delivery or accept it only with res-
ervations.
n Note scope of the damage on the transport docu-
ments or on the transporter's delivery slip.
n Initiate a complaint.
Complain about any defect as soon as it is

detected. Damage claims can only be made
within 12 months after acquisition of the
machine. Special agreements (e.g. mainte-
nance contract) are possible.

5.3 Transport
Attachment points The following attachment points are provided:
Fig. 32: Attachment points

1 Attachment points for transport with a crane
2 Lashing eyes for transport on a trailer (on both sides)
3 Attachment points for transport with a fork lift (continuous)
The attachment points (Fig. 32/1 and 2) are

marked with the symbol Fig. 33 and the fork
eyes (Fig. 32/3) with the symbol Fig. 34.
Fig. 33: Attachment point
Fig. 34: Fork eyes

Transport with a crane Transport pieces can be transported with a crane under
the following conditions:
n The crane and lifts must be designed for the weight
of the aerial access platform.
n The user must be authorised to operate the crane.
n The aerial access platform must be in the transport
position.
n Belts and chains must be the same length and suffi-
ciently long.
Attaching Protective equipment: n Protective helmet
n Safety boots
WARNING!
Property damage due to improper attach-
ment!
The use of unsuitable attachment points can
cause damage to the machine.
– Only use the attachment points specified
here.
1. Put the machine in transport position (Ä Chapter

6.7 „Putting the machine in transport posi-
tion“ on page 81).
2. Switch the machine off (Ä Chapter 6.2 „Switching
the machine on/off“ on page 64).
3. Attach belts or chains to all four support pads with
shackles according to Fig. 35.
The attachment points/lashing eyes are

marked with the Fig. 36 symbol.
Fig. 35: Attachment point for

4. Align the boom of the crane so that the lifting
support pads accessories are evenly loaded.

5. If necessary, protect the paint of the aerial access

platform with suitable underlay materials.
6. Begin transport.
Fig. 36: Attachment point

symbol
Transport with a fork lift The aerial access platform can be transported with a
fork lift under the following conditions:
n The fork lift must be designed for the weight of the
aerial access platform.
position.
Transport Protective equipment: n Protective helmet
n Safety boots

2. Move the crawler chassis all the way out
(Ä Chapter 6.8 „Height and width adjustment
crawler chassis“ on page 86).
3. Switch off the machine (Ä Chapter 6.2 „Switching
Fig. 37: Transport with a fork lift the machine on/off“ on page 64).
4. Insert the forks of the fork lift into the fork eyes pro-
vided (Fig. 37/1).
The fork eyes are marked with the

Fig. 38 symbol.
5. Insert the forks until they protrude on the other

Fig. 38: Fork eyes side.
6. Lift the aerial access platform and begin transport.

Transport on a trailer The aerial access platform can be transported on a

trailer or transporter under the following conditions:
n The trailer or transporter must be designed for the
weight and the dimensions of the aerial access plat-
form.
position.
n The aerial access platform must be anchored to the
means of transport with safety belts on the lashing
rings (Fig. 40/1) provided.

Loading Protective equipment: n Protective helmet

n Safety boots
WARNING!
Property damage due to improper lashing!
The use of unsuitable attachment points can
cause damage to the machine.
– Only use the lashing eyes specified here.
WARNING!
Danger of injury due to improper moving
of the aerial access platform!
With improper moving, the machine can tip or
slide. This can cause severe injuries and sig-
nificant property damage.
– The incline of the ramps may not exceed
36 %.
– During loading, do not stand downhill
behind the aerial access platform.
– Go up the ramps forwards.
– Do not turn the aerial access platform on
the ramp or loading area.
Fig. 39: Transport on a trailer

1. Move the aerial access platform forwards on the
ramps (Fig. 39/1).
2. When the machine begins to tip on the loading
area (Fig. 39/2), slow down.
When the aerial access platform has been set
completely on the loading area (Fig. 39/2) with the
chains, it is safe to speed up again.

3. Anchor and secure the aerial access platform to

the means of transport, e.g. with safety belts in the
lashing eyes (Fig. 40/1)(two on a side).
4. Begin transport.
Fig. 40: Lashing eyes
Unloading Unloading from a loading area takes place in reverse.

To do this, proceed as follows:
1. Back the aerial access platform up slowly.
2. Before tipping, slow down and drive carefully past
the tipping point.
After passing the tipping point, it is safe to speed
up again.
5.4 Storage
Storage of the machine Store the machine under the following conditions:
n Do not store outdoors.
n Store dry and dust-free.
n Do not subject to any aggressive media.
n Protect against solar radiation.
n Avoid mechanical shocks.
n Storage temperature: 15 to 35 °C.
n Relative humidity: max. 60 %.
n In case of storage longer than 3 months, check the
condition of all parts regularly. If necessary, freshen
or replace the rust-proofing.
n Turn the main battery switch to position "0".


Operation
6 Operation
6.1 Safety instructions for operation
Improper operation
WARNING!
Danger of injury due to improper opera-
tion!
Improper operation can cause severe injuries
and significant property damage.
– Execute all operating steps according to
the details and instructions in these
instructions.
– Always perform all work with at least two
people.
– Before beginning work, heed the following:
– Make sure that all covers and safety
equipment are installed and functioning
properly.
– Make sure that there are no people in
the danger zone.
– Never take safety equipment out of
service or bypass it during operation.

Operation
6.2 Switching the machine on/off

Personnel: n Trained people
Protective equipment: n Protective clothing
n Safety boots
n Protective helmet
The power is supplied either by the power network

(construction side feed) using an extension cable (Ä
„Cable lengths“ on page 41) or by the combustion
engine, which is not connected to the power network.
6.2.1 Switching the machine on/off via the mains supply
DANGER!
Upon contact with voltage-conducting parts,
there is an immediate danger to life due to
electric shock. Damage to the insulation or
individual components can present a danger
to life.
– In case of damage to the insulation, switch
off the power supply immediately and
have the machine repaired.
– Before performing work on voltage-con-
ducting parts, pull the mains plug.
– Never bypass fuses or take them out of
operation. When changing fuses, adhere
to the correct amperage.
– Keep humidity away from voltage-con-
ducting parts. This can cause a short-cir-
cuit.

Operation
Switching on
Connect the plug (Fig. 41/1) to the extension cable
(230V). Here, heed the required cable lengths (Ä
„Cable lengths“ on page 41).
The machine is ready for operation when the green
light is blinking.
The green light blinks if the machine is not

Fig. 41: 230V connection
braced or is not braced correctly.
The green light stays on if the machine is
braced correctly.
Switching off
Disconnect the plug (Fig. 42/1) from the extension
cable or press Emergency Stop.
Fig. 42: 230V connection
6.2.2 Switching the machine on/off via the Otto engine
NOTICE!
Voltage drop of the starter battery
Frequent starting of the Otto engine can
cause a voltage drop of the starter battery.
– Avoid frequent starting of the Otto motor.

Operation
See also operating instructions for the Otto engine

(Ä Appendix C „Honda Otto engine“ on page 153).
1. Start the Otto engine by turning and holding the
toggle switch (Fig. 43/1) to and release the
toggle switch immediately when the Otto engine
has started.
NOTICE!
Long starting processes can cause
damage to the starter.
Fig. 43: Starting the Otto 2. Let the Otto engine warm up for approximately 15
engine
seconds before starting to operate the aerial
access platform.
Switching off
To switch off the Otto engine, turn the toggle
switch (Fig. 44/1) on the control panel to and
hold it until the Otto engine stops.
Fig. 44: Stopping the Otto

engine
6.2.3 Switching the machine on/off via diesel engine (option)
NOTICE!
Voltage drop of the starter battery
Frequent starting of the diesel engine can
cause a voltage drop of the starter battery.
– Avoid frequent starting of the diesel motor:

Operation
See also operating instructions for the diesel engine

(Ä Appendix D „Kubota diesel engine“ on page 179).
1. Press the button (Fig. 45/1) and hold until it goes
out.
2. Start the diesel engine by turning and holding the
toggle switch (Fig. 45/2) to and release the
toggle switch immediately when the diesel engine
has started.
NOTICE!
Long starting processes can cause
Fig. 45: Pre-heating and damage to the starter.
starting
3. Let the diesel engine warm up for approximately
15 seconds before starting to operate the aerial
access platform.
Switching off
To switch off the diesel engine, turn the toggle
switch (Fig. 46/1) on the control panel to and
hold it until the diesel engine stops.
Fig. 46: Engine toggle switch
6.3 Shutting down in case of emergency

In dangerous situations, movements of components
must be stopped as quickly as possible and the power
supply switched off.
In case of emergency, proceed as follows:
1. Trigger immediate emergency stop with Emer-
gency Stop button.
2. If there is no danger to your own health, rescue
people in the danger zone.
3. If necessary, start first aid measures.
4. Inform the fire brigade and/or rescue service.
5. Inform responsible people in the deployment loca-
tion.

Operation
6. Switch off the machine and secure against

switching on again.

Operation
6.4 Moving the machine

n Safety boots
n Protective helmet
n Harness

Operation
WARNING!
Danger of injury due to improper moving
of the aerial access platform!
There is a danger of severe injuries or even
death due to improper moving of the aerial
access platform.
– While in the working basket, always put on
a safety harness and hook into the attach-
ment points provided.
people, whereby one person must remain
on the ground in order to activate the
emergency control if necessary.
– Do not exceed maximum working basket
load of 200 kg.
– Heed openings in the floor when moving.
– Do not drive over materials with sharp
edges.
– Do not make any abrupt changes of direc-
tion.
– In case of stop on an incline, secure the
machine against rolling away.
– Make sure that the ladder is folded up and
locked.
– When moving across the slope (max.
10.5° or 20 %), do not stay on the down-
slope side next to the aerial access plat-
form.
– In case of moving on an incline (max.
14.5° or 26 %), no people may be on the
downslope behind the aerial access plat-
form.
– Only go up and down slopes forwards.
– Avoid contact of the rubber tracks with oil,
gasoline, diesel and salt, and clean if nec-
essary.

Operation
Moving the machine can either be carried out from the

working basket or with the control panel as remote con-
trol.
Fig. 47: Control panel

2. Set toggle switch (Fig. 47/1) to move (Fig. 48/1).
Fig. 48: Drive operation

3. With the pre-selection lever (Fig. 47/3) select fast
(Fig. 49/1) or crawl speed (Fig. 49/2).
Fig. 49: Move function

Operation
4. Move machine according to the table:

Operation Effect
Press only the left control The machine turns for-
lever (Fig. 47/2) forwards wards in a clockwise
direction
Press only the right con- The machine turns for-
trol lever (Fig. 47/4) forwards in an anti-clock-
wards wise direction
Press only the left control The machine turns
lever (Fig. 47/2) back- backwards in an anti-
wards clockwise direction
Press only the right con- The machine turns
trol lever (Fig. 47/4) backwards in a clock-
backwards wise direction
Press both control levers The machine moves
(Fig. 47/2 and 4) for- forwards
wards
Pull both control levers The machine moves
(Fig. 47/2 and 4) back- backwards
wards
By pressing the control levers (Fig. 47/2

and 4) slowly, the speed can be
adapted.

Operation
6.5 Putting the machine in working position

n Safety boots
n Protective helmet
n Harness
WARNING!
Danger of injury due to improper bracing!
With improper bracing, the machine can tip or
– Always put the safety harness on when in
the working basket.
people.
– Ensure sufficient load capacity of the sub-
surface (Ä Chapter 3 „Technical
data“ on page 37).
– Heed maximum guard rail angle
(Ä Chapter 3 „Technical
data“ on page 37).
– If necessary, use base plates.
– Make sure that the base plates are
aligned horizontally (maximum deviation
of ± 8°).
– Do not anchor the outriggers with chains,
ropes, pegs, etc.
– Always observe the movement of the out-
riggers when extending.
– Make sure that no people, supply lines or
other objects are in the area around the
outriggers.

Operation
In order to put the machine in work position, the outrig-

gers can be extended manually or automatically.
Bracing the machine can optionally be carried out from
the working basket or with the control panel as remote
control.
Manual bracing
1. Switch on the machine (Ä Chapter 6.2 „Switching

2. Set toggle switch (Fig. 50/1) to outriggers
(Fig. 51/1).
Fig. 51: Operation of outriggers

3. With the pre-selection lever (Fig. 50/3) select the
outriggers 2 and 3 (Fig. 52/1) or 1 and 4
(Fig. 52/2).
Fig. 52: Outrigger function

Operation
4. Extend the outriggers evenly according to the

table:
Pre-selection lever Operation Effect
position
Press the left control lever (Fig. 50/2) for- Outrigger 1 extends
wards
Press the right control lever (Fig. 50/4) for- Outrigger 2 extends
wards
Press the left control lever (Fig. 50/2) for- Outrigger 3 extends
wards
Press the right control lever (Fig. 50/4) for- Outrigger 4 extends
wards

and 4) slowly, the speed of the outrig-
gers can be adapted.
5. Put the chassis in a horizontal position by aligning

the outriggers according to the circular level
(Fig. 53)(Item no. 4001/0298). The bubble
(Fig. 53/1) of the circular level must be within the
1° circle (Fig. 53/2).
ð With proper bracing, the green light on the con-
trol panel remains lit.

Operation
Automatic bracing

(Fig. 55/1).

3. Select the auto function Fig. 54 with the pre-selec-
tion lever (Fig. 56/3).
4. Extend the outriggers evenly according to the
Fig. 56: Automatic bracing table:
When bracing on an inclined surface,

heed the following: Press the control
lever for automatic bracing (full speed for
downward movement of the outriggers)
only until all support pads have made
contact with the ground. Then throttle
back the speed by approximately 50%
by pulling the control lever back.

position
Press the left (Fig. 54/2) or right All outriggers extend
(Fig. 54/4) control lever forwards simultaneously
ð The chassis aligns itself horizontally automati-

cally.

Operation
WARNING!
Danger of injury due to uneven lifting!
With uneven lifting, the machine can tip or
– In case of uneven lifting, cancel the
process immediately and align the
machine manually.
– Have the automatic bracing checked by
Service.
5. Check alignment on the circular level (Fig. 57)(Item

no. 4001/0298). The bubble (Fig. 57/1) of the cir-
cular level must be within the 1° circle (Fig. 57/2).
ð With proper bracing, the green light on the con-
trol panel remains lit.

Operation
6.6 Operating the machine

n Safety boots
n Protective helmet
n Harness
WARNING!
Danger of injury due to improper opera-
tion!
Improper operation can cause severe injuries
and significant property damage.
– While in the working basket, always wear
a safety harness, do not swing or move
jerkily.
people, whereby one person must remain
on the ground in order to activate the
emergency control if necessary.
– Make sure that the ladder is folded up and
locked.
– Do not climb onto the safety fence around
the basket.
– Do not work on or near high-voltage lines.
– Watch out for high obstacles.
– Make sure that when moving the working
basket, no body parts are crushed, e.g.
against a wall.
– At wind speeds above 12.5 m/s (wind
strength 6), stop work immediately.
1. Put the machine in work position (Ä Chapter 6.5

„Putting the machine in working posi-

Operation
2. Set toggle switch (Fig. 58/1) to platform (Fig. 59/1).
Fig. 59: Platform operation

3. Select the platform functions (Fig. 60/1 or 2) with
the pre-selection lever (Fig. 58/3).
Automatic function for collision

avoidance
If the upper and lower boom are in the
transport support and if the
[Lift upper boom] function is then
selected, then the upper boom tele-
scopes out a few centimetres automati-
cally before it lifts itself up.
If the upper and lower boom are then
lowered back into the transport supports,
then the upper boom telescopes a few
centimetres in by itself after the corre-
sponding control lever is no longer acti-
Fig. 60: Platform function vated.

Operation
4. Operate the platform according to the table:

position
Press the left control lever (Fig. 58/2) for- Lift lower boom and
wards extend
Press the left control lever (Fig. 58/2) back- Lift lower boom and
wards retract
Press the right control lever (Fig. 58/4) for- Upper boom lifts
wards
Press the right control lever (Fig. 58/4) Lower the upper
backwards boom

position
Press the left control lever (Fig. 58/2) for- The platform swivels
wards clockwise (seen from
above)
Press the left control lever (Fig. 58/2) back- The platform swivels
wards anti-clockwise (seen
from above)
Press the right control lever (Fig. 58/4) for- Extends the transport
wards of the upper boom
Press the right control lever (Fig. 58/4) Retract the transport
backwards of the upper boom
CAUTION!
Property damage due to incorrectly-
aligned platform!
If the platform is not aligned correctly, the
transport attachments can be damaged when
moving in.
Fig. 61: Red arrows – Make sure that the red arrows (Fig. 61/1)
on the rotating assembly are aligned with
one another when moving into the trans-
port position.
By pressing the control levers (Fig. 58/2 and

4) slowly, the speed of the platform can be
adapted.

Operation
6.7 Putting the machine in transport position

n Safety boots
n Protective helmet
n Harness
Definition of transport position:

n The outriggers (Fig. 62/2) are retracted.
n The lower boom (Fig. 62/4) is on the transport
attachment (Fig. 62/5).
n The upper boom (Fig. 62/3) is on the transport
attachment (Fig. 62/1).
n The basket arm (Fig. 62/6) is in the transport cen-
tring device (Fig. 62/7).
WARNING!
Fig. 62: Transport position Danger of injury when lowering!
Due to uneven lowering of the outriggers, the
machine can tip or slide. This can cause
severe injuries and significant property
damage.
– Always put the safety harness on when in
the working basket.
people.
– Always observe the movement of the out-
riggers and of the chassis while retracting.
– Make sure that no limbs or supply lines
are underneath the crawler chassis.
– Lower the machine evenly.
By pressing the control levers (Fig. 64/2 and

4) slowly, the speed of the platform can be
adapted.

Operation
In order to put the machine in transport position, the

outriggers can be retracted manually or automatically.
Lowering the machine can optionally be carried out
from the working basket or with the control panel as
remote control.
Manual control 1. Switch on the machine (Ä Chapter 6.2 „Switching
Automatic function for collision avoidance

If the upper and lower boom are in the trans-
port support and if the [Lift upper boom] func-
tion is then selected, then the upper boom
telescopes out a few centimetres automati-
If the upper and lower boom are then lowered
back into the transport supports, then the
upper boom telescopes a few centimetres in
by itself after the corresponding control lever
is no longer activated.
2. Extend or retract the upper boom to approximately

20 cm (Ä Chapter 6.6 „Operating the
machine“ on page 78).
3. If necessary, retract the lower boom (Ä Chapter
6.6 „Operating the machine“ on page 78).
4.
CAUTION!
aligned platform!
If the platform is not aligned correctly,
the transport attachments can be dam-
aged when moving in.
Fig. 63: Red arrows

Put the platform in transport position (Ä Chapter
Make sure that the red arrows are across from one
another (Fig. 63).

Operation
5. Lower the upper and lower boom completely

(Ä Chapter 6.6 „Operating the

6. Retract the upper boom completely only now.
Make sure that the basket arm (Fig. 65/2) is sitting
correctly in the transport centring device
(Fig. 65/1).
Fig. 65: Transport centring

device
(Fig. 66/1).

8. With the pre-selection lever (Fig. 64/3) select the
outriggers 1 and 2 (Fig. 67/1) or 3 and 4
(Fig. 67/2).
Fig. 67: Outrigger function

Operation
9. Retract the outriggers evenly according to the

table:
position
Press the left control lever (Fig. 64/2) back- Outrigger 1 retracts
wards
Press the right control lever (Fig. 64/4) Outrigger 2 retracts
backwards
Press the left control lever (Fig. 64/2) back- Outrigger 3 retracts
wards
Press the right control lever (Fig. 64/4) Outrigger 4 retracts
backwards

and 4) slowly, the speed at which the
outriggers retract can be adapted.
Automatic control 1. Switch on the machine (Ä Chapter 6.2 „Switching

Automatic function for collision avoidance

If the upper and lower boom are in the trans-
port support and if the [Lift upper boom] func-
tion is then selected, then the upper boom
telescopes out a few centimetres automati-
If the upper and lower boom are then lowered
back into the transport supports, then the
upper boom telescopes a few centimetres in
by itself after the corresponding control lever
is no longer activated.
2. Extend or retract the upper boom to approximately

20 cm (Ä Chapter 6.6 „Operating the

Operation
3. If necessary, retract the lower boom (Ä Chapter

4.
CAUTION!
aligned platform!
If the platform is not aligned correctly,
the transport attachments can be dam-
aged when moving in.
Fig. 68: Red arrows

Put the platform in transport position (Ä Chapter
Make sure that the red arrows are across from one
another (Fig. 68).
5. Lower the upper and lower boom completely
(Ä Chapter 6.6 „Operating the

6. Retract the upper boom completely only now.
Make sure that the basket arm (Fig. 70/2) is sitting
correctly in the transport centring device
(Fig. 70/1).
Fig. 70: Transport centring

device
(Fig. 71/1).

Operation
8. Select the auto function Fig. 69 with the pre-selec-

tion lever (Fig. 72/3).
9. Retract the outriggers evenly according to the
Fig. 72: Automatic lowering table:

position
Press the left (Fig. 69/2) or right All outriggers retract
(Fig. 69/4) control lever backwards simultaneously

and 4) slowly, the speed at which the
outriggers retract can be adapted.
6.8 Height and width adjustment crawler chassis

n Safety boots
n Protective helmet
Both crawler chassis can be adjusted independently of

one another in their height and thus simultaneously in
their width in 3 levels. The adjustment is done mechani-
cally.
Moving out crawler chassis

2. Lift the machine up using the outriggers until the
crawler chassis is unloaded (Fig. 73/h = max.
20 mm) (Ä Chapter 6.5 „Putting the machine in
working position“ on page 73).
Fig. 73: Unload the crawler

chassis

Operation
WARNING!
Danger of injury due to crushing between
crawler chassis and floor!
When operating the height adjustment, there
can be severe injuries due to crushing
between the crawler chassis and the floor.
– Make sure that there are no limbs
3. 1. Person: release the locking mechanism by

pressing the locking lever (Fig. 74/1).
ð The crawler chassis slips out down to the floor.
Fig. 74: Release locking mech-

anism
4. 2. Person: With both outriggers on the side of the
crawler chassis to be moved out, carefully lift the
machine until the crawler chassis loses contact
with the floor and it moves out further (Ä Chapter
6.5 „Putting the machine in working posi-
Fig. 75: Moving the chassis out ð The locking mechanism snaps in when it rea-
ches the 2nd stage.
To reach the 3rd stage, repeat steps

2 to 4.
5. Make sure that the locking mechanism is snapped

in properly.

