TIGIEFFE AIRO A Series Manuel utilisateur

PIATTAFORME AEREE SEMOVENTI

SELF-PROPELLED WORK-PLATFORMS

PLATES-FORMES DE TRAVAIL AUTOMOTRICES

SELBSTFAHRENDE HUBARBEITSBÜHNEN

PLATAFORMAS ELEVADORAS AUTOPROPULSADAS

ZELFRIJDENDE HOOGWERKERS

SJÄLVGÅENDE ARBETSPLATTFORMAR

SAMOKRETNE RADNE PLATFORME

"A" SERIES

A16 J A18 J

USE AND MAINTENANCE MANUAL

- ENGLISH - ORIGINAL INSTRUCTIONS

AIRO is a division of TIGIEFFE SRL

Via Villa Superiore, 82 - 42045 Luzzara (RE) ITALY-

+39-0522-977365 - +39-0522-977015

WEB: www.airo.com

040.20.UEM-EN

2020-01

Use and Maintenance Manual –A16 J A18 J Series

Page 2

Revision date

Description of revision

2010-01

•Update due to new machine directive 2006/42/EC.

•Model names updated.

2010-11

•Biodegradable oil instructions introduced

•Temperatures and oil list updated.

2011-05

•Amended information on “Commissioning and first inspection, subsequent inspections

and title transfer report”.

•Inserted “Total quantity of battery electrolyte” in Technical Data (added optional batteries

in ED).

•Corrected "Max. power" diesel engine and inserted "Adjusted Power".

2011-08

•Changed the second part of the manual, with updated diagrams for 48V-12V converter

change in systems JE to JED.

2012-09

•Removed parking brakes in electric and electro-diesel versions: changed descriptions

and hydraulic diagram.

2013-10

•Specified instructions for harness anchoring points.

2014-09

•Inserted information on maximum limits of manual forces.

•Changed Name and Surname of CEO.

2015-01

•CE Conformity Declaration Updated.

•Hand Position Instructions Added.

2015-10

•Type of usable hydraulic oil updated.

•Added indication for spare parts. They must be original or approved by the manufacturer

of the machine in any way.

•Added "Leaving at height”.

•Updated operating system on the charger and overload in platform.

2017-01

•Added description of new overload controller.

2019-06

•Added “AIRO SENTINEL” secondary safety system description.

2019-07

•Updated procedure description of commissioning declaration in Italy.

2020-01

•Updated normative references and certifying body.

 
Use and Maintenance Manual –A16 J A18 J Series 
Page 3 
 
Tigieffe thanks you for purchasing a product of its range, and invites you to read this manual. Here you can find all the 
necessary information for a correct use of the purchased machine; therefore, you are advised to follow the instructions carefully 
and to read the manual thoroughly. The manual should be kept in a suitable place where no damage can occur to it. The 
content of this manual may be modified without prior notice and further obligations in order to add changes and improvements 
to the units already delivered. No reproduction or translation may take place without the written permission of the owner. 
 
Contents: 
 