Operation
Moving in the crawler chassis

2. Lift the machine up using the outriggers until the
crawler chassis is unloaded (Fig. 76/h = max.
20 mm) (Ä Chapter 6.5 „Putting the machine in
working position“ on page 73).
WARNING!
Danger of injury due to crushing between
crawler chassis and floor!
Fig. 76: Unload the crawler
chassis When operating the height adjustment, there
can be severe injuries due to crushing
– Make sure that there are no limbs
3. 1. Person: release the locking mechanism by

pressing and holding the locking lever (Fig. 77/1).
ð The crawler chassis slips out down to the floor.
Fig. 77: Release locking mech-

anism
4. 2. Person: With both outriggers on the side of the
crawler chassis to be moved in, carefully lower the
machine so that the crawler chassis moves in
(Ä Chapter 6.5 „Putting the machine in working
position“ on page 73).
5. Let the locking mechanism snap in at the desired
Fig. 78: Moving in the crawler move-in height.
chassis 6. Make sure that the locking mechanism is snapped
in properly.

Operation
6.9 Changing the working basket

n Safety boots
n Protective helmet
It is recommended that you change the

working basket with two people.
Removing the working basket 1. Put the machine in transport position (Ä Chapter
2. Pull the spring cotter pin (Fig. 79/1) out of the fas-
tening bolts (Fig. 79/2).
Fig. 79: Pulling out the spring

cotter pin
3. Pull out the fastening bolts (Fig. 80/1).
Fig. 80: Pulling out the fas-

tening bolts

Operation
4. Lift the working basket slightly until it can be

tipped.
Fig. 81: Lifting the working

basket
5. Tip the working basket and pull out at an angle.
For easier moving of the working basket,

two rollers are attached to the bottom.
By tipping it appropriately, the working
basket can be moved on the rollers.
Fig. 82: Pulling out the working

basket
Inserting the working basket

6. Insert the working basket at an angle with the
adapter (Fig. 83/4) on the bolts (Fig. 83/3).
7. Press the working basket in the direction of the
machine and move it with the attachments
(Fig. 83/1) on the bolts (Fig. 83/2).
Fig. 83: Inserting the working

basket
8. Insert the fastening bolts (Fig. 84/1).
Fig. 84: Inserting the fastening

bolts

Operation
9. Secure the fastening bolts (Fig. 85/2) with the

spring cotter pin (Fig. 85/1).
Fig. 85: Securing the fastening

bolts
6.10 Attaching/removing the floodlight mast (optional)

n Safety boots
n Protective helmet
It is recommended that you change the flood-

light mast with two people.
Attaching the floodlight mast 1. Put the machine in transport position (Ä Chapter
2. Remove the working basket (Ä Chapter 6.9
„Changing the working basket“ on page 89).
3. Remove the remote control from the control panel.
4. Unplug the 30-pin plug connector of the remote
control and plug in the included extension cable.
5. Connect the other end of the extension cable to
the remote control.
6. Insert the floodlight mast at an angle with the
adapter (Fig. 86/4) on the bolts (Fig. 86/3).
7. Press the floodlight mast in the direction of the
machine and move it with the attachments
(Fig. 86/1) on the bolts (Fig. 86/2).
Fig. 86: Inserting the floodlight

mast

Operation
8. Insert the fastening bolts (Fig. 87/1).
Fig. 87: Inserting the fastening

bolts
9. Secure the fastening bolts (Fig. 88/2) with the
spring cotter pin (Fig. 88/1).
10. Connect the 4-pin plug connector to the adapter
plug connector of the floodlight mast.
11. Operate the floodlight mast (Ä Chapter 6.11
„Operating the floodlight mast
(optional)“ on page 95).
Fig. 88: Securing the fastening

bolts
Removing the floodlight mast 12. Switch off the floodlight mast (Ä Chapter 6.11
„Operating the floodlight mast
(optional)“ on page 95).

Operation
WARNING!
The floodlights of the floodlight mast can heat
up a lot in operation. Skin contact with hot
surfaces causes severe burns to the skin.
– Before removing the floodlight mast, make
sure that all surfaces have cooled off to
the ambient temperature.
13. Pull the spring cotter pin (Fig. 89/1) out of the fas-
tening bolts (Fig. 89/2).
Fig. 89: Pulling out the spring

cotter pin
14. Pull out the fastening bolts (Fig. 90/1).
Fig. 90: Pulling out the fas-

tening bolts

Operation
15. Lift the floodlight mast slightly until it can be tipped.
Fig. 91: Lifting up the floodlight

mast
16. Tip the floodlight mast and pull out at an angle.
Fig. 92: Pulling out the flood-

light mast

Operation
6.11 Operating the floodlight mast (optional)

n Safety boots
n Protective helmet
CAUTION!
Property damage due to improper opera-
tion!
The simultaneous operation of the floodlight
mast and the aerial access platform causes
an overload of the mains supply or of the
generator.
– Do not operate the floodlight mast and
aerial access platform simultaneously.
Switching on 1. Make sure that the floodlight mast is properly

mounted (Ä Chapter 6.10 „Attaching/removing the
floodlight mast (optional)“ on page 91).
2. Plug the 230V plug of the floodlight mast into the
230V working basket outlet.
3. Put the aerial access platform in work position
(Ä Chapter 6.5 „Putting the machine in working
4. Put the floodlight mast with the aerial access plat-
form in position (Ä Chapter 6.6 „Operating the
5. Switch on the floodlight mast with the included
remote control.
Switching off 6. After finishing work, switch off the floodlight mast
with the remote control.
Only switch the floodlight mast on again

after a 10-minute cooling-off phase.
7. Put the aerial access platform in transport position

(Ä Chapter 6.7 „Putting the machine in transport

Operation
WARNING!
The floodlights of the floodlight mast can heat
up a lot in operation. Skin contact with hot
surfaces causes severe burns to the skin.
– Before removing the floodlight mast, make
sure that all surfaces have cooled off to
the ambient temperature.
8. Disconnect the 230V plug of the floodlight mast.

9. If necessary, remove the floodlight mast
(Ä Chapter 6.10 „Attaching/removing the floodlight
mast (optional)“ on page 91).
6.12 Emergency operation

n Safety boots
n Protective helmet
The aerial access platform has an emergency operation

mode which allows operation of the aerial access plat-
form even without a power supply. The emergency ope-
ration is only intended for sideways, moving in and
turning motions in the direction of the transport position.
1. Switch off the machine and make sure that the
mains plug is disconnected (Ä Chapter 6.2
„Switching the machine on/off“ on page 64).
If the machine is still connected with the

mains plug, the hand pump will not work!
2. Unscrew the cover (Fig. 93/1 and 2).
The valves for outrigger operation are

under the cover (Fig. 93/1) and the
valves for platform operation are under
the cover (Fig. 93/2).
Fig. 93: Removing the cover

Operation
3. Remove the hand lever (Fig. 94/1) and screw into

the adaptor ends (Fig. 94/2) of the hand pump.
Fig. 94: Hand lever

4. Take out the operating lever (Fig. 95/1).
Operating lever item no. 5500/1148
Fig. 95: Operating lever

5.
The operation of the platform will be
explained in exemplary fashion below.
The operation of the outriggers takes
place in the same manner (Ä Chapter
6.14 „Valve settings“ on page 102).
These are black-white valves, that is, the

speed of the platform movement cannot
Fig. 96: Activating the valve be regulated. There are only the posi-
tions "open" or "closed".
Activate the desired valve (Fig. 96/3) by pressing

in with the operating lever (Fig. 96/2) and simulta-
neously pumping with the hand pump (Fig. 96/1).
6. Hold the valve down (Fig. 96/3) and pump with the
hand pump (Fig. 96/1) until the selected compo-
nent has reached the desired position.
7. Remove the operating lever.

Operation
CAUTION!
aligned platform!
If the platform is not aligned correctly, the
transport attachments can be damaged when
retracting.
Fig. 97: Red arrows – Make sure that the red arrows (Fig. 97/1)
on the rotating assembly are aligned with
one another when moving into the trans-
port position.
6.13 Service operation

n Safety boots
n Protective helmet
The aerial access platform has a service mode which

allows operation of the aerial access platform without a
control panel/remote control.
Service mode is not emergency operation

mode!
1. Unscrew the cover (Fig. 98/1 and 3 and 4 if neces-

sary).
Under the cover (Fig. 98/1) there are

valves for outrigger operation and the
two-way valves (Ä Chapter 6.14 „Valve
settings“ on page 102), under the cover
Fig. 98: Removing the cover (Fig. 98/2) are the valves for platform
operation (Ä Chapter 6.14 „Valve set-
tings“ on page 102), under the cover
(Fig. 98/3) the combustion engine
release valve and under the cover
(Fig. 98/4) the combustion engine.
2. Switch on the machine with the electric motor or

combustion engine (Ä Chapter 6.2 „Switching the
machine on/off“ on page 64).

Operation
3. Screw the release valve (Fig. 99/1) in clockwise up

to the stop.
Fig. 99: Locking the release

valve
4. To activate the working basket level, the working
basket release valve must be opened. To do this,
screw the release valve (Fig. 100/1) in clockwise
up to the stop.

release valve
5. For outrigger operation, screw the valve
(Fig. 101/2) in clockwise up to the stop.
For platform operation, screw the valve (Fig. 101/3)
in clockwise up to the stop.
Always screw in only one valve

(Fig. 101/2 or 3). The other one must
always be unscrewed. Before changing
Fig. 101: Select operating from platform operation to outrigger ope-
mode ration or vice-versa, the proportional
valve must always be unscrewed.
6. Screw the proportional valve (Fig. 101/1) in clock-

wise up to the stop.
7. Take out the operating lever (Fig. 102/1).
Operating lever item no. 5500/1148
Fig. 102: Operating lever

Operation
8.
The operation of the platform will be
explained in exemplary fashion below.
The operation of the outriggers takes
place in the same manner (Ä Chapter
6.14 „Valve settings“ on page 102).
These are black-white valves, that is, the

speed of the platform movement cannot
be regulated. There are only the posi-
tions "open" or "closed".
Fig. 103: Activating the valve
Activate the desired valve (Fig. 103/2) by screwing

it in with the operating lever (Fig. 103/1).
9. Hold the valve (Fig. 103/2) down until the selected
component has reached the desired position.
10. Remove the operating lever.
11. After service mode, unscrew the valves (Fig. 104/1
to 3) anti-clockwise.
WARNING!
Danger of injury due to uncontrolled
movements!
In case the valves are set incorrectly in
normal operation, there is a danger of
Fig. 104: Unscrewing the valves uncontrolled movements. This can cause
severe injuries.
– Make sure that for operation via con-
trol panel/remote control, the valves
(Fig. 104/1 to 3) are unscrewed com-
pletely.
12. Unlock the release valve (Fig. 105/1).
Fig. 105: Unlocking the release

valve

Operation
13. If necessary, unlock the working basket release

valve (Fig. 106/1).

release valve
14. Screw the covers (Fig. 107/1 and 3 and 4 if neces-
sary) back on. Here, pay attention to proper and
tight fit.
Fig. 107: Covers

Operation
6.14 Valve settings

6.14.1 Valve setting for platform
Fig. 108: Valve setting for platform

Operation
Explanation of symbols for upper valve row
Lift the lower Extend the Extend the Lift the upper Swivel the Tip working
boom lower boom upper boom boom platform anti- basket back-
clockwise wards
(seen from
above)
Explanation of symbols for lower valve row
Lower the Retract the Retract the Lower the Swivel the Tip working
lower boom lower boom upper boom upper boom platform basket for-
clockwise wards
(seen from
above)

Operation
6.14.2 Valve setting outriggers
The valves for outrigger operation are num-

bered sequentially according to the outrigger
number.
Fig. 109: Valve setting outriggers

1 Extend outrigger 1 5 Retract outrigger 4

Maintenance
7 Maintenance
7.1 Safety instructions for maintenance
Electrical system
DANGER!
Danger to life from electric power!
Contact with live parts may prove fatal. When
switched on, electric components may be
subject to uncontrolled movements and may
cause grave injury.
– Switch off the power supply before starting
work and make sure that it cannot be
switched on again.
Securing to prevent restart

WARNING!
Danger to life from an unauthorised
restart!
In the event of an unauthorised restart of the
power supply during maintenance, there is a
danger of serious injuries or death for per-
sons in the danger zone.
– Switch off all power supplies before
starting work and make sure they cannot
be switched on again.

Maintenance
Improperly-executed mainte-
nance work WARNING!
Danger of injury due to improperly-exe-
cuted maintenance work!
Improper maintenance can cause severe inju-
ries and significant property damage.
– Before starting work, ensure that there is
sufficient assembly space.
– Make sure the assembly space is orderly
and clean! Loosely-stacked components
and tools or those left lying around are a
source of accidents.
– Do not loosen connections sealed with
yellow signal paint.
– If components have been removed, make
sure they are assembled correctly, re-fit all
fastening elements and adhere to screw
tightening torques.
– Before recommissioning, heed the fol-
lowing points:
– Make sure that all maintenance work is
performed and completed according to
instructions.
the danger zone.
properly.
Exhaust gases
WARNING!
air.

Maintenance
Batteries
WARNING!
of batteries!
contact with eyes.
inflamed.

liquids:
tact.
tance.

Maintenance
Hot surfaces
WARNING!
burns to the skin.
blocks.
Hot operating materials

WARNING!
Danger of injury due to hot materials!
Operating materials (coolant liquids or motor
oils) can attain high temperatures in use. Skin
contact with hot materials causes severe
burns to the skin.
– Avoid contact with hot operating materials.
– Check before all work with operating
materials, as to whether these are hot. If
necessary, allow them to cool.
Anti freeze agents

WARNING!

Maintenance

freeze agents:
Engine oil
WARNING!
carcinogenic.
agents.
Environmental protection Observe the following environmental protection instruc-

tions during maintenance work:
n In respect of all lubrication points supplied manually
with lubricant, remove any escaping, used or surplus
grease and dispose of in accordance with applicable
local regulations.
n Catch replaced oils in suitable containers and dis-
pose of in accordance with applicable local regula-
tions.

Maintenance
7.2 Maintenance plan

The next sections describe the maintenance work that
is required for optimal and fault-free operation of the
machine.
Insofar as increased wear can be detected during reg-
ular checks, the required maintenance intervals must be
abbreviated according to the actual signs of wear. In
case of questions about maintenance work and inter-
vals, contact the manufacturer. See contact data on
page 2.
For the maintenance work for the combustion

engine, see the appendix to the instructions
(Ä Appendix C „Honda Otto
engine“ on page 153 or optionally
Ä Appendix D „Kubota diesel
engine“ on page 179).
The operating hours counter (Fig. 110/1) is

on the control box (Fig. 110/2).
Fig. 110: Operating hours

counter

Maintenance
Interval Maintenance work Personnel

As necessary Charge battery (Ä Appendix C „Honda Otto Trained people
engine“ on page 153 or Ä Appendix D „Kubota
diesel engine“ on page 179)
Tension chain (Ä Chapter 7.3.2 „Tensioning the Qualified per-
chain“ on page 113) sonnel
Clean machine (Ä Chapter 7.3.1 Trained people
„Cleaning“ on page 112)
After the first 50 Tighten fastening screws on the rotating assembly Qualified per-
hours of operation (Ä Chapter 7.3.9 „Rotating assembly tightening tor- sonnel
ques“ on page 125)
Every 50 hours of Grease the grease nipple on the rotating assembly Qualified per-
operation and rotating assembly drive (Ä Chapter 7.3.3 sonnel
„Lubricating the rotating assembly“ on page 115
and Ä Chapter 7.3.8 „Lubrication
plan“ on page 123)
Lubricate the bolts (Ä Chapter 7.3.8 „Lubrication Qualified per-
plan“ on page 123) sonnel
Check the hydraulic oil level (Ä Chapter 7.3.5 Qualified per-
„Checking the hydraulic oil level“ on page 118) sonnel
Every 150 hours Lubricate transport guide slide bearing (Ä Chapter Qualified per-
of operation 7.3.4 „Greasing the transport“ on page 116) sonnel
Check hydraulic hoses for damage and leaks Qualified per-
sonnel
Check energy supply chains for wear and damage Qualified per-
sonnel
Every 800 hours Tighten fastening screws on the rotating assembly Qualified per-
of operation or (Ä Chapter 7.3.9 „Rotating assembly tightening tor- sonnel
annually ques“ on page 125)
Replace hydraulic filter (Ä Chapter 7.3.7 Qualified per-
„Replacing the hydraulic filter“ on page 122) sonnel
Carry out annual maintenance according to Expert
"Checklist - Leo Maintenance -" (see Annex of
Machine Record)
Check the gearbox oil level (Ä Chapter 7.3.6 Qualified per-
„Checking the gearbox oil level of the chain sonnel
drive“ on page 120)
Replace hydraulic filter (Ä Chapter 7.3.7 Qualified per-
„Replacing the hydraulic filter“ on page 122) sonnel

Maintenance
Interval Maintenance work Personnel

Every 2000 hours Change battery (Ä Appendix C „Honda Otto Qualified per-
of operation or engine“ on page 153 or Ä Appendix D „Kubota sonnel
every 2 years diesel engine“ on page 179)
Every 6 years Replace all hydraulic hoses Hydraulics Spe-
cialist
7.3 Maintenance work

7.3.1 Cleaning
Personnel: n Qualified personnel
n Safety boots
NOTICE!
Property damage due to improper
cleaning!
Improper cleaning can cause damage to the
machine.
– Do not use any acidic or aggressive
cleaning agents.
– Remove all cleaning agents thoroughly
with clear water.

2. Make sure that all covers are mounted properly.
3. Loosen coarse dirt with the high-pressure cleaner.
Do not clean the appropriately-marked compo-
nents (Fig. 111) with the high-pressure cleaner.
4. Clean machine with a sponge, acid-free household
cleanser and a water hose.
5. After cleaning the machine, lubricate it according
to Ä Chapter 7.3.8 „Lubrication plan“ on page 123.
Fig. 111: Cleaning forbidden

Maintenance
7.3.2 Tensioning the chain

Protective equip- n Protective clothing
ment: n Safety boots
Special tool: n Grease gun
Materials: n Multi-purpose lubricant (Item
no. 3917/0095)
1. Put the machine in work position (Ä Chapter 6.5

„Putting the machine in working posi-
tion“ on page 73). The machine must be braced
completely and the chains may no longer touch the
floor.
3. Unscrew the cover (Fig. 112/1) and remove the lid
(Fig. 112/2).
Fig. 112: Lid and cover

4. Pull the sliding coupling (Fig. 113/2) out of the
bracket (Fig. 113/1).
Fig. 113: Sliding coupling

Maintenance
5. Push the sliding coupling (Fig. 114/1) with the

grease nipple (Fig. 114/2) in front onto the grease
tension cylinder (Fig. 114/3).
Fig. 114: Put back the sliding

coupling
6. Turn the sliding coupling (Fig. 115/1) by 180°
clockwise until the grease nipple (Fig. 115/2)
points outward.
7. With a grease gun on the grease nipple
(Fig. 115/2), insert sufficient multi-purpose lubri-
cant (Item no. 3917/0095) that the chain has slack
(Fig. 116/X) of 10–15 mm.
Fig. 115: Turning the sliding

coupling
8. Make sure that no lubricant escapes on the grease
nipple (Fig. 115/2).
Fig. 116: Slack X

9. Turn the sliding coupling (Fig. 117/1) back by 180°
anti-clockwise and pull it out of the grease tension
cylinder (Fig. 117/2).
Fig. 117: Pulling out the sliding

coupling

Maintenance
10. Put the sliding coupling (Fig. 118/2) back into the
bracket (Fig. 118/1).
Fig. 118: Sliding coupling

11. Re-mount the cover (Fig. 119/1) and re-mount the
lid (Fig. 119/2).
Fig. 119: Lid and cover
7.3.3 Lubricating the rotating assembly

Special tool: n Grease gun
Materials: n High-performance lubricant
(Item no. 3917/0130)
1. Use the grease gun on the grease nipples

(Fig. 120/1) of the rotating assembly to insert high-
performance lubricant (Item no. 3917/0130).
2. Remove the excess lubricant and dispose of it
properly.
Fig. 120: Lubricating the

rotating assembly

Maintenance
7.3.4 Greasing the transport

Materials: n White paste spray (Art No 3917 /
0037)
n Thinner EPI Biosol special (art
no 3910 / 0168)
Greasing the upper boom 1. Put the machine in broad work position (Ä Chapter
transport 6.5 „Putting the machine in working posi-
2. Lift the upper boom (Fig. 121/1) until it stands
approximately horizontal (Ä Chapter 6.6 „Oper-
ating the machine“ on page 78).
3. Support upper boom transport with a belt slip or
with a rolling cart.
WARNING!
Fig. 121: Lifting the upper boom
Danger of injury due to deactivated safety
equipment!
The further operation of the platform can only
take place in service mode (Ä Chapter 6.13
„Service operation“ on page 98). In service
mode, all safety equipment does not function.
– Follow the operating sequence below and
follow the instructions precisely.
4. Change to service mode (Ä Chapter 6.13 „Service

operation“ on page 98).
5. Extend the upper boom transport (Fig. 122/1) com-
pletely (Ä Chapter 6.13 „Service opera-
6. Clean the sliding surfaces of the upper boom
transport on all side with thinned EPI Biosol spezial
(Item no. 3910/0168) and then grease on all sides
Fig. 122: Extending the upper with white paste spray (Item no. 3917/0037).
boom transport 7. Lift the upper boom up so that when extending the
lower boom transport, the working basket cannot
crash into the lift boom holder (Ä Chapter 6.13
„Service operation“ on page 98).
8. Support lower boom transport with a belt slip or
with a rolling cart.

Maintenance
9. Extend the lower boom transport (Fig. 123/1) com-

pletely (Ä Chapter 6.13 „Service opera-
10. Clean the sliding surfaces of the lower boom trans-
port on all sides with thinned EPI Biosol spezial
(Item no. 3910/0168) and then grease on all sides
Fig. 123: Extending the lower with white paste spray (Item no. 3917/0037).
boom transport
11. Retract the lower boom completely (Ä Chapter
6.13 „Service operation“ on page 98).
12. Retract the upper boom completely (Ä Chapter
6.13 „Service operation“ on page 98).
13. Remove the belt slip or rolling cart.
The following step can be carried out in

normal mode.
14. Leave service mode (Ä Chapter 6.13 „Service

operation“ on page 98).
15. Operate the machine (Ä Chapter 6.6 „Operating
the machine“ on page 78) or if necessary, put it in
transport position (Ä Chapter 6.7 „Putting the
machine in transport position“ on page 81).

Maintenance
7.3.5 Checking the hydraulic oil level

Materials: n Hydraulic oil (Item no.
3917/0066)
NOTICE!
Property damage due to improper filling!
An incorrect oil level or incorrect hydraulic oil
can cause failure of and damage to the
hydraulic system.
– Check the oil level regularly.
– Only use prescribed oils (Ä Chapter 3.9
„Lubricants“ on page 42).
– Do not mix types of oil.

2. Make sure that the aerial access platform is
aligned horizontally.
4. Check the oil level on the inspection glass
(Fig. 124/1).
Fig. 124: Hydraulic oil inspec-

tion glass

Maintenance
5. If necessary, top up hydraulic oil (Item no.

3917/0066)(Ä Chapter 3.9 „Lubri-
cants“ on page 42). To do this, unscrew the cover
(Fig. 125/1).
Fig. 125: Opening the cover

6. Open the padlock of the lid (Fig. 126/1) with the
corresponding spanner and remove it (Ä Chapter
4.7.1 „Keys“ on page 53).
7. Unscrew the cover (Fig. 126/1) from the hydraulic
oil tank.
8. Fill up the hydraulic oil up to the maximum marking
on the inspection glass (Fig. 124/1).
9. Screw the lid (Fig. 126/1) back on and secure with
Fig. 126: Unscrewing the lid the padlock.
10. Screw on the cover (Fig. 127/1).
Fig. 127: Screwing on the cover

Maintenance
7.3.6 Checking the gearbox oil level of the chain drive

Materials: n Gearbox oil (Item no.
3917/0130)
NOTICE!
Property damage due to improper filling!
An incorrect oil level or incorrect gearbox oil
can cause failure of and damage to the
gearbox.
– Check the oil level regularly.
– Only use prescribed oils (Ä Chapter 3.9
„Lubricants“ on page 42).
The chain drives each have a separate gearbox. The

following instructions apply for one gearbox.
2. Align the machine so that the lower edge of the
screw connection (Fig. 128/1) is on the middle axis
(Fig. 128/2) of the gearbox unit (Fig. 128/3).
3. Make sure that the machine is aligned horizontally.
Fig. 128: Aligning the aerial

access platform

Maintenance
5. Unscrew the screw connections (Fig. 129/1 and 2).
If necessary, catch escaping gearbox oil

and dispose of it properly.
Fig. 129: Unscrewing the screw

connections
6. Check the oil level visually. The gearbox must be
filled with oil up to the lower edge of the threaded
hole (Fig. 130/1).
7. If necessary, top up gearbox oil (Item no.
3917/0122)(Ä Chapter 3.9 „Lubri-
cants“ on page 42). To do this, tip oil slowly
through the hole (Fig. 130/2) until it reaches the
lower edge of the threaded hole (Fig. 130/1).
8. Make sure that the seals and copper washers of
the screw connections are present and undam-
aged.
Fig. 130: Checking the oil level
9. Re-tighten the screw connections (Fig. 131/1 and
2) with the seals or copper washers.
Fig. 131: Tightening the screw

connections

Maintenance
7.3.7 Replacing the hydraulic filter

Materials: n Filter insert (Item no.
3162/0019)

2. Switch off the the machine, if necessary pull the
mains plug.
3. Unscrew the cover (Fig. 132/1).
Fig. 132: Loosen the cover

4. Place a suitable container for hydraulic oil under
the high-pressure filters (Fig. 133/1 and 2).
5. Unscrew the filter bowls (Fig. 133/1 and 2) care-
fully.
6. Catch escaping hydraulic oil and dispose of it prop-
erly.
Fig. 133: Unscrewing the filter

bowl
7. Remove the filter inserts (Fig. 134/1 and 2) and
insert new filter inserts.
The filter insert (Item no. 3162/0019) can

be ordered from the manufacturer.
Please see page 2 for the contact data.
Fig. 134: Filter insert

Maintenance
8. Screw the filter bowls (Fig. 135/1 and 2) back on

carefully.
Fig. 135: Hydraulic filters

9. Screw the cover (Fig. 136/1) back on and check for
tight fit.
10. Check the hydraulic oil level (Ä Chapter 7.3.5
„Checking the hydraulic oil level“ on page 118).
Fig. 136: Fastening the cover
7.3.8 Lubrication plan
When handling lubricants, always heed the

manufacturer's safety data sheet. With speci-
fication of the item number, the lubricants can
be ordered from the manufacturer. Please
see page 2 for the contact data.
The interval details relate to normal soiling. In

case of heavier soiling, it may be necessary
to adapt the intervals.

Maintenance
Fig. 137: Lubrication plan
No. Designation Lubricant TEUPEN item Interval

number
1 Bolts Lubricant spray 3917/0005 every 50 hours of
operation
2 Transport guides slide White paste spray 3917/0037 every 150 hours of
bearing operation
3 Rotating drive (3 grease Grease 3917/0095 every 50 hours of
nipples) operation
4 Bracing pads (ball pins) Grease 3917/0095 every 50 hours of
4x operation
5 Slide bearings outriggers Grease 3917/0095 every 50 hours of
operation
Bh = hours of operation

Maintenance
7.3.9 Rotating assembly tightening torques
WARNING!
Danger due to incorrect tightening tor-
ques!
If screws are tightened with the incorrect
tightening torque, components can come
loose and cause personal injury and property
damage.
– Never exceed the maximum allowable
tightening torque.
– Check the tightening torques regularly.
– Always heed the relevant guidelines and
design criteria for screw connections.
The table shows the required tightening torques for ach-

ieving the most reliable initial tension for the screws of
the rotating assembly.
Screw size Screw quality Tightening

torque
M 12 10.9 110 Nm
M16 10.9 270 Nm

Maintenance

Faults
8 Faults
The following section describes possible causes of
faults and the work to remedy them.
In case of faults that occur more than once, abbreviate
the maintenance intervals according to the actual uti-
lisation.
In case of faults that cannot be remedied using the fol-
lowing instructions, contact the manufacturer, see con-
tact data on page 2.
8.1 Safety instructions for fault repair

Electrical system
DANGER!
Danger to life from electric power!
Contact with live parts may prove fatal. When
switched on, electric components may be
subject to uncontrolled movements and may
cause grave injury.
– Switch off the power supply before starting
work and make sure that it cannot be
switched on again.
Securing to prevent restart

WARNING!
Danger to life from an unauthorised
restart!
In the event of an unauthorised restart of the
power supply while tracking down and recti-
fying a fault, there is a danger of serious inju-
ries or death for persons in the danger zone.
– Switch off all power supplies before
starting work and make sure they cannot
be switched on again.

Faults
Improperly-performed work for

fault repair WARNING!
Danger of injury due to improper fault
repair!
Improperly-performed work for fault repair
can cause severe injuries and significant
property damage.
– Before starting work, ensure that there is
sufficient assembly space.
– Make sure the assembly space is orderly
and clean! Loosely-stacked components
and tools or those left lying around are a
source of accidents.
– Do not loosen connections sealed with
yellow signal paint.
– If components have been removed, make
sure they are assembled correctly, re-fit all
fastening elements and adhere to screw
tightening torques.
– Before recommissioning, heed the fol-
lowing points:
– Make sure that all fault repair work is
performed and completed according to
instructions.
the danger zone.
properly.
Moving parts
WARNING!
Danger of injury from moving parts!
Rotating parts and/or parts moving in linear
fashion may cause serious injuries.
– Before carrying out any troubleshooting
work on moving parts, shut down the
machine and take precautions to prevent
restarting. Wait until all parts have
stopped moving.
– When in the danger zone, wear close-fit-
ting protective work clothing with low tear
strength.

Faults
Exhaust gases
WARNING!
air.
Batteries
WARNING!
of batteries!
contact with eyes.
inflamed.

Faults

liquids:
tact.
tance.
Hot surfaces
WARNING!
burns to the skin.
blocks.
Hot operating materials

WARNING!
Danger of injury due to hot materials!
Operating materials (coolant liquids or motor
oils) can attain high temperatures in use. Skin
contact with hot materials causes severe
burns to the skin.
– Avoid contact with hot operating materials.
– Check before all work with operating
materials, as to whether these are hot. If
necessary, allow them to cool.

Faults
Anti freeze agents

WARNING!

freeze agents:
Engine oil
WARNING!
carcinogenic.
agents.
Behaviour in the event of faults

The following applies in principle:
1. Immediately initiate an emergency stop in the
event of faults posing an immediate danger to
people or property.
2. Ascertain the cause of the fault.

Faults
3. If fault rectification requires work in the danger

zone, shut down the machine and secure to pre-
vent restarting.
Immediately notify those responsible at the place
of use about the fault.
4. Depending on the nature of the fault, have it recti-
fied by authorised specialised personnel or rectify
it yourself.
The fault table below provides information

about who is authorised to rectify the fault.
8.2 Fault table
In addition to the following table, follow the

operating instructions for the combustion
engine (Ä Appendix C „Honda Otto
engine“ on page 153 or Ä Appendix D
„Kubota diesel engine“ on page 179).
If the fault is not included in the table below or

if it cannot be repaired with the measures
described, make contact with the manufac-
turer (see page 2 for the contact data).
Fault descrip- Cause Remedy Per-

tion sonnel
No function of Fuel tank empty Fill fuel tank Trained
the combustion people
engine

Faults

tion sonnel
Safety equipment Check safety equipment and switch on Trained
has been trig- or replace if necessary (Ä Chapter people
gered (fuse, FI 8.4.1 „Changing fuses“ on page 138 or
circuit breaker) Ä Chapter 8.4.2 „Switching the circuit
breaker on/off“ on page 140)
Starter battery Charge starter battery (Ä Appendix C Trained
discharged „Honda Otto engine“ on page 153 or people
Ä Appendix D „Kubota diesel
engine“ on page 179)
Emergency Stop Unlock Emergency Stop button (Ä Trained
button activated „Emergency Stop button“ on page 28) people
No function for Safety equipment Check safety equipment and switch on Trained
power supply via has been trig- or replace if necessary (Ä Chapter people
construction-side gered (fuse, FI 8.4.1 „Changing fuses“ on page 138 or
feed circuit breaker) Ä Chapter 8.4.2 „Switching the circuit
Extension cable Replace extension cable Trained
faulty people
Incorrect cable Adhere to permissible cable length Trained
cross-section or and cable cross-section (Ä „Cable people
incorrect cable lengths“ on page 41)
length
Emergency Stop Unlock Emergency Stop button (Ä Trained
button activated „Emergency Stop button“ on page 28) people
Chain does not Switch position on Move toggle switch to "Move" Trained
move the control panel (Ä Chapter 6.4 „Moving the people
incorrect machine“ on page 69)
Bracing not pos- Switch position on Move toggle switch to "Outriggers" Trained
sible the control panel (Ä Chapter 6.5 „Putting the machine in people
incorrect working position“ on page 73)

Faults

tion sonnel
Machine not in Put the machine in transport position Trained
transport position (Ä Chapter 6.7 „Putting the machine in people
transport position“ on page 81)
No platform func- Emergency Stop Unlock Emergency Stop button (Ä Trained
tion possible button activated „Emergency Stop button“ on page 28) people
Bracing not cor- Brace machine correctly (Ä Chapter Trained
rect 6.5 „Putting the machine in working people
Switch position on Move toggle switch to "Platform" Trained
the control panel (Ä Chapter 6.6 „Operating the people
incorrect machine“ on page 78)
No or insufficient Check voltage supply Qualified
voltage supply Electri-
cian
Extension of Safety equipment Check safety equipment and switch on Trained
upper boom not has been trig- or replace if necessary (Ä Chapter people
possible gered (fuse, FI 8.4.1 „Changing fuses“ on page 138 or
Swivelling not Upper and lower Lift lower boom out of the transport Trained
possible boom still in the attachment (Ä Chapter 6.6 „Operating people
transport attach- the machine“ on page 78)
ment
Green light on Bracing not cor- Check bracing (Ä Chapter 6.5 „Putting Trained
the control panel rect the machine in working posi- people
is blinking tion“ on page 73)

Faults

tion sonnel
Red light on the Operating lever Activate Emergency Stop and re-start Trained
control panel is moved during the control (unlock Emergency Stop people
always lit start process button)
System error Call service Trained
people
Red light on the Basket level is Align basket using valve control (emer- Trained
control panel is tilted more than ± gency mode)(Ä Chapter 6.12 „Emer- people
blinking 5° gency operation“ on page 96)
Red and green Safety equipment Check safety equipment and switch on Trained
lights never light has been trig- or replace if necessary (Ä Chapter people
up gered (fuse, FI 8.4.1 „Changing fuses“ on page 138 or
Motor pump runs Hydraulic hose Checking the hydraulic hoses Qualified
and stalls kinked personnel
Hydraulic filter Replace filter insert (Ä Chapter 7.3.7 Qualified
soiled „Replacing the hydraulic personnel
filter“ on page 122)
Cylinder lowers Hydraulic system Take machine out of service immedi- Trained
by itself defective ately and call service people
Loud motor Too little hydraulic Check hydraulic oil level and top up if Trained
pump noise and oil in the tank necessary (Ä Chapter 7.3.5 „Checking people
movements get the hydraulic oil level“ on page 118)
slower and then
stop Hydraulic system Call service Trained
is leaking people
Outlet in the Power supply Check power supply Qualified
working basket interrupted Electri-
has no voltage cian
Plug not in the Plug in plug (Ä Chapter 6.2 „Switching Trained
outlet the machine on/off“ on page 64) people
Safety equipment Check the fuses (Ä Chapter 8.5 Trained
has triggered „Fuses“ on page 141) people
Great wear on Drive ring Call service Trained
the crawler track severely worn people
Steel wires of the Excessive tension Call service Trained
rubber tracks on the chain people
broken bands due to
stones caught,
abrupt swerving

Faults

tion sonnel
on rough floor,
defective spring
set, frozen mate-
rial between the
rollers
8.3 Notes about the rubber track

Damage During operation, the rubber track is subject to normal
wear. Some kinds of damage are explained in the table
below.
Damage Possible cause Note

Cracks in the profile n Hard use in the field. No compromise of opera-
foot n Crossing sharp-edged or high tion.
hurdles.
n With old, little-used tracks, pos-
sible material fatigue as a
result of bending load.
Cracks on the outside n Hard use in the field. No compromise of opera-
flanks n Crossing sharp-edged or high tion.
hurdles.
Cracks on the inside n Various causes. No compromise of opera-
by the metal core tion.
Wear of the metal core n Normal wear due to cams of Heed chain tension. The
the drive wheel. metal core can become bent
n Increased wear with use on by great wear. This can
very sandy ground. cause breaks with progres-
sive wear. Change rubber
tracks early.
Wear of the profile n Normal occurrence. Depending on the area of
n Depending on the area of application, the rubber
application earlier or later. tracks must be replaced
appropriately early. Essen-
tially, however, can be
moved until there is no more
profile.

Faults
Remedies n Brief daily visual inspection.

n Careful moving in swampy ground, especially when
slowing down.
n In case of palpable resistance, first determine the
cause. Do not move forward with force.
n Use care when driving on impassable and hilly land,
especially when slowing down.
n Execute control manoeuvres with appropriate cau-
tion.
n Clean chain drive after completing work.
n If there is a danger of frost, clean the drive and track
inside by driving on clean ground. Then park the
machine on wooden boards.

Faults
8.4 Work for fault repair

8.4.1 Changing fuses
n Safety boots
DANGER!
In case of contact with live components, there
is danger to life. Switched-on electric compo-
nents can make uncontrolled movements and
cause extremely severe injuries.
– Before starting work, switch off the power
supply and secure against switching on
again.
– When changing fuses, adhere to the cor-
rect amperage.

2. Unscrew the cover (Fig. 138/1).
Fig. 138: Loosen the cover

3. Open control box door (Fig. 139/1) with the
included double bit key (Ä Chapter 4.7.1
„Keys“ on page 53).
Fig. 139: Opening the control

box door

Faults
4. The fuses are on the fuzzy control card

(Fig. 140/1).
Replace defective fuse with a new fuse of equal
amperage (Ä Chapter 8.5.1 „Fuzzy control
card“ on page 141).
Fig. 140: Fuzzy control card

5. Close control box door (Fig. 141/1) and lock with
the double bit key.
Fig. 141: Close control box

door
6. Screw the cover (Fig. 142/1) back on and check for
tight fit.
Fig. 142: Fastening the cover

Faults
8.4.2 Switching the circuit breaker on/off

n Safety boots
DANGER!
In case of contact with live components, there
is danger to life. Switched-on electric compo-
nents can make uncontrolled movements and
cause extremely severe injuries.
– Before starting work, switch off the power
supply and secure against switching on
again.
– When changing fuses, adhere to the cor-
rect amperage.

2. Open control box door (Fig. 143/1) with the
included double bit key (Ä Chapter 4.7.1
„Keys“ on page 53).
Fig. 143: Control box

3. Switch the FI circuit breaker (Fig. 144/1) or fuse for
outlet on the working basket (Fig. 144/2) on or off.
4. Close the control box (Fig. 143/1).
Fig. 144: Circuit breaker

Faults
8.5 Fuses
8.5.1 Fuzzy control card
The fuzzy control card is in the control box on the left
side of the aerial access platform. The control boxes
are opened with a double bit key.
No Position Designation Type
.
1 - Voltage supply to fuzzy Glass fuse M
control card 1.25 A
2 A2.8 Fault light Glass fuse
FF 4 A
A2.9 Outrigger light
A2.10 Signal transmitter
(option)
A2.11 Changeover valve plat-
form/outriggers
3 A2.4 Release hydraulic Glass fuse
FF 4 A
A2.5 Electric motors
A2.6 Speed 1
A2.7 Speed 2
4 A2.0 Current regulating Glass fuse
valve FF 4 A
A2.1 Lower the upper boom
A2.2 Lift the upper boom
A2.3 Retract upper boom
5 A8.4 Chain right backwards Glass fuse
Fig. 145: Fuzzy control card FF 4 A
A8.5 Chain right forwards
A8.6 Chain left backwards
A8.7 Chain left forwards
6 A8.0 Outrigger 1 Glass fuse
FF 4 A
A8.1 Outrigger 2
A8.2 Outrigger 3
A8.3 Outrigger 4

Faults
8.5.2 Working basket fuse and FI circuit breaker

The fuse for the outlet on the working basket and the FI
circuit breaker are in the control box next to the
hydraulic tank.
1 FI circuit breaker
2 Fuse for outlet on working basket
Fig. 146: Fuses

Disposal
9 Disposal
After the service life of the machine has ended, the
machine must be disposed of in environmentally-
friendly fashion.
WARNING!
Danger of injury through incorrect dis-
posal!
Improper disposal can cause severe injuries.
– Permit disposal only through authorised
specialist agencies.
If no there is no take-back or disposal agreement,

submit disassembled components for recycling:
n Dispose all liquids in an environmentally correct
manner.
n Scrap metals.
n Give plastic elements to recycling.
n Dispose off other components sorted according to
their material properties.
NOTICE!
Danger to the environment due to incor-
rect disposal!
Improper disposal can present a danger to
the environment.
– Have electrical scrap, electronic compo-
nents, lubricants and other auxiliary mate-
rials disposed of by an approved opera-
tion.
– In case of doubt, obtain information about
environmentally-friendly disposal from the
local municipal authorities or a special dis-
posal operation.

Disposal

Index
10 Index
A Engine switch......................................... 51
Accident.................................................. 34 Environmental protection
Aerial access platform............................ 78 Cleaning liquids.................................. 35
Attachment points................................... 56 Cooling water..................................... 36
B Frost protection.................................. 36
Battery main switch................................ 29 Fuels.................................................. 36
Bracing Hydraulic oil........................................ 36
automatic...................................... 76, 84 Lubricants........................................... 36
manual......................................... 73, 81 F
C Fault table............................................. 132
Cable lengths.......................................... 41 FI circuit breaker................................... 142
Chain drive............................................. 48 Fire......................................................... 34
Chassis................................................... 48 First aid................................................... 34
Circuit breaker...................................... 142 Floodlight mast
Circular level........................................... 30 attaching/removing............................. 91
Connections............................................ 52 operating............................................ 95
Contact person....................................... 11 Fuses.................................................... 141
Control card.......................................... 141 Fuzzy control card................................ 141
Control lever..................................... 50, 51 H
Control panel.......................................... 50 Hand pump....................................... 30, 51
Copyright.................................................. 9 Hazards.................................................. 13
Crawler chassis................................ 48, 86 Height adjustment................................... 86
moving in............................................ 88 Honda iGX 440....................................... 40
moving out.......................................... 86 Hydraulics............................................... 18
Customer service.................................... 11 K
D Keys........................................................ 53
Danger zones......................................... 53 Kubota Z-602.......................................... 40
Diesel engine.................................... 40, 49 L
Disposal................................................ 143 Light
Double bit key......................................... 53 green.................................................. 51
E red...................................................... 51
Electric current........................................ 15 Lighting................................................... 52
Electric motor.................................... 40, 49 Light switch............................................. 52
Emergency............................................. 67 Limitation of rotation area....................... 31
Emergency operation............................. 51 Limit switch............................................. 29
Emergency Stop..................................... 67 Lubricants....................................... 42, 123
Emergency Stop button.................... 28, 51 Lubrication plan.................................... 123

Index
M Storage................................................... 61
Main dimensions..................................... 37 Symbols
Motor...................................................... 49 in the instructions................................. 7
Moving.................................................... 69 on the machine................................... 32
Moving the machine............................... 69 T
O Tightening torque................................. 125
Oil recommendations.............................. 42 Tilt sensor............................................... 30
Operating conditions............................... 41 Toggle switch.......................................... 50
Operation................................................ 78 Transport
Otto engine....................................... 40, 49 crane.................................................. 57
Outriggers............................................... 47 Fork lift............................................... 58
Overview........................................... 45, 46 Trailer................................................. 59
Owner..................................................... 21 Transport inspection............................... 55
P Transport position................................... 81
Personnel............................................... 23 Type plate............................................... 43
Platform.................................................. 47 U
Platform operation.................................. 78 Use......................................................... 21
Pre-heating switch.................................. 51 V
Pre-selection lever.................................. 51 Valves
Proper use.............................................. 21 Emergency operation......................... 30
Protective equipment.............................. 25 Outrigger function............................... 30
R Platform function................................ 31
Remaining risks...................................... 13 Valve setting
Remote control....................................... 50 Outriggers........................................ 104
Rescue measures................................... 67 Platform............................................ 102
Rotating assembly................................ 125 W
S Warranty provisions................................ 10
Safety devices........................................ 26 Width adjustment.................................... 86
Safety equipment............................. 27, 28 Work areas............................................. 53
Safety harness........................................ 54 Work diagram......................................... 38
Screw tightening torque........................ 125 Working basket....................................... 48
Service.................................................... 11 changing............................................. 89
Service work........................................... 52 Working position..................................... 73

Appendix
Appendix

Appendix
Table of contents of the appendix

A Circuit diagram............................................... 149
B Hydraulic plan................................................. 151
C Honda Otto engine.......................................... 153
D Kubota diesel engine....................................... 