INTRODUCTION................................................................................................................................................ 6 
1. Legal aspects...................................................................................................................................................... 6 
1.1. Delivery of the machine......................................................................................................................................... 6 
1.2. Declaration of commissioning, first check, further periodical checks and transfers of ownership............................... 6 
1.2.1. Declaration of commissioning and first check ......................................................................................................... 6 
1.2.2. Further periodical checks....................................................................................................................................... 7 
1.2.3. Transfers of ownership.......................................................................................................................................... 7 
1.3. Operator training and information........................................................................................................................... 7 
2. Tests performed before delivery......................................................................................................................... 7 
3. Intended use........................................................................................................................................................ 7 
3.1. Leaving at height................................................................................................................................................... 8 
4. Description of the machine................................................................................................................................. 8 
5. Control panels..................................................................................................................................................... 9 
6. Power supply....................................................................................................................................................... 9 
7. Machine life, demolition and decommissioning................................................................................................. 9 
8. Identification ..................................................................................................................................................... 10 
9. Location of main components.......................................................................................................................... 11 
TECHNICAL FEATURES OF STANDARD MACHINES...............................................................................12 
1. Model A16 JE..................................................................................................................................................... 12 
2. Model A16 JED.................................................................................................................................................. 15 
3. Model A16 JRTD................................................................................................................................................ 18 
4. Model A18 JE..................................................................................................................................................... 21 
5. Model A18 JED.................................................................................................................................................. 24 
6. Model A18 JRTD................................................................................................................................................ 27 
7. Vibrations and noise......................................................................................................................................... 30 
SAFETY PRECAUTIONS................................................................................................................................31 
1. Personal protective equipment (PPE)............................................................................................................... 31 
2. General safety norms........................................................................................................................................ 31 
3. Use instructions................................................................................................................................................ 32 
3.1. General............................................................................................................................................................... 32 
3.2. Handling ............................................................................................................................................................. 32 
3.3. Operating procedures.......................................................................................................................................... 33 
3.4. Wind speed according to Beaufort scale .............................................................................................................. 34 
3.5. Pressure of the machine on ground and load-bearing capacity of ground.............................................................. 35 
3.6. High-tension lines................................................................................................................................................ 36 
4. Dangerous situations and/or accidents............................................................................................................ 36 
INSTALLATION AND PRELIMINARY CHECKS........................................................................................... 37 
1. Becoming acquainted with the machine........................................................................................................... 37 
2. Preliminary operation checks........................................................................................................................... 37 
USE INSTRUCTIONS......................................................................................................................................38 
1. Platform control panel ...................................................................................................................................... 38 
1.1. Drive and steering............................................................................................................................................... 40 
1.2. Platform positioning movements.......................................................................................................................... 41 
1.2.1. Pantograph (lower boom) lifting/lowering.............................................................................................................. 41 
1.2.2. Upper boom lifting/lowering ................................................................................................................................. 41 
1.2.3. Jib lifting/lowering................................................................................................................................................ 41 
1.2.4. Telescopic boom extension/retraction .................................................................................................................. 42 
1.2.5. Turret orientation (rotation).................................................................................................................................. 42 