Circuit diagram
A Circuit diagram

Circuit diagram

Hydraulic plan
B Hydraulic plan

Hydraulic plan

Honda Otto engine
C Honda Otto engine

Honda Otto engine

INTRODUCTION
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 OWNER’S MANUAL
carefully before operating the engine. If a problem should arise, or
if you have any questions about your engine, consult an
MANUEL DE L’UTILISATEUR
authorized Honda servicing dealer. MANUAL DEL PROPIETARIO
All information in this publication is based on the latest product
information available at the time of printing. Honda Motor Co., Ltd. iGX440
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.
This manual should be considered a permanent part of the engine

and should remain with the engine if resold.
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 The engine exhaust from this product
by your dealer. contains chemicals known to the State of
California to cause cancer, birth defects
SAFETY MESSAGES or other reproductive harm.
Your safety and the safety of others are very important. We have
provided important safety messages in this manual and on the CONTENTS
engine. Please read these messages carefully.
INTRODUCTION ........................1 SPARK PLUG .......................11
A safety message alerts you to potential hazards that could hurt SAFETY MESSAGES .................1 SPARK ARRESTER ..............11
you or others. Each safety message is preceded by a safety alert SAFETY INFORMATION ...........2 FUSE.....................................12
symbol and one of three words, DANGER, WARNING, or SAFETY LABEL LOCATION ......2 HELPFUL TIPS &
CAUTION. COMPONENT & CONTROL SUGGESTIONS .......................13
LOCATION .................................2 STORING YOUR ENGINE ....13
These signal words mean: FEATURES .................................3 TRANSPORTING .................14
You WILL be KILLED or SERIOUSLY BEFORE OPERATION TAKING CARE OF
HURT if you don’t follow instructions. CHECKS .....................................3 UNEXPECTED PROBLEMS .....14
OPERATION ...............................4 TECHNICAL INFORMATION ...15
You CAN be KILLED or SERIOUSLY SAFE OPERATING Serial Number Location ......15
HURT if you don’t follow instructions. PRECAUTIONS ......................4 Battery Connections for
STARTING THE ENGINE .......4 Electric Starter .....................16
You CAN be HURT if you don’t follow STOPPING THE ENGINE .......6 Carburetor Modifications for
instructions. SETTING ENGINE SPEED......6 High Altitude Operation ......16
SERVICING YOUR ENGINE ......6 Emission Control System
Each message tells you what the hazard is, what can happen, and THE IMPORTANCE OF Information ..........................17
what you can do to avoid or reduce injury. MAINTENANCE .....................6 Air Index ...............................17
MAINTENANCE SAFETY.......6 Specifications ......................18
DAMAGE PREVENTION MESSAGES SAFETY PRECAUTIONS ........6 Tuneup Specifications.........18
MAINTENANCE Quick Reference
You will also see other important messages that are preceded by SCHEDULE .............................7 Information ..........................19
the word NOTICE. REFUELING ............................7 Muffler Deflector Kit
ENGINE OIL............................8 Installation ...........................19
This word means: Recommended Oil .............8 Wiring Diagrams .................19
Your engine or other property can be damaged if you Oil Level Check...................8 CONSUMER INFORMATION ..23
don’t follow instructions. Oil Change ..........................9 DISTRIBUTOR/DEALER
AIR CLEANER.........................9 LOCATOR INFORMATION ..23
The purpose of these messages is to help prevent damage to your Inspection ...........................9 CUSTOMER SERVICE
engine, other property, or the environment. Cleaning .............................9 INFORMATION ....................23
SEDIMENT CUP ...................10
2005 - 2008 Honda Motor Co., Ltd. −All Rights Reserved Cleaning ...........................10
37Z3S605 GX440IU·GX440IR
00X37-Z3S-6050
ENGLISH 1
SAFETY INFORMATION COMPONENT & CONTROL LOCATION
Understand the operation of all controls and learn how to stop STANDARD TYPES
the engine quickly in case of emergency. Make sure the operator MUFFLER FUEL TANK FUEL FILLER CAP
receives adequate instruction before operating the equipment. LED
Do not allow children to operate the engine. Keep children and AIR CLEANER
pets away from the area of operation.
Your engine’s exhaust contains poisonous carbon monoxide.
Do not run the engine without adequate ventilation, and never RECOIL STARTER
run the engine indoors. (applicable types)
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 ECM
is running. STARTER GRIP
IGNITION COIL SPARK PLUG (applicable types)
(Inside ignition coil)
SAFETY LABEL LOCATION
OIL FILLER CAP/DIPSTICK
(STANDARD TYPES)
This label warns you of potential hazards that can cause serious
injury. Read it carefully.
If the label comes off or becomes hard to read, contact your Honda OIL EXTENSION
dealer for replacement. (applicable types)
ELECTRIC STARTER
(applicable types)
FUSE
(applicable types)
OIL DRAIN PLUG
ELECTRIC STARTER TYPES
For Canada: MANUAL START LEVER THROTTLE

French label is packaged CONTROL
with the engine. (applicable
types)
ENGINE
SWITCH
(applicable
types)
RECOIL STARTER TYPES

CHOKE LEVER
THROTTLE
CONTROL
(LOW PROFILE TYPES) (applicable
These labels are packed in the box. types)
ENGINE
SWITCH
Gasoline is highly flammable and explosive. (applicable
Turn engine off and let cool before refueling. types)
FUEL VALVE LEVER

The engine emits toxic poisonous carbon (applicable types)
monoxide gas. Do not run in an enclosed area.
LOW PROFILE TYPES
OIL FILLER CAP/DIPSTICK
MUFFLER
(applicable types) ELECTRIC STARTER
(applicable types)
Read Owner’s Manual before operation.
RECOIL STARTER
(applicable types)
STARTER GRIP
(applicable types)
IGNITION COIL AIR CLEANER

2 ENGLISH
BEFORE OPERATION CHECKS
IS YOUR ENGINE READY TO GO?
For your safety, 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
ELECTRIC STARTER TYPES RECOIL STARTER TYPES 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:
MANUAL START LEVER CHOKE LEVER
Check the General Condition of the Engine
FEATURES 1. Look around and underneath the engine for signs of oil or
gasoline leaks.
OIL ALERT SYSTEM
‘‘Oil Alert is a registered trademark in the United States’’ 2. Remove any excessive dirt or debris, especially around the
The Oil Alert system is designed to prevent engine damage muffler and recoil starter.
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 3. Look for signs of damage.
Alert system will either shut off the engine or issue a warning.
Refer to the instructions provided by the equipment manufacturer. 4. Check that all shields and covers are in place, and all nuts, bolts,
and screws are tightened.
If the ECM is set to stop the engine:
Check the Engine
Engine type Oil Alert action
Electric start The LED on the ECM blinks twice. 1. Check the fuel level (see page 7 ). Starting with a full tank will
The engine stops. help to eliminate or reduce operating interruptions for refueling.
The engine will not restart.
Recoil start The engine stops. 2. Check the engine oil level (see page 8 ). Running the engine
The engine will not restart. with a low oil level can cause engine damage.
If the ECM is set to continue engine operation: 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.
Engine type Oil Alert action However, to avoid the inconvenience of an unexpected
Electric start The LED on the ECM blinks twice. shutdown, always check the engine oil level before startup.
The engine continues to operate.
The engine will not restart. 3. Check the air filter element (see page 9, 10 ). A dirty air filter
Recoil start The engine continues to operate. element will restrict air flow to the carburetor, reducing engine
The engine will not restart. performance.
If the engine stops and/or will not restart, check the oil level (see 4. Check the equipment powered by this engine.
page 8 ) before troubleshooting in other areas.
Review the instructions provided with the equipment powered
by this engine for any precautions and procedures that should
If you continue to operate the engine after the Oil Alert system has be followed before engine startup.
been activated, you can damage the engine.
ENGLISH 3
OPERATION If the electric starter will not operate:
(with recoil starter types)
SAFE OPERATING PRECAUTIONS
1. Push the manual start lever.
Before operating the engine for the first time, please review the
SAFETY INFORMATION section on page 2 and the BEFORE STANDARD TYPES
OPERATION CHECKS on page 3 . MANUAL START LEVER
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.
Push
Exhaust contains poisonous carbon monoxide gas

that can build up to dangerous levels in closed areas.
Breathing carbon monoxide can cause LOW PROFILE TYPES
unconsciousness or death. MANUAL START LEVER
CLOSE
Never run the engine in a closed, or even partly

closed area where people may be present.
Push
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.
STARTING THE ENGINE

ELECTRIC STARTER TYPES:
Do not move the manual start lever after the engine starts.
1. Turn the engine switch to the
START position, and hold it 2. Turn the engine switch to the ON position.
there until the engine starts.
ON
The engine switch opens the
fuel valve and operates the
automatic choke.
Some engine applications do

not include the engine-
mounted engine switch
shown here. Refer to the ON
instructions provided by the START ENGINE SWITCH
equipment manufacturer.
If the engine fails to start 3. Pull the starter grip lightly until you feel resistance, then pull
within 5 seconds, release the briskly in the direction of the arrow as shown below. Return the
engine switch, and wait at starter grip gently.
least 10 seconds before
operating the starter again.
STARTER GRIP
Using the electric starter for

ENGINE SWITCH
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 Direction to pull
position.
2. Warm up the engine for 2 or 3 Do not allow the starter grip to snap back against the engine.
minutes. Return it gently to prevent damage to the starter.
4. Warm up the engine for 2 or 3 minutes.
4 ENGLISH
RECOIL STARTER TYPES: 4. Pull the starter grip lightly until you feel resistance, then pull
briskly in the direction of the arrow as shown below. Return the
1. Move the fuel valve lever (applicable types) to the ON position. starter grip gently.
FUEL VALVE LEVER Do not allow the starter grip to snap back against the engine.
(applicable types) Return it gently to prevent damage to the starter.
ON
STARTER GRIP
ON
2. To start a cold engine, move the choke lever to the CLOSED Direction to pull
position.
5. Warm up the engine for 2 or 3 minutes.
Some engine types use a remote-mounted choke lever. Refer to
the instructions provided by the equipment manufacturer. If the choke lever was moved to the CLOSED position to start the
engine, gradually move it to the OPEN position as the engine
STANDARD TYPES warms up.
CLOSE STANDARD TYPES
CLOSE
OPEN
CHOKE LEVER
LOW PROFILE TYPES CHOKE LEVER
LOW PROFILE TYPES

CLOSE CHOKE LEVER
CLOSE
CHOKE LEVER
OPEN
To restart a warm engine, leave the choke lever in the OPEN
position.
3. Turn the engine switch to the ON position.
Some engine types use a remote-mounted engine switch. Refer

to the instructions provided by the equipment manufacturer.
ON
ENGINE SWITCH
ENGLISH 5
STOPPING THE ENGINE SERVICING YOUR ENGINE
To stop the engine in an emergency, simply turn the engine switch THE IMPORTANCE OF MAINTENANCE
to the OFF position. Under normal conditions, use the following Good maintenance is essential for safe, economical and trouble-
procedure. free operation. It will also help reduce pollution.
1. Move the throttle control to the MIN. position.
Some engine types use a remote-mounted throttle control. Refer Improper maintenance, or failure to correct a
to the instructions provided by the equipment manufacturer. problem before operation, can cause a malfunction in
which you can be seriously hurt or killed.
2. Turn the engine switch to the OFF position.
Always follow the inspection and maintenance
Some engine types use a remote-mounted engine switch. Refer recommendations and schedules in this owner’s
to the instructions provided by the equipment manufacturer. manual.
MIN 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
OFF
THROTTLE CONTROL 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 servicing dealer
ENGINE SWITCH
for recommendations applicable to your individual needs and use.
Maintenance, replacement, or repair of the emission control

3. Move the fuel valve lever (applicable types) to the OFF position. devices and systems may be performed by any engine repair
establishment or individual, using parts that are ‘‘certified’’ to
EPA standards.
FUEL VALVE LEVER
(applicable types)
MAINTENANCE SAFETY
OFF
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.
OFF
Failure to properly follow maintenance instructions
and precautions can cause you to be seriously hurt or
killed.
SETTING ENGINE SPEED Always follow the procedures and precautions in this
owner’s manual.
Adjust the throttle control for the desired engine speed.
SAFETY PRECAUTIONS
Some engine types use a remote-mounted throttle control, rather Make sure the engine is off before you begin any maintenance
than the engine-mounted throttle control shown here. Refer to the or repairs. This will eliminate several potential hazards:
instructions provided by the equipment manufacturer. −Carbon monoxide poisoning from engine exhaust.
Be sure there is adequate ventilation whenever you operate
For engine speed recommendations, refer to the instructions the engine.
provided with the equipment powered by this engine. −Burns from hot parts.
Let the engine and exhaust system cool before touching.
−Injury from moving parts.
Do not run the engine unless instructed to do so.
Read the instructions before you begin, and make sure you have
the tools and skills required.
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.
Remember that an authorized Honda servicing dealer knows your
MIN MAX engine best and is fully equipped to maintain and repair it.
To ensure the best quality and reliability, use only new Honda
THROTTLE CONTROL Genuine parts or their equivalents for repair and replacement.
6 ENGLISH
MAINTENANCE SCHEDULE REFUELING (LOW PROFILE TYPES)
STANDARD TYPES Follow the equipment manufacturers recommendation for

REGULAR SERVICE PERIOD (3) Each First Every 6 Every Every Refer refueling.
Perform at every Use Month Months Year 2 Years to REFUELING (STANDARD TYPES)
indicated month or or or or or Page
operating hour interval, 20 Hrs 100 Hrs 300 Hrs 500 Hrs Recommended Fuel
whichever comes first. Unleaded gasoline
ITEM U.S. Pump octane rating 86 or higher
Engine oil Check level 8 Except U.S. Research octane rating 91 or higher
Change 9 Pump octane rating 86 or higher
Air cleaner Check 9
Clean (1) 9 This engine is certified to operate on unleaded gasoline with a
Replace pump octane rating of 86 or higher (a research octane rating of 91
Sediment cup Clean 10 or higher).
Spark plug Check-adjust 11 Refuel in a well-ventilated area with the engine stopped. If the
Replace engine has been running, allow it to cool first. Never refuel the
Spark arrester Clean 11 engine inside a building where gasoline fumes may reach flames
Valve clearance Check-adjust (2) Shop or sparks.
manual You may use unleaded gasoline containing no more than 10%
Timing belt Check After every 500 Hrs. (2) (4) Shop ethanol (E10) or 5% methanol by volume. In addition, methanol
manual must contain cosolvents and corrosion inhibitors. Use of fuels
Combustion Clean After every 500 Hrs. (2) Shop with content of ethanol or methanol greater than shown above
chamber manual may cause starting and/or performance problems. It may also
Fuel tank & Clean (2) Shop damage metal, rubber, and plastic parts of the fuel system. Engine
filter manual damage or performance problems that result from using a fuel
Fuel tube Check Every 2 years Shop with percentages of ethanol or methanol greater than shown
(Replace if necessary) (2) manual above are not covered under warranty.
LOW PROFILE TYPES If your equipment will be used on an infrequent or intermittent

REGULAR SERVICE PERIOD (3) Each First Every 3 Every 6 Every Refer basis, please refer to the fuel section of the HELPFUL TIPS &
Perform at every Use Month Months Months Year to SUGGESTIONS chapter (see page 13 ) for additional information
indicated month or or or or or Page regarding fuel deterioration.
operating hour interval, 20 Hrs 50 Hrs 100 Hrs 300 Hrs
whichever comes first.
ITEM
Engine oil Check level 8
Change 9 Gasoline is highly flammable and explosive, and you
Air cleaner Check 10 can be burned or seriously injured when refueling.
Clean (1) 10 Stop engine and keep heat, sparks, and flame away.
Replace Refuel only outdoors.
Sediment cup Clean 10 Wipe up spills immediately.
Spark plug Check-adjust 11
Replace
Spark arrester Check-Clean 12
Fuel can damage paint and some types of plastic. Be careful not to
Valve clearance Check-adjust (2) Shop spill fuel when filling your fuel tank. Damage caused by spilled
manual fuel is not covered under the Distributor’s Limited Warranty.
Timing belt Check After every 500 Hrs. (2) (4) Shop
manual Never use stale or contaminated gasoline or an oil/gasoline
Combustion Clean After every 500 Hrs. (2) Shop mixture. Avoid getting dirt or water in the fuel tank.
chamber manual
Fuel tube Check Every 2 years Shop 1. With the engine stopped and on a level surface, remove the fuel
(Replace if necessary) (2) manual filler cap and check the fuel level. Refill the tank if the fuel level
is low.
(1) Service more frequently when used in dusty areas.
(2) These items should be serviced by your Honda servicing
dealer, unless you have the proper tools and are mechanically
proficient. Refer to the Honda shop manual for service
procedures.
(3) For commercial use, log hours of operation to determine
proper maintenance intervals.
(4) Check that there is no crack and abnormal wear-out in the belt,
and replace if it is abnormal.
Failure to follow this maintenance schedule could result in non-

warrantable failures.
ENGLISH 7
2. Add fuel to the bottom of the maximum fuel level limit of the ENGINE OIL
fuel tank. Do not overfill. Wipe up spilled fuel before starting the Oil is a major factor affecting performance and service life. Use
engine. 4-stroke automotive detergent oil.
FUEL FILLER CAP Recommended Oil
Use 4-stroke motor oil that

meets or exceeds the
CHAIN
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 AMBIENT TEMPERATURE
equivalent).
SAE 10W-30 is recommended for general use. Other viscosities

MAXIMUM FUEL LEVEL
shown in the chart may be used when the average temperature in
your area is within the indicated range.
Oil Level Check
Check the engine oil level with the engine stopped and in a level
position.
1. Remove the oil filler cap/dipstick and wipe it clean.

Refuel carefully to avoid spilling fuel. Do not fill the fuel tank
completely. It may be necessary to lower the fuel level depending 2. Insert the oil filler cap/dipstick into the oil filler neck as shown,
on operating conditions. After refueling, screw the fuel filler cap but do not push it in, then remove it to check the oil level.
back on until it clicks.
3. If the oil level is below the upper limit mark on the dipstick, fill
Keep gasoline away from appliance pilot lights, barbecues, with the recommended oil to the upper limit mark. Do not
electric appliances, power tools, etc. overfill.
Spilled fuel is not only a fire hazard, it causes environmental 4. Reinstall and tighten the oil filler cap/dipstick.
damage. Wipe up spills immediately.
DIPSTICK OIL FILLER CAP/DIPSTICK
UPPER LIMIT
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.
8 ENGLISH
Oil Change AIR CLEANER
Drain the used oil when the engine is warm. Warm oil drains A dirty air cleaner will restrict air flow to the carburetor, reducing
quickly and completely. engine performance. If you operate the engine in very dusty areas,
clean or replace the air filter more often than specified in the
1. Place a suitable container below the engine to catch the used oil, MAINTENANCE SCHEDULE.
then remove the oil filler cap/dipstick, oil drain plug and washer.
2. Allow the used oil to drain completely, then reinstall the oil drain Operating the engine without an air filter, or with a damaged air
plug and new washer, and tighten the oil drain plug securely. filter, will allow dirt to enter the engine, causing rapid engine wear.
This type of damage is not covered by the Distributor’s Limited
Please dispose of used motor oil in a manner that is compatible Warranty.
with the environment. We suggest you take used oil in a sealed
container to your local recycling center or service station for Inspection (standard types)
reclamation. Do not throw it in the trash, pour it on the ground,
or pour it down a drain. Remove the air cleaner cover and inspect the filter elements.
Clean or replace dirty filter elements. Always replace damaged
3. With the engine in a level position, fill with the recommended oil filter elements.
to the upper limit mark on the dipstick (see page 8 ).
Cleaning (standard types)
Running the engine with a low oil level can cause engine 1. Remove the nut from the air NUT
damage. This type of damage is not covered by the Distributor’s cleaner cover, and remove
Limited Warranty. the cover. AIR CLEANER
COVER
4. Install the oil filler cap/dipstick and push it in securely. 2. Remove the wing nut from
the air filter, and remove the WING NUT
filter.
OIL FILLER CAP/DIPSTICK PAPER FILTER
DIPSTICK 3. Remove the foam filter from ELEMENT
the paper filter.
FOAM FILTER
4. Inspect both air filter ELEMENT
UPPER LIMIT
elements, and replace them if
they are damaged. Always GASKET
replace the paper air filter
element at the scheduled
interval (see page 7 ).
5. Clean the filter elements if they are to be reused.

WASHER
OIL DRAIN PLUG 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, then squeeze out all
excess oil. The engine will smoke when started if too much oil is
left in the foam.
Dry
Soak Squeeze Oil Squeeze
ENGLISH 9
6. Wipe dirt from the inside of the air cleaner case and cover using 5. Clean the foam filter element if it is to be reused.
a moist rag. Be careful to prevent dirt from entering the air duct
that leads to the carburetor. Clean in warm soapy water, rinse, and allow to dry thoroughly. Or
clean in non-flammable solvent and allow to dry.
7. Place the foam filter element over the paper element, and Dip the filter element in clean engine oil, then squeeze out all
reinstall the assembled air filter. Be sure the gasket is in place excess oil. The engine will smoke when started if too much oil is
beneath the air filter. Tighten the air filter wing nut securely. left in the foam.
8. Install the air cleaner cover, and tighten the nut securely.
Inspection (low profile types)

Dry
Do not blow with compressed air or brush the paper filter
element.
Remove the air cleaner cover and inspect the filter elements. Soak Squeeze Oil Squeeze
Visually inspect the filter elements. Clean the foam filter element
or replace the dirty paper filter element. Always replace damaged
filter elements. 6. 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
Cleaning (low profile types) that leads to the carburetor.
1. Loosen the cover screws and remove the air cleaner cover. 7. Put the air cleaner grid on the paper filter element and install
them to the air cleaner case.
2. Remove the foam filter element from the air cleaner cover.
8. Install the foam filter element to the air cleaner cover.
3. Remove the air cleaner grid and paper filter element.
9. Install the air cleaner cover and tighten the cover screw.
4. Inspect both filter elements, and replace them if they are
damaged. Always replace the paper filter element at the SEDIMENT CUP (applicable types)
scheduled interval (see page 7 ).
Cleaning
If the paper filter element is dirty, replace it with a new one.
Do not clean the paper filter element.
AIR CLEANER GRID Gasoline is highly flammable and explosive, and you
can be burned or seriously injured when handling
fuel.
Stop engine and keep heat, sparks, and flame away.
Handle fuel only outdoors.
Wipe up spills immediately.
1. Remove the fuel sediment cup, O-ring and filter.
2. Wash the sediment cup in non-flammable solvent, and dry it

thoroughly.
AIR CLENER
CASE
PAPER FILTER COVER SCREW

ELEMENT
FOAM FILTER
ELEMENT FILTER
AIR CLEANER COVER
O-RING
SEDIMENT
CUP
3. Reinstall the sediment cup. Tighten the sediment cup securely.
10 ENGLISH
SPARK PLUG SPARK ARRESTER
Recommended Spark Plugs: BKR7E-E (NGK) The spark arrester must be serviced every 6 months or 100 hours
K22PR-UR (DENSO) to keep it functioning as designed.
The recommended spark plug has the correct heat range for If the engine has been running, the muffler will be hot. Allow it to
normal engine operating temperatures. cool before servicing the spark arrester.
Spark Arrester Removal (standard types)

An incorrect spark plug can cause engine damage.
1. Remove the three 6 mm nuts and breather tube from the air
For good performance, the spark plug must be properly gapped cleaner, remove the air cleaner, and remove the 6 × 20 mm
and free of deposits. stud bolt.
BREATHER TUBE
1. Remove the nut from the ignition coil, and remove the ignition
coil/spark plug cap. Remove any dirt from around the spark plug
area. IGNITION COIL/ SPARK PLUG AIR CLEANER
SPARK PLUG CAP
CLAMP
6 × 20 mm
STUD BOLT 6 mm NUTS
NUT 2. Remove the three 6 mm bolts from the muffler protector, and
remove the muffler protector.
2. Remove the spark plug with a SPARK PLUG WRENCH 3. Remove the 5 × 8 mm screw from the spark arrester, and
5/8-inch spark plug wrench. remove the spark arrester from the muffler.
3. Inspect the spark plug.

Replace it if damaged or 6 mm BOLTS
badly fouled, if the sealing
washer is in poor condition,
or if the electrode is worn.
4. Measure the spark plug SIDE SPARK ARRESTER

5 × 8 mm SCREW
ELECTRODE
electrode gap with a wire-
type feeler gauge. Correct the 0.7−0.8 mm
gap, if necessary, by carefully (0.028−0.031 in)
bending the side electrode.
The gap should be:
0.7−0.8 mm (0.028−0.031 in)
SEALING
WASHER
5. Install the spark plug carefully,
by hand, to avoid cross-
threading.
6. After the spark plug is seated, tighten with a 5/8-inch spark plug
wrench to compress the sealing washer.
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.
7. Set the harness in the clamp portion of the ignition coil/spark

plug cap. Then, attach the ignition coil to the spark plug and
tighten the nut securely.
ENGLISH 11
Spark Arrester Removal (low profile types)
6 mm BOLT 10 × 35 mm
1. Remove the three 6 mm bolts from the exhaust pipe protector FLANGE BOLT
and remove the exhaust pipe protector.
2. Remove the two 6 mm bolts from the lower shroud and

remove the lower shroud.
3. Loosen the two 6 × 16 mm bolt washers and 10 × 35 mm

flange bolt to make the clearance for 6 mm bolts removing,
then slide the muffler stay as shown.
4. Remove the six 6 mm bolts from the lower muffler protector MUFFLER STAY
and remove the lower muffler protector.
6 × 16 mm
5. Remove the three 6 mm bolts from the muffler protector and BOLT WASHERS
slide the muffler protector to upside.
6. Remove the 5 × 8 mm screw from the spark arrester and Spark Arrester Cleaning & Inspection
remove the spark arrester from the muffler.
1. Use a brush to remove carbon
deposits from the spark arrester
6 mm BOLT EXHAUST PIPE PROTECTOR screen. Be careful not to damage
the screen. Replace the spark
arrester if it has breaks or holes.
2. Install the spark arrester to the
muffler. SCREEN
3. STANDARD TYPES
Install the muffler protector and air cleaner in the reverse order
of disassembly.
LOW PROFILE TYPES

Install the exhaust pipe protector, lower shroud, lower muffler
protector and muffler in the reverse order of disassembly.
FUSE (applicable types)

6 mm BOLT LOWER SHROUD If the fuse is blown, the battery cannot be charged.
Fuse change FUSE COVER

6 mm BOLT 1. Remove the fuse cover and
pull the fuse out. FUSE
2. Replace the fuse with a fuse (30 A)
FUSE
MUFFLER of the same type and rating. (3 A)
PROTECTOR
Never use a fuse with different

rating from that specified.
Serious damage to the electrical
system or fire may result.
3. Install the fuse cover.

SPARK ARRESTER
6 mm BOLT
5 × 8 mm SCREW
LOWER MUFFLER
PROTECTOR
12 ENGLISH
HELPFUL TIPS & SUGGESTIONS Engine Oil
STORING YOUR ENGINE 1. Change the engine oil (see page 9 ).
Storage Preparation 2. Remove the spark plug (see page 11 ).

Proper storage preparation is essential for keeping your engine
trouble-free and looking good. The following steps will help to 3. Pour a tablespoon 5−10 cm (5−10 cc) of clean engine oil into
keep rust and corrosion from impairing your engine’s function and the cylinder.
appearance, and will make the engine easier to start when you use
it again. 4. With recoil starter types:
Pull the starter grip (applicable types) several times to distribute
Cleaning the oil in the cylinder.
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 Without recoil starter types:
damaged paint, and coat other areas that may rust with a light film Turn the engine switch to the START position to distribute the oil
of oil. in the cylinder.
5. Reinstall the spark plug.

Using a garden hose or pressure washing equipment can force
water into the air cleaner or muffler opening. Water in the air 6. With recoil starter types:
cleaner will soak the air filter, and water that passes through the Pull the starter rope slowly until resistance is felt and the notch
air filter or muffler can enter the cylinder, causing damage. on the starter pulley aligns with the projection at the top of the
recoil starter cover. This will close the valves so moisture cannot
Fuel enter the engine cylinder. Return the starter rope gently.
Align the notch on the pulley with

the projection at the top of the cover.
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 Without recoil starter types:
such factors as gasoline blend, your storage temperatures, and Remove the nuts and remove the fan cover.
whether the fuel tank is partially or completely filled. The air in a Rotate the fin until resistance is felt and the fin with a notch
partially filled fuel tank promotes fuel deterioration. Very warm (standard types)/alignment mark (low profile types) aligns with
storage temperatures accelerate fuel deterioration. Fuel the projection at the top of the cover. This will close the valves
deterioration problems may occur within a few months, or even so moisture cannot enter the engine cylinder.
less if the gasoline was not fresh when you filled the fuel tank.
Fuel system damage or engine performance problems resulting STANDARD TYPES

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.
Adding a Gasoline Stabilizer to Extend Fuel Storage Life

Align the fin with a notch
When adding a gasoline stabilizer, fill the fuel tank with fresh with the projection at the
gasoline. If only partially filled, air in the tank will promote fuel top of the cover.
deterioration during storage. If you keep a container of gasoline
LOW PROFILE TYPES
for refueling, be sure that it contains only fresh gasoline.
NUTS
1. Add gasoline stabilizer following the manufacturer’s instructions.
2. 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.
Align the fin with a alignment
mark with the projection at
3. Stop the engine. the top of the cover.
ENGLISH 13
Draining the Carburetor 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.
Gasoline is highly flammable and explosive, and you
can be burned or seriously injured when handling If the cylinder was coated with oil during storage preparation, the
fuel. engine will smoke briefly at startup. This is normal.
Stop engine and keep heat, sparks, and flame away. TRANSPORTING
Handle fuel only outdoors.
Wipe up spills immediately. 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
1. Place an approved gasoline container below the carburetor, and and can ignite some materials.
use a funnel to avoid spilling fuel.
Keep the engine level when transporting to reduce the possibility
2. Loosen the carburetor drain screw and drain the gasoline from of fuel leakage.
the carburetor.
TAKING CARE OF UNEXPECTED PROBLEMS
ELECTRIC STARTER TYPES:
Check the LED on the ECM
3. After all the fuel has drained into the container, tighten the drain
screw securely.
LED ECM
Storage Precautions
If your engine will be stored with gasoline in the fuel tank and
carburetor, it is important to reduce the hazard of gasoline vapor To perform the LED check, the engine must be connected to a
ignition. Select a well-ventilated storage area away from any battery and the engine switch must be in the ON position.
appliance that operates with a flame, such as a furnace, water
heater, or clothes dryer. Also avoid any area with a spark- ENGINE WILL Possible Cause Correction
producing electric motor, or where power tools are operated. NOT START
1. LED is not lit. Fuse burnt out. Replace fuse
If possible, avoid storage areas with high humidity, because that (p. 12).
promotes rust and corrosion. after replacing fuse,
turn the engine
Keep the engine level in storage. Tilting can cause fuel or oil switch to the ON
leakage. position once
again.
With the engine and exhaust system cool, cover the engine to 2. LED is lit. Fuel, engine oil, Check the BEFORE
keep out dust. A hot engine and exhaust system can ignite or melt spark plug, etc. OPERATION
some materials. Do not use sheet plastic as a dust cover. CHECKS (p. 3).
A nonporous cover will trap moisture around the engine, 3. LED blinks Engine oil level Fill with the
promoting rust and corrosion. twice. low. recommended oil
to the proper level
If equipped with a battery for electric starter types, recharge the (p. 8).
battery once a month while the engine is in storage. 4. LED blinks 3 or ECM, Take engine to an
This will help to extend the service life of the battery. more times. TE sensor, authorized Honda
power coil. servicing dealer, or
Removal from Storage refer to shop
Check your engine as described in the BEFORE OPERATION manual.
CHECKS section of this manual (see page 3 ). 5. Take engine to ECM, Replace or repair
an authorized sensors, etc. faulty components
Honda as necessary.
servicing
dealer, or refer
to shop
manual.
14 ENGLISH
ENGINE WILL Possible Cause Correction TECHNICAL INFORMATION
NOT START
1. Electric Battery Recharge battery. Serial Number Location STANDARD TYPES
starting discharged. Record the engine serial
(applicable number, engine type, and date
types): Fuse burnt out. Replace fuse. of purchase in the space below.
Check battery (p. 12). You will need this information
and fuse. when ordering parts and when
2. Check control Choke open. Move choke lever making technical or warranty
positions. (Recoil starter to CLOSED inquiries.
types) position unless the
engine is warm.
Engine switch Turn engine switch
OFF. to ON position.
3. Check engine Engine oil level Fill with the SERIAL NUMBER &
oil level. low. recommended oil ENGINE TYPE LOCATION
to the proper level ELECTRIC STARTER
(p. 8). (applicable types)
4. Check fuel. Out of fuel. Refuel (p. 7). LOW PROFILE TYPES
Bad fuel; engine Drain fuel tank and ELECTRIC STARTER
stored without carburetor (p. 14). (applicable types)
treating or Refuel with fresh
draining gasoline (p. 7).
gasoline, or
refueled with
bad gasoline.
5. Remove and Spark plug faulty, Gap or replace
inspect spark fouled, or spark plug (p. 11).
SERIAL NUMBER &
plug. improperly ENGINE TYPE LOCATION
gapped.
Spark plug wet Dry and reinstall
with fuel spark plug. Start Engine serial number: __ __ __ __ − __ __ __ __ __ __ __
(flooded engine). engine with
throttle lever in Engine type: ___ ___ ___ ___
MAX. position.
6. Take engine to Fuel filter Replace or repair Date Purchased: ______ / ______ / ______
an authorized restricted, faulty components
Honda carburetor as necessary.
servicing malfunction,
dealer, or refer ignition
to shop malfunction,
manual. valves stuck, etc.
ENGINE LACKS Possible Cause Correction

POWER
1. Check air filter. Filter element(s) Clean or replace
restricted. filter element(s)
(p. 9−10).
2. Check fuel. Bad fuel; engine Drain fuel tank and
stored without carburetor (p. 14).
treating or Refuel with fresh
draining gasoline (p. 7).
gasoline, or
refueled with
bad gasoline.
3. Take engine to Fuel filter Replace or repair
an authorized restricted, faulty components
Honda carburetor as necessary.
servicing malfunction,
dealer, or refer ignition
to shop malfunction,
manual. valves stuck, etc.
ENGLISH 15
Battery Connections for Electric Starter (applicable types) Carburetor Modifications for High Altitude Operation
Recommended Battery At high altitude, the standard carburetor air-fuel mixture will be
iGX440 12 V−24 Ah too rich. Performance will decrease, and fuel consumption will
increase. A very rich mixture will also foul the spark plug and
Be careful not to connect the battery in reverse polarity, as this will cause hard starting. Operation at an altitude that differs from that
short circuit the battery charging system. Always connect the at which this engine was certified, for extended periods of time,
positive (＋) battery cable to the battery terminal before may increase emissions.
connecting the negative (−) battery cable, so your tools cannot
cause a short circuit if they touch a grounded part while tightening High altitude performance can be improved by specific
the positive (＋) battery cable end. 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
A battery can explode if you do not follow the correct high altitude use, will meet each emission standard throughout its
procedure, seriously injuring anyone nearby. useful life.
Keep all sparks, open flames, and smoking materials Even with carburetor modification, engine horsepower will
away from the battery. decrease about 3.5% for each 300-meter (1,000-foot) increase in
altitude. The effect of altitude on horsepower will be greater than
1. Connect the battery positive (＋) cable to the starter solenoid this if no carburetor modification is made.
terminal as shown.
2. Connect the battery negative (−) cable to an engine mounting
bolt, frame bolt, or other good engine ground connection. When the carburetor has been modified for high altitude operation,
3. Connect the battery positive (＋) cable to the battery positive (＋) the air-fuel mixture will be too lean for low altitude use. Operation
terminal as shown. at altitudes below 1,500 meters (5,000 feet) with a modified
4. Connect the battery negative (−) cable to the battery negative carburetor may cause the engine to overheat and result in serious
(−) terminal as shown. engine damage. For use at low altitudes, have your servicing
5. Coat the terminals and cable ends with grease. dealer return the carburetor to original factory specifications.
POSITIVE (＋)
BATTERY CABLE
NEGATIVE (−) BATTERY CABLE
16 ENGLISH
Emission Control System Information Replacement Parts
The emission control systems on your Honda engine were
Source of Emissions designed, built, and certified to conform with EPA, California
The combustion process produces carbon monoxide, oxides of (models certified for sale in California), and Canadian emission
nitrogen, and hydrocarbons. Control of hydrocarbons and oxides regulations. We recommend the use of Honda Genuine parts
of nitrogen is very important because, under certain conditions, whenever you have maintenance done. These original-design
they react to form photochemical smog when subjected to replacement parts are manufactured to the same standards as the
sunlight. Carbon monoxide does not react in the same way, but it original parts, so you can be confident of their performance. The
is toxic. use of replacement parts that are not of the original design and
quality may impair the effectiveness of your emission control
Honda utilizes appropriate air/fuel ratios and other emissions system.
control systems to reduce the emissions of carbon monoxide,
oxides of nitrogen, and hydrocarbons. A manufacturer of an aftermarket part assumes the responsibility
Additionally, Honda fuel systems utilize components and control that the part will not adversely affect emission performance. The
technologies to reduce evaporative emissions. 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
The U.S., California Clean Air Acts and Environment Canada emission regulations.
EPA, California and Canadian regulations require all
manufacturers to furnish written instructions describing the Maintenance
operation and maintenance of emission control systems. Follow the maintenance schedule on page 7. Remember that this
schedule is based on the assumption that your machine will be
The following instructions and procedures must be followed in used for its designed purpose. Sustained high-load or high-
order to keep the emissions from your Honda engine within the temperature operation, or use in unusually wet or dusty conditions,
emission standards. will require more frequent service.
Tampering and Altering Air Index

Tampering with or altering the emission control system may
increase emissions beyond the legal limit. Among those acts that An Air Index Information label is applied to engines certified to an
constitute tampering are: emission durability time period in accordance with the
requirements of the California Air Resources Board.
Removal or alteration of any part of the intake, fuel, or exhaust
systems. The bar graph is intended to provide you, our customer, the ability
Altering or defeating the governor linkage or speed-adjusting to compare the emissions performance of available engines. The
mechanism to cause the engine to operate outside its design lower the Air Index, the less pollution.
parameters.
The durability description is intended to provide you with
Problems That May Affect Emissions information relating to the engine’s emission durability period.
If you are aware of any of the following symptoms, have your The descriptive term indicates the useful life period for the engine’s
engine inspected and repaired by your servicing dealer. emission control system. See your Emission Control System
Warranty for additional information.
Hard starting or stalling after starting.
Rough idle. Descriptive Term Applicable to Emissions Durability Period
Misfiring or backfiring under load. Moderate 50 hours [0−80 cm (0−80 cc) inclusive]
Afterburning (backfiring). 125 hours [greater than 80 cm (80 cc)]
Black exhaust smoke or high fuel consumption. Intermediate 125 hours [0−80 cm (0−80 cc) inclusive]
250 hours [greater than 80 cm (80 cc)]
Extended 300 hours [0−80 cm (0−80 cc) inclusive]
500 hours [greater than 80 cm (80 cc)]
1,000 hours [225 cm (225 cc) and greater]
ENGLISH 17
Specifications (standard types) Tuneup Specifications
ITEM SPECIFICATION MAINTENANCE
PTO shaft type S Spark plug gap 0.7−0.8 mm Refer to page: 11
Length × Width × 407 × 505 × 456 mm (0.028−0.031 in)
Height (16.0 × 19.9 × 18.0 in) Valve clearance IN: 0.12 ± 0.02 mm See your
Dry mass [weight] 39.4 kg (86.9 lbs) (cold) EX: 0.15 ± 0.02 mm authorized
Engine type 4-stroke, overhead camshaft, single Honda dealer
cylinder Other No other adjustments needed.
Displacement 438 cm (26.7 cu-in) specifications
[Bore × Stroke] [88.0 × 72.1 mm (3.46 × 2.84 in)]
Net power 9.5 kW (12.9 PS, 12.7 bhp)
(in accordance with SAE J1349＊) at 3,600 rpm
Max. Net torque 29.8 N·m (3.04 kgf·m, 22.0 lbf·ft)
Engine oil capacity 1.1 L (1.2 US qt, 1.0 lmp qt)
Fuel tank capacity 5.1 L (1.35 US gal, 1.12 lmp gal)
Cooling system Forced air
Ignition system CDI type magneto ignition
PTO shaft rotation Counterclockwise
Specifications (low profile types)
PTO shaft type V