 
Use and Maintenance Manual –A16 J A18 J Series 
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1.2.6. Platform rotation.................................................................................................................................................. 42 
1.2.7. Platform levelling................................................................................................................................................. 42 
1.3. Other functions of the platform control panel ........................................................................................................ 43 
1.3.1. Selection of electric/thermic propulsion (OPTIONAL)............................................................................................ 43 
1.3.2. Electrical pump start button 12V (Battery) or 230V/380V three-phase mains (power mains) - (OPTIONAL)............ 43 
1.3.3. Heat engine start button (“ED”, “D” models) ......................................................................................................... 43 
1.3.4. Manual horn........................................................................................................................................................ 43 
1.3.5. Emergency stop.................................................................................................................................................. 43 
1.3.6. Warning lights..................................................................................................................................................... 44 
1.3.6.1 Enabled control panel green warning light (ZA) .................................................................................................... 44 
1.3.6.2 Flat battery red warning light (ZB) –electric models only ...................................................................................... 44 
1.3.6.3 Diesel engine fault / low fuel red warning light (ZC) .............................................................................................. 44 
1.3.6.4 Danger red warning light (ZD).............................................................................................................................. 45 
1.3.6.5 Overload red warning light (ZE) ........................................................................................................................... 45 
1.4. “AIRO SENTINEL” Anti-Trapping System - OPTIONAL ........................................................................................ 46 
1.4.1. SENTINEL control logic....................................................................................................................................... 47 
2. Ground control panel (electric control unit)..................................................................................................... 48 
2.1. On-off key and control panel selector (A) ............................................................................................................. 49 
2.2. Emergency stop button (B).................................................................................................................................. 49 
2.3. Diesel/electric drive power selector (C) ................................................................................................................ 49 
2.4. Heat engine start button (D)................................................................................................................................. 49 
2.5. User interface display (E) .................................................................................................................................... 50 
2.6. Battery charger warning light (F).......................................................................................................................... 50 
2.7. Enabled control panel warning light (G)................................................................................................................ 50 
2.8. Diesel engine warning lights (H, L, M, N).............................................................................................................. 50 
2.9. Levers of movement of the platform (O, P, Q, R, S, T, U) ..................................................................................... 50 
3. Platform access................................................................................................................................................. 51 
4. Machine start-up ............................................................................................................................................... 51 
4.1. Diesel engine start-up ......................................................................................................................................... 52 
4.2. Starting the 230V single-phase electric pump (OPTIONAL) .................................................................................. 53 
4.3. Start-up of 380V three-phase work electrical pump (OPTIONAL).......................................................................... 54 
4.4. Start-up of 12V emergency electrical pump (OPTIONAL for models “D”)............................................................... 55 
5. Machine stop..................................................................................................................................................... 56 
5.1. Normal stop ........................................................................................................................................................ 56 
5.2. Emergency stop.................................................................................................................................................. 56 
5.3. Diesel engine stop............................................................................................................................................... 56 
5.4. Stopping the 380V three-phase or 230V single-phase electrical pump (optional)................................................... 56 
6. Emergency manual controls............................................................................................................................. 57 
7. Socket for electric tool connection (Optional).................................................................................................. 58 
8. Fuel level and re-fuelling (models “ED”, “D”)................................................................................................... 58 
9. End of work ....................................................................................................................................................... 58 
HANDLING AND CARRYING.........................................................................................................................59 
1. Handling............................................................................................................................................................ 59 
2. Transportation................................................................................................................................................... 60 
3. Emergency towing of the machine ................................................................................................................... 62 
MAINTENANCE ...............................................................................................................................................63 
1. Machine cleaning .............................................................................................................................................. 63 
2. General maintenance........................................................................................................................................ 64 
2.1. Various adjustments............................................................................................................................................ 65 
2.2. Greasing............................................................................................................................................................. 66 
2.3. Hydraulic circuit oil level check and change.......................................................................................................... 67 
2.3.1 Biodegradable hydraulic oil (Optional).................................................................................................................. 68 
2.3.2 Emptying ............................................................................................................................................................ 68 
2.3.3 Filters ................................................................................................................................................................. 68 
2.3.4 Washing ............................................................................................................................................................. 68 
2.3.5 Filling.................................................................................................................................................................. 68 
2.3.6 Commissioning / check........................................................................................................................................ 68 
2.3.7 Mix ..................................................................................................................................................................... 69 

 
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2.3.8 Micro-filtration ..................................................................................................................................................... 69 
2.3.9 Disposal.............................................................................................................................................................. 69 
2.3.10 Topping up.......................................................................................................................................................... 69 
2.4. Hydraulic filter replacement ................................................................................................................................. 70 
2.4.1. Suction filters ...................................................................................................................................................... 70 
2.4.2. Return filter......................................................................................................................................................... 70 
2.5. Drive reduction gear oil level check and change................................................................................................... 71 
2.5.1 Checks in the use of synthetic biodegradable oil in drive reduction gears.............................................................. 71 
2.6. Air purging from oscillating axle locking cylinders ................................................................................................. 72 
2.7. Telescopic boom sliding blocks clearance adjustment .......................................................................................... 73 
2.8. Drive circuit pressure relief valve adjustment and operation check........................................................................ 74 
2.9. Circuit movements pressure relief valve operation check...................................................................................... 75 
2.10. Operation check and adjustment of the braking valves ......................................................................................... 76 
2.11. Inclinometer operation check............................................................................................................................... 77 
2.12. Operation check and adjustment of platform overload controller ........................................................................... 79 
2.13. Overload controller by-pass –ONLY FOR EMERGENCY OPERATIONS ............................................................. 81 
2.14. Operation check of M1 microswitches.................................................................................................................. 82 
2.15. Dead-man pedal safety system operation check................................................................................................... 82 
3. Starter battery ................................................................................................................................................... 83 
3.1. Starter battery models “D” “ED” ........................................................................................................................... 83 
3.2. Starter type battery for models “E” ....................................................................................................................... 83 
3.3. Starter battery maintenance................................................................................................................................. 83 
3.4. Starter battery recharge....................................................................................................................................... 83 
4. “DRIVE” battery for models “E” and “ED” ....................................................................................................... 84 
4.1. General instructions for DRIVE battery................................................................................................................. 84 
4.2. DRIVE battery maintenance ................................................................................................................................ 84 
4.3. DRIVE battery recharge ...................................................................................................................................... 85 
4.4. Battery charger: fault report................................................................................................................................. 86 
4.5. Battery replacement ............................................................................................................................................ 86 
MARKS AND CERTIFICATIONS....................................................................................................................87 
PLATES AND STICKERS...............................................................................................................................88 
CHECK REGISTER .........................................................................................................................................90 
ELECTRIC DIAGRAMS.................................................................................................................................107 
HYDRAULIC DIAGRAM................................................................................................................................120 
CE CERTIFICATES .......................................................................................................................................124 
 