Length × Width × 553 × 553 × 346 mm
Height (21.8 × 21.8 × 13.6 in)
Dry mass [weight] 42.8 kg (94.4 lbs)
Engine type 4-stroke, overhead camshaft, single
cylinder
Displacement 438 cm (26.7 cu-in)
[Bore × Stroke] [88.0 × 72.1 mm (3.46 × 2.84 in)]
Net power 9.5 kW (12.9 PS, 12.7 bhp)
Max. Net torque 29.8 N·m (3.04 kgf·m, 22.0 lbf·ft)
Engine oil capacity 1.1 L (1.2 US qt, 1.0 lmp qt)
Cooling system Forced air
Ignition system CDI type magneto ignition
PTO shaft rotation Counterclockwise
＊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.
18 ENGLISH
Quick Reference Information Wiring Diagrams
［1］ FUSE 3 A ［13］ FUEL CUT SOLENOID
Fuel Unleaded gasoline (Refer to page 7) ［2］ FUSE 30 A ［14］ IGINITION COIL
U.S. Pump octane rating 86 or higher ［3］ FUEL CUT SOLENOID ［15］ SPARK PLUG
Except Research octane rating 91 or higher RECTIFIER ［16］ OIL LEVEL SWITCH
U.S. Pump octane rating 86 or higher ［4］ REGULATOR RECTIFIER ［17］ ECM
Engine oil SAE 10W-30, API SJ or later, for general use. ［5］ ENGINE GROUND ［18］ STEP MOTOR (GOV)
Refer to page 8. ［6］ BATTERY ［19］ STEP MOTOR (CHOKE)
Spark plug BKR7E-E (NGK) ［7］ STARTER MOTOR ［20］ PC CONNECTOR
K22PR-UR (DENSO) ［8］ POWER COIL ［21］ ENGINE TEMPERATURE
Maintenance Before each use: ［9］ FUEL CUT SOLENOID COIL SENSOR
Check engine oil level. Refer to page 8. ［10］ CHARGE COIL 20 A ［22］ THROTTLE CONTROL
Check air filter. Refer to page 9−10. ［11］ CHARGE COIL 3 A ［23］ COMBINATION SWITCH
First 20 hours: ［12］ CRANKSHAFT POSITION ［24］ RECTIFIER
Change engine oil. Refer to page 9. (CKP) SENSOR ［25］ ENGINE STOP SWITCH
Subsequent:
Refer to the maintenance schedule on page 7. Bl Black Br Brown
Y Yellow O Orange
Muffler Deflector Kit Installation (standard types) Bu Blue Lb Light blue
G Green Lg Light green
Muffler deflector (applicable types) R Red P Pink
W White Gr Gray
Turn the outlet of the muffler deflector downward and tighten the
three 4 × 6 mm screws securely.
ATTACHMENT POSITION
4 × 6 mm SCREWS MUFFLER DEFLECTOR
ENGLISH 19
ELECTRIC STARTER TYPES (20 A)
20 ENGLISH
ELECTRIC STARTER TYPES (3 A)
ENGLISH 21
RECOIL STARTER TYPES
22 ENGLISH
TECHNICAL & CONSUMER INFORMATION Canada:
Honda Canada, Inc.
DISTRIBUTOR/DEALER LOCATOR INFORMATION 715 Milner Avenue
Toronto, ON
United States, Puerto Rico, and U.S. Virgin Islands: M1B 2K8
Call (800) 426-7701
or visit our website: www.honda-engines.com Telephone: (888) 9HONDA9 Toll free
(888) 946-6329
Canada: (416) 299-3400 Local Toronto dialing area
Call (888) 9HONDA9 Facsimile: (877) 939-0909 Toll free
or visit our website: www.honda.ca (416) 287-4776 Local Toronto dialing area
For European Area: Australia:

visit our website: http://www.honda-engines-eu.com Honda Australia Motorcycle and Power Equipment Pty. Ltd.
1954−1956 Hume Highway Campbellfield Victoria 3061
CUSTOMER SERVICE INFORMATION Telephone: (03) 9270 1111

Facsimile: (03) 9270 1133
Servicing dealership personnel are trained professionals. They
should be able to answer any question you may have. If you For European Area:
encounter a problem that your dealer does not solve to your Honda Europe NV.
satisfaction, please discuss it with the dealership’s management. European Engine Center
The Service Manager, General Manager, or Owner can help.
Almost all problems are solved in this way. http://www.honda-engines-eu.com
United States, Puerto Rico, and U.S. Virgin Islands: All Other Areas:
If you are dissatisfied with the decision made by the dealership’s Please contact the Honda distributor in your area for assistance.
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.
All Other Areas:

If you are dissatisfied with the decision made by the dealership’s
management, contact the Honda Office as shown.
《Honda’s Office》
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 15 )
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
United States, Puerto Rico, and U.S. Virgin Islands:

American Honda Motor Co., Inc.
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
ENGLISH 23
Kubota diesel engine
D Kubota diesel engine

Kubota diesel engine

ENGLISH
FOREWORD
You are now the proud owner of a KUBOTA Engine. This engine is a
product of KUBOTA quality engineering and manufacturing. It is made
of fine materials and under a rigid quality control system. It will give
you long, satisfactory service. To obtain the best use of your engine,
please read this manual carefully. It will help you become familiar with
the operation of the engine and contains many helpful hints about
engine maintenance. It is KUBOTA's policy to utilize as quickly as
possible every advance in our research. The immediate use of new
techniques in the manufacture of products may cause some small
parts of this manual to be outdated. KUBOTA distributors and dealers
will have the most up-to-date information. Please do not hesitate to
consult with them.
3 SAFETY FIRST
This symbol, the industry's "Safety Alert Symbol", is used throughout
this manual and on labels on the machine itself to warn of the
possibility of personal injury. Read these instructions carefully. It is
essential that you read the instructions and safety regulations before
you attempt to assemble or use this unit.
3 DANGER : Indicates an imminently hazardous situation which,

if not avoided, will result in death or serious
injury.
3 WARNING : Indicates a potentially hazardous situation which,

if not avoided, COULD result in death or serious
injury.
3 CAUTION: Indicates a potentially hazardous situation which,

if not avoided, MAY result in minor or moderate
injury.
IMPORTANT : Indicates that equipment or property damage

could result if instructions are not followed.
NOTE : Gives helpful information.

ENGLISH
CONTENTS
SAFE OPERATION ................................................................................................ 1
SERVICING OF THE ENGINE .................................................................................... 1
NAMES OF PARTS ..................................................................................................... 2
PRE-OPERATION CHECK ......................................................................................... 3
BREAK-IN ................................................................................................................ 3
DAILY CHECK ......................................................................................................... 3
OPERATING THE ENGINE......................................................................................... 4
STARTING THE ENGINE(NORMAL) ...................................................................... 4
COLD WEATHER STARTING ................................................................................. 5
STOPPING THE ENGINE........................................................................................ 6
CHECKS DURING OPERATION............................................................................. 6
Radiator Cooling water(Coolant) ...................................................................................... 6
Oil pressure lamp..............................................................................................................6
Fuel................................................................................................................................... 7
Color of exhaust................................................................................................................ 7
Immediately stop the engine if; ......................................................................................... 7
REVERSED ENGINE REVOLUTION AND REMEDIES.......................................... 7
How to tell when the engine starts running backwards..................................................... 7
Remedies.......................................................................................................................... 7
MAINTENANCE........................................................................................................... 8
SERVICE INTERVALS ............................................................................................ 9
PERIODIC SERVICE................................................................................................. 11
FUEL ...................................................................................................................... 11
Fuel level check and refueling ........................................................................................ 11
Air bleeding the fuel system............................................................................................ 11
Checking the fuel pipes .................................................................................................. 12
Cleaning the fuel filter pot ............................................................................................... 12
ENGINE OIL........................................................................................................... 13
Checking level and adding engine oil ............................................................................. 13
Changing engine oil ........................................................................................................ 14
Replacing the oil filter cartridge ...................................................................................... 15
RADIATOR............................................................................................................. 15
Checking coolant level, adding coolant .......................................................................... 15
Changing coolant............................................................................................................ 16
Checking radiator hoses and clamp ............................................................................... 16
Precaution at overheating............................................................................................... 17
Anti-freeze ...................................................................................................................... 17
Radiator cement ............................................................................................................. 17
AIR CLEANER ....................................................................................................... 18
For the air cleaner with a dust cup (optional).................................................................. 18
BATTERY............................................................................................................... 18
Battery charging.............................................................................................................. 19
Direction for long term storage ....................................................................................... 20
ELECTRIC WIRING ............................................................................................... 20
CONTENTS
ENGLISH
FAN BELT .............................................................................................................. 20

Adjusting Fan Belt Tension............................................................................................. 20
CARRIAGE AND STORAGE..................................................................................... 21
CARRIAGE ............................................................................................................ 21
STORAGE.............................................................................................................. 21
TROUBLESHOOTING............................................................................................... 22
SPECIFICATIONS..................................................................................................... 24
WIRING DIAGRAMS ................................................................................................. 25
SAFE OPERATION 1
ENGLISH
SAFE OPERATION
Careful operation is your best assurance against an accident. Read and understand this section carefully before
operating the engine. All operators, no matter how much experience they may have, should read this and other
related manuals before operating the engine or any equipment attached to it. It is the owner's obligation to provide
all operators with this information and instruct them on safe operation.
Be sure to observe the following for safe operation.
1. OBSERVE SAFETY INSTRUCTIONS

A Read and understand carefully this "OPERATOR'S MANUAL" and
"LABELS ON THE ENGINE" before attempting to start and operate the
engine.
A Learn how to operate and work safely. Know your equipment and its
limitations. Always keep the engine in good condition.
A Before allowing other people to use your engine, explain how to operate
and have them read this manual before operation.
A DO NOT modify the engine. UNAUTHORIZED MODIFICATIONS to the
engine may impair the function and/or safety and affect engine life. If the
engine does not perform properly, consult your local Kubota Engine
Distributor first.
2. WEAR SAFE CLOTHING AND PERSONAL PROTECTIVE EQUIPMENT (PPE)

A DO NOT wear loose, torn or bulky clothing around the machine that may
catch on working controls and projections or into fans, pulleys and other
moving parts causing personal injury.
A Use additional safety items-PPE, e.g. hard hat, safety protection, safety
goggles, gloves, etc., as appropriate or required.
A DO NOT operate the machine or any equipment attached to it while
under the influence of alcohol, medication, or other drugs, or while
fatigued.
A DO NOT wear radio or music headphones while operating the engine.
2 SAFE OPERATION
ENGLISH
3. CHECK BEFORE STARTING & OPERATING THE ENGINE

A Be sure to inspect the engine before operation. Do not operate the
engine if there is something wrong with it. Repair it immediately.
A Ensure all guards and shields are in place before operating the engine.
Replace any that are damaged or missing.
A Check to see that you and others are a safe distance from the engine
before starting.
A Always keep the engine at least 3 feet (1 meter) away from buildings and
other facilities.
A DO NOT allow children or livestock to approach the machine while the
engine is running.
A DO NOT start the engine by shorting across starter terminals. The
machine may start in gear and move. Do not bypass or defeat any safety
devices.
4. KEEP THE ENGINE AND SURROUNDINGS CLEAN

A Be sure to stop the engine before cleaning.
A Keep the engine clean and free of accumulated dirt, grease and trash to
avoid a fire. Store flammable fluids in proper containers and cabinets
away from sparks and heat.
A Check for and repair leaks immediately.
A DO NOT stop the engine without idling; Allow the engine to cool down,
first. Keep the engine idling for about 5 minutes before stopping unless
there is a safety problem that requires immediate shut down.
5. SAFE HANDLING OF FUEL AND LUBRICANTS -KEEP AWAY FROM FIRE

A Always stop the engine before refueling and/or lubricating.
A DO NOT smoke or allow flames or sparks in your work area. Fuel is
extremely flammable and explosive under certain conditions.
A Refuel at a well ventilated and open place. When fuel and/or lubricants
are spilled, refuel after letting the engine cool down.
A DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause
a fire or severe engine damage.
A Do not use unapproved containers e.g. buckets, bottles, jars. Use
approved fuel storage containers and dispensers.
SAFE OPERATION 3
ENGLISH
6. EXHAUST GASES & FIRE PREVENTION
A Engine exhaust fumes can be very harmful if allowed to accumulate. Be
sure to run the engine in a well ventilated location and where there are
no people or livestock near the engine.
A The exhaust gas from the muffler is very hot. To prevent a fire, do not
expose dry grass, mowed grass, oil or any other combustible materials
to exhaust gas. Keep the engine and muffler clean at all times.
A To avoid a fire, be alert for leaks of flammable substances from hoses
and lines. Be sure to check for leaks from hoses or pipes, such as fuel
and hydraulic fluid by following the maintenance check list.
A To avoid a fire, do not short across power cables and wires. Check to
see that all power cables and wirings are in good condition. Keep all
electrical connections clean. Bare wire or frayed insulation can cause a
dangerous electrical shock and personal injury.
7. ESCAPING FLUID
A Relieve all pressure in the air, the oil and the cooling systems before
disconnecting any lines, fittings or related items.
A Be cautious of possible pressure relief when disconnecting any device
from a pressurized system that utilizes pressure. DO NOT check for
pressure leaks with your hand. High pressure oil or fuel can cause
personal injury.
A Escaping fluid under pressure has sufficient force to penetrate skin
causing serious personal injury.
A Fluid escaping from pinholes may be invisible. Use a piece of cardboard
or wood to search for suspected leaks: do not use hands and body. Use
safety goggles or other eye protection when checking for leaks.
A If injured by escaping fluid, see a medical doctor immediately. This fluid
can produce gangrene or severe allergic reaction.
4 SAFE OPERATION
ENGLISH
8. CAUTIONS AGAINST BURNS & BATTERY EXPLOSION

A To avoid burns, be cautious of hot components, e.g. muffler, muffler
cover, radiator, hoses, engine body, coolants, engine oil, etc. during
operation and after the engine has been shut off.
A DO NOT remove the radiator cap while the engine is running or
immediately after stopping. Otherwise hot water will spout out from the
radiator. Wait until the radiator is completely cool to the touch before
removing the cap. Wear safety goggles.
A Be sure to close the coolant drain valve, secure the pressure cap, and
fasten the pipe band before operating. If these parts are taken off, or
loosened, it will result in serious personal injury.
A The battery presents an explosive hazard. When the battery is being
charged, hydrogen and oxygen gases are extremely explosive.
A DO NOT use or charge the battery if its fluid level is below the LOWER
mark.
Otherwise, the component parts may deteriorate earlier than expected,
which may shorten the service life or cause an explosion. Immediately,
add distilled water until the fluid level is between the UPPER and
LOWER marks.
A Keep sparks and open flames away from the battery, especially during
charging. DO NOT strike a match near the battery.
A DO NOT check the battery charge by placing a metal object across the
terminals. Use a voltmeter or hydrometer.
A DO NOT charge a frozen battery. There is a risk of explosion. When
frozen, warm the battery up to at least 16 C (61 F).
9. KEEP HANDS AND BODY AWAY FROM ROTATING PARTS

A Be sure to stop the engine before checking or adjusting the belt tension
and cooling fan.
A Keep your hands and body away from rotating parts, such as the cooling
fan, V-belt, fan drive V-belt, pulley or flywheel. Contact with rotating
parts can cause severe personal injury.
A DO NOT run the engine without safety guards. Install safety guards
securely before operation.
SAFE OPERATION 5
ENGLISH
10. ANTI-FREEZE & DISPOSAL OF FLUIDS
A Anti-freeze contains poison. Wear rubber gloves to avoid personal
injury. In case of contact with skin, wash it off immediately.
A DO NOT mix different types of Anti-freeze. The mixture can produce a
chemical reaction causing harmful substances. Use approved or
genuine KUBOTA Anti-freeze.
A Be mindful of the environment and the ecology. Before draining any
fluids, determine the correct way to dispose of them. Observe the
relevant environmental protection regulations when disposing of oil, fuel,
coolant, brake fluid, filters and batteries.
A When draining fluids from the engine, place a suitable container
underneath the engine body.
A DO NOT pour waste onto the ground, down a drain, or into any water
source. Dispose of waste fluids according to environmental regulations.
11. CONDUCTING SAFETY CHECKS & MAINTENANCE

A When inspecting the engine or servicing, place the engine on a large flat
surface. DO NOT work on anything that is supported ONLY by lift jacks
or a hoist. Always use blocks or the correct stands to support the engine
before servicing.
A Disconnect the battery from the engine before conducting service. Put a
"DO NOT OPERATE!" tag on the key switch to avoid accidental starting.
A To avoid sparks from an accidental short circuit always disconnect the
battery's ground cable (-) first and reconnect it last.
A Be sure to stop the engine and remove the key when conducting daily
and periodic maintenance, service and cleaning.
A Check or conduct maintenance after the engine, coolant, muffler, or
muffler cover have cooled off completely.
A Always use the appropriate tools and fixtures. Verify that they are in
good condition before performing any service work. Make sure you
understand how to use them before service.
A Use ONLY correct engine barring techniques for manually rotating the
engine. DO NOT attempt to rotate the engine by pulling or prying on the
cooling fan and V-belt. This practice can cause serious personal injury
or premature damage to the cooling fan and belt.
A Replace fuel pipes and lubricant pipes with their hose clamps every 2
years or earlier whether they are damaged or not. They are made of
rubber and age gradually.
A When servicing is performed together by two or more persons, take care
to perform all work safely.
A Keep a first aid kit and fire extinguisher handy at all times.
6 SAFE OPERATION
ENGLISH
12. WARNING AND CAUTION LABELS

Part No.19077-8724-1 or 16667-8724-1
(55mm in diameter) (37mm in diameter)
Part No.TA040-4957-1
Stay clear of engine
fan and fan belt
13. CARE OF WARNING AND CAUTION LABELS

1. Keep warning and caution labels clean and free from obstructing material.
2. Clean warning and caution labels with soap and water, dry with a soft cloth.
3. Replace damaged or missing warning and caution labels with new labels from your local KUBOTA dealer.
4. If a component with warning and caution label(s) affixed is replaced with a new part, make sure the new label(s) is (are)
attached in the same location(s) as the replaced component.
5. Mount new warning and caution labels by applying to a clean dry surface and pressing any bubbles to the outside edge.
SERVICING OF THE ENGINE 1
ENGLISH
SERVICING OF THE ENGINE
Your dealer is interested in your new engine and has the
desire to help you get the most value from it. After reading
this manual thoroughly, you will find that you can do some
of the regular maintenance yourself.
However, when in need of parts or major service, be sure
to see your KUBOTA dealer.
For service, contact the KUBOTA Dealership from which
you purchased your engine or your local KUBOTA dealer.
When in need of parts, be prepared to give your dealer the
engine serial number.
Locate the serial number now and record them in the
space provided.
Type Serial No.

(1) Engine serial number
Engine
Date of Purchase
Name of Dealer
(To be filled in by purchaser)
2 NAMES OF PARTS
ENGLISH
NAMES OF PARTS
(1) Intake manifold (10) Oil filler plug

(2) Speed control lever (11) Exhaust manifold
(3) Engine stop lever (12) Alternator
(4) Injection pump (13) Starter
(5) Fuel feed pump (14) Oil level gauge
(6) Cooling fan (15) Oil pressure switch
(7) Fan drive pulley (16) Flywheel
(8) Oil filter cartridge (17) Oil drain plug
(9) Water drain cock (18) Oil pan
PRE-OPERATION CHECK 3
ENGLISH
PRE-OPERATION CHECK
BREAK-IN
During the engine break-in period, observe the following by all means:
1. Change engine oil and oil filter cartridge after the first 50 hours of operation (See "ENGINE OIL" in Periodic Service
Section).
2. When ambient temperature is low, operate the machine after the engine has been completely warmed up.
DAILY CHECK
To prevent trouble from occurring, it is important to know the conditions of the engine well. Check it before starting.
To avoid personal injury:

A Be sure to install shields and safeguards attached to the engine when operating.
A Stop the engine at a flat and wide space when checking.
A Keep dust or fuel away from the battery, wiring, muffler and engine to prevent a fire.
Check and clear them before operating everyday. Pay attention to the heat of the exhaust pipe or exhaust
gas so that it can not ignite trash.
Item Ref. page

1. Parts which had trouble in previous operation -
2. By walking around the machine (1) Oil or water leaks 13 to 15
(2) Engine oil level and contamination 13
(3) Amount of fuel 11
(4) Amount of coolant 15
(5) Dust in air cleaner dust cup 18
(6) Damaged parts and loosened bolts and nuts -
3. By inserting the key into the (1) Proper functions of meters and pilot lamps; no stains on
-
starter switch these parts
(2) Proper function of glow lamp timer -
4. By starting the engine (1) Color of exhaust fumes 7
(2) Unusual engine noise 7
4 OPERATING THE ENGINE
ENGLISH
OPERATING THE ENGINE

STARTING THE ENGINE(NORMAL) 1. Set the fuel lever to "ON".

A Do not allow children to approach the machine
while the engine is running.
A Be sure to install the machine on which the
engine is installed, on a flat place.
A Do not run the engine on gradients.
A Do not run the engine in an enclosed area.
Exhaust gas can cause air pollution and
exhaust gas poisoning.
A Keep your hands away from rotating parts
(such as fan, pulley, belt, flywheel etc.) during
operation.
A Do not operate the machine while under the
influence of alcohol or drugs.
A Do not wear loose, torn or bulky clothing (1) Fuel lever (A) "ON"
around the machine. It may catch on moving (B) "OFF"
parts or controls, leading to the risk of
accident. Use additional safety items, e.g. hard
hat, safety boots or shoes, eye and hearing 2. Place the engine stop lever in the
protection, gloves, etc., as appropriate or "START" position.
required.
3. Place the speed control lever at more
A Do not wear radio or music headphones while
operating engine. than half "OPERATION"
A Check to see if it is safe around the engine
before starting.
A Reinstall safeguards and shields securely and
clear all maintenance tools when starting the
engine after maintenance.
A Do not use ether or any starting fluid for starting the

engine, or a severe damage will occur.
A When starting the engine after a long storage (of more
than 3 months), first set the stop lever to the "STOP"
position and then activate the starter for about 10
seconds to allow oil to reach every engine part.
(1) Speed Control lever (A) "OPERATION"

(B) "IDLING"
OPERATING THE ENGINE 5
ENGLISH
4. Insert the key into the key switch and COLD WEATHER STARTING
turn it "ON". If the ambient temperature is below* -5 C(23 F) and the
engine is very cold, start it in the following manner:
Take steps (1) through (4) left.
5. Turn the key to the "PREHEATING"

position and keep it there for a certain
period mentioned below.
A Shown below are the standard preheating times for

various temperatures. This operation, however, is not
required, when the engine is warmed up.
Preheating time
Ambient
temperature With glow lamp
Ordinary heat type
timer
(A) "OFF" SWITCHED OFF
(B) "ON" OPERATION Above 10 C (50 F) NO NEED
(C) "GL" PREHEATING 10 C (50 F) to Approx.
(D) "ST" STARTING -5 C (23 F) 5 seconds
Approx. See NOTE:
5. Turn the starter switch to the *Below -5 C (23 F)
10 seconds
"PREHEATING" position to allow the Limit of
glow lamp to redden. 20 seconds
continuous use
6. Turn the key to the "STARTING"
position and the engine should start.
A In case of installing standard glow lamp, glow lamp
Release the key immediately when the goes off after about 6 seconds, when the starter switch
engine starts. key is turned to the "PREHEATING" position. However
7. Check to see that the oil pressure lamp if necessary, keep the starter switch key at the
and charge lamp are off. If the lamps "PREHEATING" position for longer time, according to
are still on, immediately stop the the left recommendation.
engine, and determine the cause.
6. Turn the key to the "STARTING"
(See "CHECKS DURING OPERATION" in Operating position and the engine should start.
the Engine Section) (If the engine fails to start after 10 seconds, turn off
the key for 5 to 30 seconds. Then repeat steps (5)
A If the oil pressure lamp should be still on, immediately and (6).)
stop the engine and check;
- if there is enough engine oil.
- if the engine oil has dirt in it. A Do not allow the starter motor to run continuously for
- if the wiring is faulty. more than 20 seconds.
A Be sure to warm up the engine, not only in winter, but
8. Warm up the engine at medium speed also in warmer seasons. An insufficiently warmed-up
without load. engine can shorten its service life.
A When there is fear of temperature dropping below
-15 C (5 F) detach the battery from the machine, and
A If the glow lamp should redden too quickly or too keep it indoors in a safe area, to be reinstalled just
slowly, immediately ask your KUBOTA dealer to check before the next operation.
and repair it.
A If the engine does not catch or start at 10 seconds after
the starter switch is set at "STARTING" position, wait
for another 30 seconds and then begin the engine
starting sequence again. Do not allow the starter
motor to run continuously for more than 20 seconds.
6 OPERATING THE ENGINE
ENGLISH
STOPPING THE ENGINE CHECKS DURING OPERATION

While running, make the following checks to see that all
1. Return the speed control lever to low idle, parts work well.
and run the engine under idling
2. Set the engine stop lever to "STOP" BRadiator Cooling water(Coolant)
position.
3. With the starter switch placed at "OFF"
position, remove the key.(Be sure to To avoid personal injury:
return the stop lever as it was after A Do not remove radiator cap until coolant
temperature is well below its boiling point.
stopping the engine, and get ready for the Then loosen cap slightly to the stop position, to
next starting.) relieve any pressure, before removing cap
completely.
When the engine overheats and hot coolant overflows

through the radiator and hoses, stop the engine
immediately and make the following checks to determine
the cause of trouble:
Check item
1. Check to see if there is any water leak;
2. Check to see if there is any obstacle around the
cooling air inlet or outlet;
3. Check to see if there is any dirt or dust between
radiator fin and tube;
4. Check to see if the fan belt is too loose;
5. Check to see if radiator water pipe is clogged;
6. Check to see if anti-freeze is mixed into coolant in
(1) Speed control lever (A) "IDLING" warm seasons.
(2) Engine stop lever (B) "OPERATION"
(C) "START"
(D) "STOP"
BOil pressure lamp
The lamp lights up to warn the operator that the engine oil
pressure has dropped below the prescribed level. If this
should happen during operation or should not go off even
after the engine is accelerated more than 1000rpm,
immediately stop the engine and check the following:
1. Engine oil level (See "ENGINE OIL" in Maintenance
Section).
2. Lubricant system (See "ENGINE OIL" in Maintenance
Section).
OPERATING THE ENGINE 7
ENGLISH
REVERSED ENGINE REVOLUTION AND
BFuel
REMEDIES

A Fluid escaping from pinholes may be invisible.
A Reversed engine operation can make the
Do not use hands to search for suspected
machine reverse and run it backwards. It may
leaks; Use a piece of cardboard or wood,
lead to serious trouble.
instead. If injured by escaping fluid, see a
A Reversed engine operation may make exhaust
medical doctor at once. This fluid can produce
gas gush out into the intake side and ignite the
gangrene or a severe allergic reaction.
air cleaner; It could catch fire.
A Check any leaks from fuel pipes or fuel
injection pipes. Use eye protection when
checking for leaks. Reversed engine revolution must be stopped immediately
since engine oil circulation is cut quickly, leading to
Be careful not to empty the fuel tank. Otherwise air may serious trouble.
enter the fuel system, requiring fuel system bleeding.
(See "FUEL" in Maintenance Section). BHow to tell when the engine starts running
backwards
BColor of exhaust 1. Lubricating oil pressure drops sharply. Oil pressure
While the engine is run within the rated output range: warning light, if used, will light.
A The color of exhaust remains colorless. 2. Since the intake and exhaust sides are reversed, the
A If the output slightly exceeds the rated level, exhaust sound of the engine changes, and exhaust gas will
may become a little colored with the output level kept come out of the air cleaner.
constant. 3. A louder knocking sound will be heard when the
A If the engine is run continuously with dark exhaust engine starts running backwards.
emission, it may lead to trouble.
BRemedies
BImmediately stop the engine if; 1. Immediately set the engine stop lever to "STOP"
A The engine suddenly slow down or accelerates. position to stop the engine.
A Unusual noises suddenly appear. 2. After stopping the engine, check the air cleaner, intake
A Exhaust fumes suddenly become very dark. rubber tube and other parts and replace parts as
A The oil pressure lamp or the water temperature alarm needed.
lamp lights up.
8 MAINTENANCE
ENGLISH
MAINTENANCE

A Be sure to conduct daily checks, periodic
maintenance, refueling or cleaning on a level
surface with the engine shut off and remove the
key.
A Before allowing other people to use your
engine, explain how to operate, and have them
read this manual before operation.
A When cleaning any parts, do not use gasoline
but use regular cleanser.
A Always use proper tools, that are in good
condition. Make sure you understand how to
use them, before performing any service work.
A When installing, be sure to tighten all bolts lest
they should be loose. Tighten the bolts by the
specified torque.
A Do not put any tools on the battery, or battery
terminals may short out. Severe burns or fire
could result. Detach the battery from the
engine before maintenance.
A Do not touch muffler or exhaust pipes while
they are hot; Severe burns could result.
MAINTENANCE 9
ENGLISH
SERVICE INTERVALS
Observe the following for service and maintenance.
The lubricating oil change intervals listed in the table below are for Classes CF, CE and CD lubricating oils of API classifi-
cation with a low-sulfur fuel in use. If the CF-4 or CG-4 lubricating oil is used with a high-sulfur fuel, change the lubricating
oil at shorter intervals than recommended in the table below depending on the operating condition.
Interval Item Ref.page

Every 50 hours Check of fuel pipes and clamp bands 12 @
See NOTE Change of engine oil (depending on the oil pan) 13,14
Cleaning of air cleaner element 18,18 *1 @
Cleaning of fuel filter 12
Every 100 hours
Check of battery electrolyte level 19,20
Check of fan belt tightness 20
Check of radiator hoses and clamp bands 16
Every 200 hours Replacement of oil filter cartridge (depending on the oil pan) 15
Check of intake air line - @
Every 400 hours Replacement of fuel filter element 12 @
Removal of sediment in fuel tank -
Every 500 hours Cleaning of water jacket (radiator interior) -
Replacement of fan belt 20
Every one or two months Recharging of battery 19,20
Every year or every 6
cleanings of air cleaner Replacement of air cleaner element 18,18 *2 @
element
Every 800 hours Check of valve clearance 22
Every 1500 hours Check of fuel injection nozzle injection pressure - *3 @
Check of turbo charger - *3 @
Every 3000 hours Check of injection pump - *3 @
Check of fuel injection timer - *3 @
Replacement of battery 19,20
Replacement of radiator hoses and clamp bands 16
Every two years Replacement of fuel pipes and clamps 12 *3 @
Change of radiator coolant (L.L.C.) 15
Replacement of intake air line - *4 @
A The jobs indicated by must be done after the first 50 hours of operation.
*1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions.
*2 After 6 times of cleaning.
*3 Consult your local KUBOTA Dealer for this service.
*4 Replace only if necessary.
A The items listed above (@ marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA
nonroad emission regulation. As the engine owner, you are responsible for the performance of the required
maintenance on the engine according to the above instruction.
Please see the Warranty Statement in detail.
10 MAINTENANCE
ENGLISH
A Lubricating oil
A Changing interval of Engine oil and oil filter With the emission control now in effect, the CF-4 and
cartridge. CG-4 lubricating oils have been developed for use of a
*Oil pan depth low-sulfur fuel on on-road vehicle engines. When an
off-road vehicle engine runs on a high-sulfur fuel, it is
101 mm 121 mm advisable to employ the CF, CD or CE lubricating oil
(3.98 in.) (4.76 in.)
with a high total base number. If the CF-4 or CG-4
50 Hrs (Initial) lubricating oil is used with a high-sulfur fuel, change
Z602-E Engine oil the lubricating oil at shorter intervals.
100 Hrs -
D902-E A Lubricating oil recommended when a low-
Oil filter cartridge 200 Hrs sulfur or high-sulfur fuel is employed.
50 Hrs (Initial) : Recommendable X : Not recommendable
Z482-E Engine oil
Lubricating Fuel
D662-E 75 Hrs 100 Hrs
Remarks
D722-E oil class Low-sulfur High-sulfur
Oil filter cartridge 150 Hrs 200 Hrs
50 Hrs (Initial) CF TBN 10
Engine oil
D782-E - 100 Hrs CF-4 X
Oil filter cartridge 200 Hrs CG-4 X
* 101 mm (3.98 in.) oil pan depth is optional for Z482-E,

D662-E, D722-E.
**Standard replacement interval
A API service classification: above CD grade
A Ambient temperature: below 35 C (95 F)
PERIODIC SERVICE 11
ENGLISH
PERIODIC SERVICE
FUEL Distillation Viscosity
Viscosity
Fuel is flammable and can be dangerous. You should Temperatures, Kinematic
Saybolt,
handle fuel with care. C( F) cSt or
SUS at
90% mm /s at
37.8 C(100 F)
Point 40 C
To avoid personal injury: Min Max Min Max Min Max

A Do not mix gasoline or alcohol with diesel fuel. 282 338
1.9 4.1 32.6 40.1
This mixture can cause an explosion. (540) (640)
A Be careful not to spill fuel during refueling. If
fuel should spill, wipe it off at once, or it may Sulfur, Copper
Cetane
cause a fire. weight Strip
Number
A Do not fail to stop the engine before refueling. % Corrosion
Keep the engine away from the fire. Max Max Min
A Be sure to stop the engine while refueling or
bleeding and when cleaning or changing fuel 0.40 No. 3 40
filter or fuel pipes. Do not smoke when working
around the battery or when refueling. The cetane number is required not less than 45.
A Check the above fuel systems at a well
ventilated and wide place. A Be sure to use a strainer when filling the fuel tank, or
A When fuel and lubricant are spilled, refuel after dirt or sand in the fuel may cause trouble in the fuel
letting the engine cool off. injection pump.
A Always keep spilled fuel and lubricant away A For fuel, always use diesel fuel. You are required not
from engine. to use alternative fuel, because its quality is unknown
or it may be inferior in quality. Kerosene, which is very
BFuel level check and refueling low in cetane rating, adversely affects the engine.
1. Check to see that the fuel level is above the lower limit Diesel fuel differs in grades depending on the
of the fuel level gauge. temperature.
2. If the fuel is too low, add fuel to the upper limit. Do not A Be careful not to let the fuel tank become empty, or air
overfill. can enter the fuel system, necessitating bleeding
before next engine start.
No.2-D is a distillate fuel oil of lower volatility for engines
in industrial and heavy mobile service. BAir bleeding the fuel system
(SAE J313 JUN87)
Grade of Diesel Fuel Oil According to ASTM D975
Carbon To avoid personal injury;
Water and A Do not bleed a hot engine as this could cause
Flash Point, Residue on, Ash,
Sediment, fuel to spill onto a hot exhaust manifold
C 10 percent weight
volume creating a danger of fire.
( F) Residuum, %
%
%
Air bleeding of the fuel system is required if;
Min Max Max Max
A after the fuel filter and pipes have been detached and
52 refitted;
0.05 0.35 0.01
(125) A after the fuel tank has become empty; or
A before the engine is to be used after a long storage.
12 PERIODIC SERVICE
ENGLISH
[PROCEDURE]
1. Fill the fuel tank to the fullest extent. Open the fuel filter
lever.
2. Loosen air vent plug of the fuel filter a few turns.
3. Screw back the plug when bubbles do not come up
any more.
4. Open the air vent plug on top of the fuel injection
pump.
5. Retighten the plug when bubbles do not come up any
more.
(1) Clamp band

(2) Fuel pipe
BCleaning the fuel filter pot

Every 100 hours of operation, clean the fuel filter in a
clean place to prevent dust intrusion.
1. Close the fuel filter lever.
(1) Fuel filter lever (A) "ON"

(2) Air vent plug (B) "OFF"
(3) Fuel filter pot
BChecking the fuel pipes
To avoid personal injury;

A Check or replace the fuel pipes after stopping
the engine. Broken fuel pipes can cause fires.
Check the fuel pipes every 50 hours of operation. When if;

1. If the clamp band is loose, apply oil to the screw of the (1) Fuel filter lever (A) "OFF"
(2) Fuel filter pot (B) "ON"
band, and tighten the band securely.
2. If the fuel pipes, made of rubber, became worn out,
replace them and clamp bands every 2 years. 2. Remove the top cap, and rinse the inside with diesel
3. If the fuel pipes and clamp bands are found worn or fuel.
damaged before 2 years' time, replace or repair them 3. Take out the element, and rinse it with diesel fuel.
at once. 4. After cleaning, reinstall the fuel filter, keeping out of
4. After replacement of the pipes and bands, air-bleed dust and dirt.
the fuel system. 5. Air-bleed the injection pump.
A When the fuel pipes are not installed, plug them at A Entrance of dust and dirt can cause a malfunction of
both ends with clean cloth or paper to prevent dirt from the fuel injection pump and the injection nozzle. Wash
entering. Dirt in the pipes can cause fuel injection the fuel filter cup periodically.
pump malfunction.
PERIODIC SERVICE 13
ENGLISH
ENGINE OIL

A Be sure to stop the engine before checking and
changing the engine oil and the oil filter
cartridge.
A Do not touch muffler or exhaust pipes while
they are hot; Severe burns could result. Always
stop the engine and allow it to cool before
conducting inspections, maintenance, or for a
cleaning procedure.
A Contact with engine oil can damage your skin.
Put on gloves when using engine oil. If you
come in contact with engine oil, wash it off
(1) O ring
(2) Filter element
immediately.
(3) Spring
(4) Filter bowl
(5) Screw ring A Be sure to inspect the engine, locating it on a
horizontal place. If placed on gradients accurately, oil
quantity may not be measured.
A Be sure to keep the oil level between upper and lower
limits of the oil gauge. Too much oil may cause a drop
in output or excessive blow-by gas. On the closed
breather type engine in which mist is sucked through
port, too much oil may cause oil hammer. While too
little oil, may seize the engine's rotating and sliding
parts. (The closed breather is an option.)
BChecking level and adding engine oil

1. Check the engine oil level before starting or more than
5 minutes after stopping the engine.
2. Remove the oil level gauge, wipe it clean and reinstall
it.
3. Take the oil level gauge out again, and check the oil
level.
(1) Oil filler plug [Lower end of oil level gauge]

(2) Oil level gauge (A):Engine oil level within this
range is proper.
14 PERIODIC SERVICE
ENGLISH
4. If the oil level is too low, remove the oil filler plug, and
add new oil to the prescribed level. BChanging engine oil
5. After adding oil, wait more than 5 minutes and check
the oil level again. It takes same time for the oil to
come down to the oil pan.
Engine oil quantity A Be sure to stop the engine before draining
engine oil.
Oil pan depth A When draining engine oil, place some
Models
*101 mm (3.98 in.) 121 mm (4.76 in.) container underneath the engine and dispose it
according to local regulations.
2.1 L 2.5 L A Do not drain oil after running the engine. Allow
Z482-E
(0.55 U.S.gals.) (0.66 U.S.gals.) engine to cool down sufficiently.
D662-E 3.2 L 3.8 L
D722-E (0.84 U.S.gals.) (1.0 U.S.gals.) 1. Change oil after the initial 50 hours of operation and
every 100 hours thereafter.
3.6 L 2. Remove the drain plug at the bottom of the engine,
D782-E -
(0.95 U.S.gals.) and drain all the old oil. Drain oil easier and completely
101 mm (3.98 in.) while the engine is hot.
Z602-E 2.5 L -
(0.66 U.S.gals.)
101 mm (3.98 in.)
D902-E 3.7 L -
(0.98 U.S.gals.)
*101mm(3.98in.) oil pan depth is optional.
Oil quantities shown are for standard oil pans.
A Engine oil should be MIL-L-2104C or have properties

of API classification CD grades or higher.
Change the type of engine oil according to the ambient
(1) Oil drain plug
temperature.
SAE30 or SAE10W-30 3. Add new engine oil up to the upper limit of the oil level
above 25 C (77 F)
SAE10W-40 gauge.
SAE20 or SAE10W-30
0 C to 25 C (32 F to 77 F)
SAE10W-40
SAE10 or SAE10W-30
below 0 C (32 F)
SAE10W-40
A When using oil different from the previous one, be sure

to drain all the previous oil before adding the new
engine oil.
PERIODIC SERVICE 15
ENGLISH
RADIATOR
BReplacing the oil filter cartridge Coolant will last for one day's work if filled all the way up
before operation start. Make it a rule to check the coolant
level before every operation.
A Be sure to stop the engine before changing the
oil filter cartridge. To avoid personal injury:
A Allow engine to cool down sufficiently, oil can A Do not stop the engine suddenly, stop it after
be hot and cause burns. about 5 minutes of unloaded idling.
A Work only after letting the engine and radiator
1. Replace the oil filter cartridge after the initial 50 hours cool off completely (more than 30 minutes after
of operation and every 200 hours thereafter. it has been stopped).
2. Remove the old oil filter cartridge with a filter wrench. A Do not remove the radiator cap while coolant is
3. Apply a film of oil to the gasket for the new cartridge. hot. When cool to the touch, rotate cap to the
4. Screw in the cartridge by hand. When the gasket first stop to allow excess pressure to escape.
contacts the seal surface, tighten the cartridge enough Then remove cap completely.
by hand. Because, if you tighten the cartridge with If overheats should occur, steam may gush out
wrench, it will be tightened too much. from the radiator or reserve tank; Severe burns
could result.
BChecking coolant level, adding coolant

1. Remove the radiator cap after the engine has
completely cooled, and check to see that coolant
reaches the supply port.
(1) Oil filter cartridge

Remove with a filter wrench
(Tighten with your hand)
5. After the new cartridge has been replaced, the engine

oil level normally decreases a little. Thus, run the
engine for a while and check oil leaks through the seal (1) Radiator pressure cap
before checking the engine oil level. Add oil if
necessary. 2. If the radiator is provided with a reserve tank, check
the coolant level of the reserve tank. When it is
between the "FULL" and "LOW" marks, the coolant will
A Wipe off any oil sticking to the machine completely. last for one day's work.
16 PERIODIC SERVICE
ENGLISH
A If the radiator cap has to be removed, follow the

caution and securely retighten the cap.
A If coolant should be leak, consult your local KUBOTA
dealer.
A Make sure that muddy or sea water does not enter the
radiator.
A Use clean, fresh water and 50% anti-freeze to fill the
recovery tank.
A Do not refill reserve tank with coolant over the "FULL"
level mark.
A Be sure to close the radiator cap securely. If the cap is
loose or improperly closed, coolant may leak out and
decrease quickly.
(1) Reserve tank (A) "FULL" BChanging coolant

(B) "LOW" 1. To drain coolant, always open both drain cocks and
3. When the coolant level drops due to evaporation, add simultaneously open the radiator cap as well. With the
water only up to the full level. radiator cap kept closed, a complete drain of water is
4. Check to see that two drain cocks; one is at the impossible.
crankcase side and the other is at the lower part of the 2. Remove the overflow pipe of the radiator pressure cap
radiator as figures below. to drain the reserve tank.
3. Prescribed coolant volume (U.S.gallons)
Models Quantity
Z482-E, Z602-E 2.8L (0.74 U.S.gals.)
D662-E, D722-E,
3.1L (0.82 U.S.gals.)
D782-E, D902-E
A Coolant quantities shown are for standard radiators.
4. An improperly tightened radiator cap or a gap between

the cap and the seat quickens loss of coolant.
5. Coolant (Radiator cleaner and anti-freeze)
Season Coolant
Pure water and radiator
Summer
cleaner
Winter (when temperature Pure water and anti-freeze
drops below 0 C (32 F) or (See "Anti-freeze" in
all season) Maintenance Section)
BChecking radiator hoses and clamp