 

Use and Maintenance Manual –A16 J A18 J Series

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1. INTRODUCTION

This Use and Maintenance Manual provides general instructions concerning the complete range of machines indicated on the

cover. Therefore the description of their components, as well as control and safety systems, may include parts not present on

Your machine since supplied on request or not available. In order to keep pace with the technical development AIRO-Tigieffe

s.r.l. reserves the right to modify the product and/or the use and maintenance manual at any time without updating the units

already delivered.

1.1. Legal aspects

1.1.1. Delivery of the machine

Within EU (European Union) member countries the machine is delivered complete with:

▪Use and Maintenance manual in your language

▪CE mark applied on the machine

▪CE conformity declaration

▪Guarantee certificate

▪Declaration of internal testing

Only for Italy:

▪Instructions on commissioning declaration with INAIL and on the application for the first periodic check on the INAIL portal.

It is to be noted that the Use and Maintenance Manual is an integral part of the machine and a copy of this, together with copies

of the documents certifying that the periodical checks have been carried out, must be kept on board in its suitable container. In

the event of a transfer of ownership the machine must always be provided with its use and maintenance manual.

1.1.2. Declaration of commissioning, first check, further periodical checks and transfers of ownership

The legal obligations of the owner of the machine vary according to the country of commissioning. It is therefore recommended

to inquiry about the procedures in force in your country from the boards responsible for industrial safety. This manual contains a

final section called "Check register" for a better filing of documents and recording of any modifications.

1.1.2.1. Declaration of commissioning and first check

In ITALY the owner of the Aerial Platform must notify the use of the machine to the local competent INAIL and submit it to

periodical compulsory checks. The first of such checks is performed by the INAIL within sixty days from a request being made.

In the event of such time passing without the inspection being made, the employer can call in the ASL (Local Health Unit) or

qualified public or private services. Subsequent checks are made by the already-mentioned parties within thirty days from a

request being made. In the event of such time passing without these checks being made, the employer can call in qualified

public or private services. The checks are on a payment basis and the employer (machine owner) will be charged for them. For

these checks, the territorial inspection boards (ASL/USL or ARPA) and INAIL can be supported by qualified public or private

services. The qualified private institutes acquire the qualification of responsible for the public service and refer directly to the

public structure that controls this function.

For the commissioning declaration in Italy it is necessary to login to the INAIL portal. Follow the instructions delivered together

with other documents during the machine delivery, as well as the information about the portal.

The INAIL will assign a serial number and when the First Check is performed the “technical identification sheet” will be

completed indicating only the details obtained from the already-operating machine or from the instruction manual. Such

document shall form an integral part of the machine documentation.

Use and Maintenance Manual –A16 J A18 J Series

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1.1.2.2. Further periodical checks

Yearly checks are compulsory. In Italy the Aerial Platform owner must apply for a periodical check - by registered letter - to the

local competent inspection board (ASL/USL or other qualified public or private services) at least twenty days before the expiry

of the year from the last check.

NB: If a machine without a valid control document should be moved in an area outside the competence of the usual inspection

board, the owner of the machine must ask the inspection board, competent for the new territory where the machine is to be

used, for the annual check.

1.1.2.3. Transfers of ownership

In case of transfer of ownership (in Italy) the new owner of the Aerial Platform must notify the ownership of the machine to the

local competent inspection board (ASL/USL or ARPA or other qualified public or private services) by enclosing a copy of:

▪Declaration of conformity issued by the manufacturer.

▪Declaration of commissioning carried out by the first owner.

1.1.3. Operator training and information

The employer must ensure that the workers appointed to use the equipment are adequately and specifically trained so they are

able to use the Mobile Elevating Work Platform in a proper and safe way and also avoid the risks caused by other people.

1.2. Tests performed before delivery

Before being placed on the market, each MEWP undergoes the following tests:

▪Braking test

▪Overload test

▪Operating test

1.3. Intended use

The machine described in this use and maintenance manual is a self-propelled elevating work platform intended for lifting

persons and materials (equipment and work materials) in order to carry out maintenance, installation, cleaning, painting, de-

painting, sand-blasting, welding operations, etc.

The max. capacity allowed (which varies according to the model –see paragraph “Technical features”) is divided as follows:

▪80 Kg for each person on board.

▪40 Kg for equipment.

▪The remaining load is represented by the material being worked.

In any case NEVER exceed the maximum capacity allowed as indicated in paragraph "Technical features”. Persons, tools and

work materials can be loaded on the platform only from the access position (platform lowered). It is absolutely forbidden to load

persons, tools and work materials on the platform when it is not in access position.

All loads must be positioned inside the cage; do not lift loads (even if complying with the maximum capacity allowed) hanging

from the platform or from the lifting structure.

Do not carry large-sized panels since they increase the resistance to wind force thus causing the machine to overturn.

While the machine is being displaced with lifted platform, no horizontal loads can be loaded onto the platform (operators on

board are not allowed to pull wires or ropes, etc.).

An overload controller stops the operation of the machine if the load on the platform exceeds by 20% approx. the nominal load

(see chapter "General use rules”) and platform is lifted.

The machine cannot be used in areas where road vehicles operate. Always surround the working area by means of suitable

signs when the machine is used in public areas.

Do not use the machine to tow trucks or other vehicles.

All types of machine use other than those for which it was designed must be approved in writing by the machine manufacturer

following a specific request on the part of the user.

Use and Maintenance Manual –A16 J A18 J Series

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Do not use the machine for purposes other than those for which it was designed, except after making a

request and having obtained written permission in this sense from the manufacturer

1.3.1. Leaving at height

The mobile elevating work platforms are not designed by taking into account the risks of the “leaving at height” because the only

access position considered is when the platform is completely lowered. For this reason, this activity is formally forbidden.

However, there are exceptional conditions in which the operator needs to access or leave the work platform not in the access

position. This activity is normally defined as “leaving at height”.

The risks connected to the “leaving at height” do not depend exclusively on the PLE (work elevating platform) characteristics; a

specific risk analysis carried out by the employer can authorize this specific use by taking into account:

▪The working environment characteristics;

▪The absolute prohibition to consider the work platform as a fixing point for people working outdoors;

▪The use of the machine at xx% of its performances to avoid that additional forces created by a specific operation or

bending of the structure move away the access zone from the unloading zone. Provide for some tests in order to

define these limitations;

▪Provide for a specific evacuation procedure in case of emergency (for example: an operator always on the work

platform, one at the ground control panel while a third operator leaves the lifted platform);

▪Provide for a specific training of the staff both as operator and transported staff;

▪Equip the unloading zone with all the devices that are necessary to avoid the risk of fall of the staff that

accesses/leaves the platform.

What said above is not a formal authorization of the manufacturer for the “leaving at height”, but it wants to supply information to

the employer - who is fully responsible for that - which can be useful for the planning of this exceptional activity.

1.4. Description of the machine

The machine described in this use and maintenance manual is a mobile elevating work platform equipped with:

▪motorized chassis equipped with wheels;

▪hydraulically driven rotating turret;

▪Articulated boom operated by hydraulic cylinders (the number of articulations and cylinders varies according to

machine model).

▪operator platform (the max. capacity varies according to the model - see chapter "Technical features”).