A Be sure to check radiator hoses and hose
clamps periodically. If radiator hose is
(1) Coolant drain cock damaged or coolant leaks, overheats or severe
burns could occur.
Check to see if radiator hoses are properly fixed every 200

hours of operation or 6 months, whichever comes first.
PERIODIC SERVICE 17
ENGLISH
1. If hose clamps are loose or water leaks, tighten hose 3. The procedure for mixing of water and anti-freeze
clamp securely. differs according to the make of the anti-freeze and the
2. Replace hoses and tighten hose clamps securely, if ambient temperature. Refer to SAE J1034 standard,
radiator hoses are swollen, hardened or cracked. more specifically also to SAE J814c.
Replace hoses and hose clamps every 2 years or earlier, 4. Mix the anti-freeze with water, and then fill in to the
if checked and found that hoses are swollen, hardened or radiator.
cracked.
A When the anti-freeze is mixed with water, the anti-
freeze mixing ratio must be less than 50%.
BPrecaution at overheating
Take the following actions in the event the coolant Vol % Freezing Point Boiling Point *
temperature be nearly or more than the boiling point, what Anti-freeze
is called "Overheating". Take these actions if the engine's
40 -24 -12 106 222
alarm buzzer sounds or the alarm lamp lights up. 50 -37 -34 108 226
1. Stop the engine operation in a safe place and keep the
engine unloaded idling. *At 1.013 x 10 Pa (760 mmHg) pressure
2. Do not stop the engine suddenly. Stop it after about 5 (atmospheric). A higher boiling point is obtained by
minutes of unloaded idling. using a radiator pressure cap which permits the
3. If the engine stalls within about 5 minutes of running development of pressure within the cooling system.
under no load, immediately leave and keep yourself
away from the machine. Never open the hood and any
other part. A The above data represent industry standards that
4. Keep yourself and others well away from the engine necessitate a minimum glycol content in the
for further 10 minutes or while the steam blown out. concentrated anti-freeze.
5. Checking that there gets no danger such as burn, get A When the coolant level drops due to evaporation, add
rid of the causes of overheating according to the water only to keep the anti-freeze mixing ratio less
manual, see "Troubleshooting" section. And then, start than 50%. In case of leakage, add anti-freeze and
again the engine. water in the specified mixing ratio before filling into the
radiator.
BAnti-freeze A Anti-freeze absorbs moisture. Keep unused anti-
freeze in a tightly sealed container.
A Do not use radiator cleaning agents when anti-freeze
has been added to the coolant. (Anti-freeze contains
To avoid personal injury: an anti-corrosive agent, which will react with the
A When using anti-freeze, put on some protection radiator cleaning agent forming sludge which will
such as rubber gloves. affect the engine parts.)
A If should drink anti-freeze, throw up at once
and take medical attention.
BRadiator cement
A When anti-freeze comes in contact with the
skin or clothing, wash it off immediately. As the radiator is solidly constructed, there is little
A Do not mix different types of anti-freeze. possibility of water leakage. Should this happen, however,
A Keep fire and children away from anti-freeze. radiator cement can easily fix it. If leakage is serious,
A Be mindful of the environment and ecology. contact your local KUBOTA dealer.
Before draining any fluids, find out the correct
way of disposing by checking with local codes.
A Also, observe the relevant environmental
protection regulations when disposing of oil,
fuel, coolant, brake fluid, filters and batteries.
If it freezes, coolant can damage the cylinders and

radiator. It is necessary, if the ambient temperature falls
below 0 C (32 F), to remove coolant after operating or to
add anti-freeze to it.
1. There are 2 types of anti-freeze available; use the
permanent type (PT) for this engine.
2. Before adding anti-freeze for the first time, clean the
radiator interior by pouring fresh water and draining it
a few times.
18 PERIODIC SERVICE
ENGLISH
AIR CLEANER
As the element of the air cleaner employed on this engine BFor the air cleaner with a dust cup
is a dry type, never apply oil to it. (optional)
1. Open the evacuator valve once a week under ordinary Remove and clean out the dust cup before it becomes half
conditions-or daily when used in a dusty place-to get full with dust; usually once a week, or even every day if the
rid of large particles of dust and dirt. working surroundings are dusty.
2. Wipe the inside air cleaner clean with cloth or the like Install the air cleaner dust cup with "TOP" indicated on the
if it is dirty or wet. rear of the cup in the upside. (However, it may be installed
3. Avoid touching the element except when cleaning. in either direction when the cover is placed at the lower
4. When dry dust adheres to the element, blow
part.)
compressed air from the inside turning the element.
Pressure of compressed air must be under 205kPa
(2.1kgf/cm , 30psi).
5. When carbon or oil adheres to the element, soak the
element in detergent for 30 minutes, then wash it
several times in water, rinse with clean water and dry
it naturally.
6. After element is fully dried, inspect inside of the
element with a light and check if it is damaged or not.
(referring to the instructions on the label attached to
the element.)
7. Replace the element every year or every six
cleanings.
(1) Element
(2) Air cleaner body
(3) Dust cup
(4) Wing bolt
(5) "TOP" mark
A If the dust cup is mounted incorrectly, dust or dirt does

not collect in the cup, and direct attachments of the
dust to the element will cause its lifetime to shorten to
a great extent.
(1) Air cleaner body BATTERY

(2) Element
(3) Wing bolt
(4) Evacuator valve
(5) "TOP" mark
(6) Dust cup
A Be careful not to let the battery electrolyte
contact your body or clothing.
A Wear eye protection and rubber gloves, since
A Make sure the wing bolt for the element is tight the diluted sulfuric acid solution burns skin
enough. If it is loose, dust and dirt may be sucked, and eats holes in clothing. Should this occur,
wearing down the cylinder liner and piston ring earlier immediately wash it off with running water and
and thereby resulting in poor power output. get medical attention.
Mishandling of the battery shortens the service life and

adds to maintenance costs. Obtain the maximum
performance and the longest life of the battery by handling
properly and with care.
Engine starting will be more difficult, if the battery charge
is low. Be careful to recharge it at an early occasion before
it is too late.
PERIODIC SERVICE 19
ENGLISH
2. To slow charge the battery, connect the charger
BBattery charging positive terminal to the battery positive terminal, and
negative to the negative.
3. Quick recharging charges the battery at a high rate in
a short time. As this is only for emergencies.
The battery comes in two types: refillable and non- 4. Recharge the battery as early as possible, or battery
refillable. life will be extremely shortened.
A For using the refillable type battery, follow the 5. When exchanging an old battery into new one, use
instructions below. battery of equal specification shown in page 26.
Do not use or charge the battery if its fluid level
stands below the LOWER (lower limit level)
mark.
Otherwise, the battery component parts may
deteriorate earlier than expected, which may
shorten the battery's service life or cause an
explosion.
Immediately, add distilled water until the
battery's fluid level is between the UPPER and
LOWER levels.

A When the battery is being activated, hydrogen
and oxygen gases in the battery are extremely
explosive. Keep open sparks and flames away (1) Thick black cable
from the battery at all times, especially when (2) Battery case
charging the battery. (3) Earth cable
A When charging the battery, remove the battery
vent plugs.
A When disconnecting the cable from the battery,
start with the negative terminal, and when
connecting them, start with the positive
terminal first.
A DO NOT check the battery charge by placing a
metal object across the terminals. Use a
voltmeter or hydrometer.
1. Make sure each electrolyte level is to the bottom of

vent wells, if necessary, add only distilled water in a
well-ventilated place.
(1) Plug (A) "HIGHEST LEVEL"

(B) "LOWEST LEVEL"
A Connect the charger positive terminal to the battery

positive terminal, and negative to the negative.
A When disconnecting the cable from the battery, start
with the negative terminal first.
When connecting the cable to the battery, start with
the positive terminal first.
If reversed, the contact of tools on the battery may
cause a short.
(1) Battery electrolyte level (A) "TOO LOW"

(B) "PROPER"
(C) "TOO HIGH"
20 PERIODIC SERVICE
ENGLISH
FAN BELT
BDirection for long term storage
1. When storing the engine for long periods of time, BAdjusting Fan Belt Tension
remove the battery, adjust the electrolyte to the proper
level, and store in a dry and dark place.
2. The battery naturally discharges while it is stored. To avoid personal injury:
Recharge it once a month in summer, and every 2 A Be sure to stop the engine and remove the key
months in winter. before checking the belt tension.
A Be sure to reinstall the detached safety shield
ELECTRIC WIRING after maintenance or checking.
A deflection of between 7 to 9 mm
Proper fan belt
(0.28 to 0.35 in.) when the belt is
tension
To avoid personal injury: pressed in the middle of the span.
C Shorting of electric cable or wiring may cause
a fire. 1. Stop the engine and remove the key.
A Check to see if electric cables and wiring 2. Apply moderate thumb pressure to belt between the
are swollen, hardened or cracked. pulleys.
A Keep dust and water away from all power 3. If tension is incorrect, loosen the alternator mounting
connections. bolts and, using a lever placed between the alternator
Loose wiring terminal parts, make bad and the engine block, pull the alternator out until the
connections. Be sure to repair them before deflection of the belt falls within acceptable limits.
starting the engine. 4. Replace fan belt if it is damaged.
Damaged wiring reduces the capacity of electrical parts.

Change of repair damaged wiring immediately. A If belt is loosen or damaged and the fan is damaged, it
could result in overheats or insufficient charging.
1. Use automobile low voltage wiring cables for this Correct or replace belt.
wiring harness.
2. Use fuse and slow blow fuse as wiring protection.
3. Generally, available current of each fuse and size of
wire in this drawing are recommendable value showed
by Kubota, use suitable size fuses and wires for each
machine to consideration to wiring setting and
connection with another lines.
4. Install slow blow fuse near by battery, and install fuse
box near by key switch.
5. Do not connect any parts which may cause induction
current like motors to AC line.
6. Use heatproof cables, if room temperature around
wire harness become over 75 (167 ).
7. Remove painting at connecting position before
installation of each cable to any parts.
(1) Fan belt (A) 7 to 9 mm (0.28 to 0.35 in.)
(2) Bolt and nut (under load of 10 kgf (22.1 lbs))
CARRIAGE AND STORAGE 21
ENGLISH
CARRIAGE AND STORAGE
CARRIAGE STORAGE
To avoid personal injury: To avoid personal injury:

A Fix the engine securely not to fall during A Do not clean the machine with engine running.
operation. A To avoid the danger of exhaust fume
A Do not stand near or under the engine while poisoning, do not operate the engine in a
carrying it. closed building without proper ventilation.
A The engine is heavy. In handling it, be very alert A When storing the engine just after running, let
not to get your hands and body caught in. the engine cool off.
1. Use carrier such as crane when carrying the engine, or Before storing the engine for more than a few months,
hurt your waist and yourself. Support the engine remove any dirt on the machine, and:
securely with rope not to fall while carrying it. 1. Drain the coolant in the radiator. Open the cock at the
2. When lifting the engine, put the hook securely to metal bottom of the radiator, and remove the pressure cap to
fittings attached to the engine. Use strong hook and drain water completely. Leave the cock open. Hang a
fittings enough to hang the engine. note written "No water" on the pressure cap. Since
water may freeze when the temperature drops below
0 C (32 F), it is very important that no water is left in
the machine.
2. Remove dirty engine oil, fill with new oil and run the
engine for about 5 minutes to let the oil penetrate to all
the parts.
3. Check all the bolts and nuts, and tighten if necessary.
4. Remove the battery from the engine, adjust the
electrolyte level, and recharge it. Store the battery in a
dry and dark place.
5. When the engine is not used for a long period of time,
run it for about 5 minutes under no load every 2 to 3
months to keep it free from rust. If the engine is stored
without any running, moisture in the air may condense
into dew over the sliding parts of the engine, resulting
in rust there.
6. If you forget to run the engine for longer than 5 to 6
months, apply enough engine oil to the valve guide
and valve stem seal and make sure the valve works
smoothly before starting the engine.
7. Store the engine in a flat place and remove the key
from engine.
8. Do not store the engine in a place where has
flammable materials such as dry grass or straw.
9. When covering the engine for storage, let engine and
muffler cool off completely.
10. Operate the engine after checking and repairing
damaged wirings or pipes, and clearing flammable
materials carried by mouse.
22 TROUBLESHOOTING
ENGLISH
TROUBLESHOOTING
If the engine does not function properly, use the following chart to identify and correct the cause.
B When it is difficult to start the engine B When output is insufficient
Cause Countermeasures Cause Countermeasures
*Check the fuel tank and fuel filter. *Clean orifice and needle valve, being
*Remove water, dirt and other impurities. Carbon stuck very careful not to damage the nozzle
Fuel is thick and *As all fuel will be filtered by the filter, if around orifice of orifice.
doesn't flow. there should be water or other foreign nozzle piece *Check nozzle to see if good. If not,
matters on the filter, clean the filter with replace with new parts.
kerosene.
*Bad valve and excessive wear of rings,
Compression is
*If air is in the fuel filter or injection lines, pistons and liners cause insufficient
insufficient.
the fuel pump will not work properly. To compression. Replace with new parts.
Leaking valves
attain proper fuel injection pressure, *Grind valves.
Air or water mixed check carefully for loosened fuel line
Fuel is insufficient. *Check fuel system.
in fuel system coupling, loose cap nut, etc.
*Loosen air vent screws stop fuel filter *Check lubricating oil system.
and fuel injection pump to eliminate all *Check to see if lubricating oil filter is
the air in the fuel system. working properly.
*Filter element deposited with impurities
*This is caused when water or dirt is
would cause poor lubrication. Change
mixed in the fuel. Clean the nozzle Overheating of
element.
Thick carbon injection piece, being careful not to moving parts
*Check the clearance of bearing are
deposits on orifice damage the orifice.
within factory specs.
of injection nozzle. *Check to see if nozzle is working
*Check injection timing.
properly or not. If not, install a new
*Adjust timing 0.366 rad(20 ) before top
nozzle.
dead center.
*Adjust valve clearance to 0.145-
Valve clearance is *Adjust to proper valve clearance of
0.185mm(0.0057-0.0072in) when the Valve clearance is
wrong. 0.145 to 0.185 mm(0.0057 to 0.0072 in.)
engine is cold. wrong.
with engine cold.
Leaking valves *Grind valve.
*Clean the element every 100 hours of
Air cleaner is dirty
*Adjust injection timing operation.
Fuel injection timing
*The injection timing is 0.366 rad(20 )
is wrong. Fuel injection *Adjust to proper pressure. 13.7Mpa
before top dead center.
pressure is wrong. (140 kgf/cm ; 1991 psi)
Engine oil becomes
*Do not use poor quality fuel for it will
thick in cold *Change grade of oil according to the
cause wear of the pump. Only use No.
weather and engine weather (temperature.)
Injection pump 2-D diesel fuel.
cranks slow.
wear *Check the fuel injection pump element
*Bad valve or excessive wear of rings, and delivery valve assembly and
Low compression pistons and liners cause insufficient replace as necessary.
compression. Replace with new parts.
Battery is *Charge battery.
discharged and the *In winter, always remove battery from
engine will not machine, charge fully and keep indoors.
crank. Install in machine at time of use.
A If the cause of trouble can not be found, contact your KUBOTA dealer.
TROUBLESHOOTING 23
ENGLISH
B When engine suddenly stops B When engine must be stopped immediately
Cause Countermeasures Cause Countermeasures
*Check the fuel tank and refill the fuel, if Engine revolution
necessary. suddenly *Check the adjustments, injection timing
Lack of fuel
*Also check the fuel system for air or decreases or and the fuel system.
leaks. increases.
*If necessary, replace with a new Unusual sound is
Bad nozzle *Check all moving parts carefully.
nozzle. heard suddenly.
*Check amount of engine oil with oil Color of exhaust
Moving parts are *Check the fuel injection system,
level gauge. suddenly turns
overheated due to especially the fuel injection nozzle.
*Check lubricating oil system. dark.
shortage of
*At every 2 times of oil change, oil filter
lubrication oil or Bearing parts are
cartridge should be replaced. *Check the lubricating system.
improper overheated.
*Check to see if the engine bearing
lubrication.
clearances is within factory specs. *Check the lubricating system.
*Check, if the engine bearing
clearances are within factory specs.
A When the engine has suddenly stopped, decompress Oil lamp lights up
*Check the function of the relieve valve
the engine by the decomp and turn the engine lightly during operation.
in the lubricating system.
by pulling on the fan belt. If the engine turns easily *Check pressure switch.
without abnormalities, the cause of the trouble is *Check filter base gasket.
usually lack of fuel or bad nozzle.
B When engine overheats
B When color of exhaust is especially bad Cause Countermeasures
Cause Countermeasures Engine oil *Check oil level. Replenish oil as
insufficient required.
Fuel governing
*Contact dealer for repairs.
device bad Fan belt broken or
*Change belt or adjust belt tension.
elongated
Fuel is of extremely *Select good quality fuel.
poor quality. Use No. 2-D diesel fuel only. Coolant insufficient *Replenish coolant.
Nozzle is bad. *If necessary, replace with new nozzle. Excessive
*Add water only or change to coolant
concentration of
*Cause is poor atomization, improper with the specified mixing ratio.
antifreeze
injection timing, etc. Because of trouble
Combustion is in injection system or in poor valve Radiator net or
incomplete. adjustment, or compression leakage, radiator fin clogged *Clean net or fin carefully.
poor compression, etc. with dust
Check for the cause.
Inside of radiator or
coolant flow route *Clean or replace radiator and parts.
corroded
Fan or radiator or
radiator cap *Replace defective parts.
defective
Thermostat *Check thermostat and replace if
defective necessary.
Temperature gauge *Check temperature with thermometer
or sensor defective and replace if necessary.
Overload running *Reduce load.
Head gasket
defective or water *Replace parts.
leakage
Incorrect injection
*Adjust to proper timing.
timing
Unsuitable fuel
*Use the specified fuel.
used
24 SPECIFICATIONS
ENGLISH
SPECIFICATIONS
Model Z482-E Z602-E D662-E D722-E D782-E D902-E
Type Vertical, water-cooled, 4-cycle diesel engine
Number of cylinders 2 3
Bore and stroke 67 x 68 72 x 73.6 64 x 68 67 x 68 67 x 73.6 72 x 73.6
mm (in.) (2.64 x 2.68) (2.83 x 2.90) (2.52 x 2.68) (2.64 x 2.68) (2.64 x 2.90) (2.83 x 2.90)
Total displacement 0.479 0.599 0.656 0.719 0.778 0.898
L (cu.in.) (29.23) (36.55) (40.03) (43.88) (47.46) (54.80)
Combustion chamber Spherical Type (ETVCS)
SAE NET Intermittent
kW / rpm 9.32 / 3600 11.6 / 3600 12.9 / 3600 14.0 / 3600 13.5 / 3200 17.5 / 3600
H.P. (SAEJ1349) (12.5 / 3600) (15.6 / 3600) (17.3 / 3600) (18.8 / 3600) (18.1 / 3200) (23.5 / 3600)
(HP / rpm)
SAE NET Continuous
kW / rpm 8.05 / 3600 10.1 / 3600 11.18 / 3600 12.15 / 3600 11.7 / 3200 15.2 / 3600
H.P. (SAEJ1349) (10.8 / 3600) (13.5 / 3600) (15.0 / 3600) (16.3 / 3600) (15.7 / 3200) (20.4 / 3600)
(HP / rpm)
Maximum bare speed
3800 3850 3800 3450 3850
rpm
Maximum bare idling
800 to 900 900 to 1000 800 to 900 900 to 1000
speed rpm
Order of firing 1-2 1-2-3
Direction of rotation Counter-clockwise (viewed from flywheel side)
Injection pump Bosch MD Type mini pump
Injection pressure 13.73 MPa, 1991 psi(140 kgf/cm )
Injection timing
0.366rad(20 ) 0.35rad(20 ) 0.366rad(20 ) 0.35rad(20 )
(Before T.D.C.)
Compression ratio 23.5 : 1 24 : 1 23.5 : 1 24 : 1
Fuel Diesel Fuel No.2-D
Lubricant
above CC grade
(API classification)
351 x 389 x 520 385 x 421 x 544 467 x 421 x 544
Dimension mm (in.) 426 x 389 x 520
(13.82 x 15.31 x (15.16 x 16.57 x (18.39 x 16.57 x
(length x width x height) (16.77 x 15.31 x 20.47)
20.47) 21.42) 21.42)
Dry weight
53.1 (117.1) 57.0 (125.7) 63.7 (140.4) 63.1 (139.1) 63.5 (140.0) 72.0 (158.7)
(BB Spec.) kg (lbs.)
Starting system Cell starter (with glow plut)
Starting motor 12 V, 0.8 kW 12 V, 1.0 kW 12 V, 0.8 kW 12 V, 1.2 kW
Charging generator 12 V, 150 W 12 V, 480 W 12 V, 150 W 12 V, 480 W
Recommended battery 12 V, 28 AH, 12 V, 52 AH,
12 V, 36 AH, equivalent
capacity (5Hr capacity) equivalent equivalent
A Specifications are subject to change without notice.

A The battery capacity is indicated in 5-hour ratio.
WIRING DIAGRAMS 25
ENGLISH
WIRING DIAGRAMS
EU standard for Alternator (Energize to stop)
KEA standard for Alternator (Energize to stop)

26 WIRING DIAGRAMS
ENGLISH
EU standard for Dynamo (Energize to stop)
KEA standard for Dynamo (Energize to stop)

Leo18gt FL GB

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Leo18gt FL GB

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Translation of the original oper-

Aerial access platform

© TEUPEN Maschinenbau GmbH 2010

2 Aerial access platform Leo18GT-FL 02.05.2011

02.05.2011 Aerial access platform Leo18GT-FL 3

3.6 Drive engines.............................................. 40

4 Aerial access platform Leo18GT-FL 02.05.2011

6.3 Shutting down in case of emergency.......... 67

02.05.2011 Aerial access platform Leo18GT-FL 5

A Circuit diagram............................................... 149

6 Aerial access platform Leo18GT-FL 02.05.2011

1.2 Explanation of symbols

02.05.2011 Aerial access platform Leo18GT-FL 7

Tips and recommendations

Additional markings To emphasise instructions, results, lists, references and

8 Aerial access platform Leo18GT-FL 02.05.2011

1.3 Limitation of liability

02.05.2011 Aerial access platform Leo18GT-FL 9

1.5 Warranty provisions

1.6 Note regarding warranty card

10 Aerial access platform Leo18GT-FL 02.05.2011

Please send the warranty card to:

Fig. 1: Sample warranty card

1.7 Customer service

02.05.2011 Aerial access platform Leo18GT-FL 11

12 Aerial access platform Leo18GT-FL 02.05.2011

2.1 Basic hazards

2.1.1 General hazards in the workplace

02.05.2011 Aerial access platform Leo18GT-FL 13

Work in high places

14 Aerial access platform Leo18GT-FL 02.05.2011

2.1.2 Danger due to electric current

02.05.2011 Aerial access platform Leo18GT-FL 15

Measures to be undertaken upon contact with battery

16 Aerial access platform Leo18GT-FL 02.05.2011

2.1.3 Danger due to mechanism

Supports and arms

02.05.2011 Aerial access platform Leo18GT-FL 17

2.1.4 Danger due to hydraulic energies

18 Aerial access platform Leo18GT-FL 02.05.2011

2.1.5 Danger due to high temperatures

2.1.6 Danger due to chemicals

Measures to be undertaken upon contact with anti

02.05.2011 Aerial access platform Leo18GT-FL 19

2.1.7 Danger due to traffic and vehicles

20 Aerial access platform Leo18GT-FL 02.05.2011

2.2 Proper use

The machine is to be used exclusively to convey

Claims of any type due to damage from misuse are

2.3 Responsibility of the owner

02.05.2011 Aerial access platform Leo18GT-FL 21

In addition to the safety instructions in these instruc-

22 Aerial access platform Leo18GT-FL 02.05.2011

2.4 Personnel requirements

In these instructions, the qualifications listed below are

02.05.2011 Aerial access platform Leo18GT-FL 23

Personnel may only include people who are at least 18

24 Aerial access platform Leo18GT-FL 02.05.2011

2.4.2 Unauthorised persons

2.5 Personal protective equipment

02.05.2011 Aerial access platform Leo18GT-FL 25

Wear the harness so that the safety rope is attached to

2.6 Safety equipment