The chassis is motorized to allow the machine to move even when the platform is lifted (see “Use instructions”). The machines

can be delivered with the following drive and steering features:

▪two driving wheels and two steering idle wheels;

▪Four driving wheels, of which two steering and two fixed.

Furthermore, to all the above combinations, it is possible to associate, optionally, a self-locking oscillating axle.

All wheels are equipped with hydraulic parking brakes, positive logic type (when drive controls are released brakes are

automatically activated).

The turret rests on a turntable fixed to the chassis and can be oriented (rotated) by 360° non-continuous around the central

axle of the machine by means of irreversible endless screw.

The lifting system, with articulated boom, can be divided into three main structures:

▪The first, with vertical extension, consists of a “double parallelogram” system named “pantograph”.

▪The second, consists of a lifting boom with telescopic extension.

▪The third, consists of the terminal boom named “Jib”.

Such lifting structures are driven by 4 double-acting hydraulic cylinders:

▪One cylinder for the “pantograph” extension.

▪One cylinder for the boom extension.

▪One cylinder for the extension/retraction of the telescopic boom.

▪One cylinder for the “jib” extension.

Use and Maintenance Manual –A16 J A18 J Series

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The hydraulic cylinders which move the articulated structure (except for the boom tilt sensor cylinder) are provided with over-

centre valves directly flanged on the same. These devices allow the booms to remain in position even if one of the supply tubes

accidentally breaks.

The platform, hinged to the end of the boom “jib”, can be rotated by 140° totally (70° on the right and 70° on the left) by means

of a rotary actuator fitted with over-centre valve. It is fitted with guardrails and toe boards of prescribed height (the guardrails

height 1100 mm; the toe boards height 150 mm). The platform levelling is automatic and is ensured by mechanical ties and

two cylinders in closed circuit. The manual level compensation is possible by acting on the relevant control only with completely

lowered booms (and with “Jib” inclination ranging between +10° and –70° with respect to the horizontal axis).

1.5. Control panels

The machine is equipped with two control panels:

▪on the platform for normal use of the machine.

▪On the turret (or on the ground) you can find the emergency controls to lower or stop the machine in emergency

situations, a key-selector to select the control panel and to start the machine.

1.6. Power supply

The machines can be powered by:

▪An electric-hydraulic system composed of rechargeable accumulators and electric pump.

▪A heat engine (Diesel engine models are identified by the abbreviation “D”; petrol engine models are identified by the

abbreviation “B”).

▪a dual-powered electric/thermic system (dual-powered Electric/Diesel models are identified by the abbreviation “ED”;

dual-powered Electric/Petrol models are identified by the abbreviation “EB”).

In any case both the hydraulic and the electric systems are equipped with all necessary protections (see wiring and hydraulic

circuit diagrams attached to this manual).

1.7. Machine life, demolition and decommissioning

The machine has been designed to last for 10 years in normal operating environments, if properly used and serviced. Within

this period, the manufacturer must carry out a complete inspection/overhaul.

If disposal of the unit is necessary, comply with current local regulations.

In Italy, the demolition/decommissioning must be notified to the local ASL / USL or ARPA.

The machine consists mainly of metal parts which are easy to be identified (steel for the most parts, and aluminium for the

hydraulic blocks); thus, we can state that the machine can be recycled at 90%.

European standards and those transposed by the member countries relating to respect for the

environment and the disposal of wastes envisage heavy administrative and penal fines in case of

infringement.

In case of demolition/decommissioning, carefully keep to the provisions of applicable regulations,

especially as regards materials such as hydraulic oil and batteries.

Use and Maintenance Manual –A16 J A18 J Series

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1.8. Identification

In order to identify the machine, when spare parts and service are required, always mention the information given in the serial

number plate. Should this plate (as well as the various stickers applied on the machine) be lost or illegible, it is to be replaced

as soon as possible. In order to identify the machine when no plate is available the serial number is also stamped on the

chassis. To locate the plate and the stamp of the serial number, see the following picture. It is recommended to copy such data

in the following boxes.

MODEL: ____________________

CHASSIS: ______________________

YEAR: __________________

Fig.1

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