Airo A Series User manual

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
A12 JE A15 JE A12 JED A15 JED A17 JE
USE AND MAINTENANCE MANUAL
- ENGLISH - ORIGINAL INSTRUCTIONS
AIRO is a division of TIGIEFFE SRL
Via Villa Superiore, 82 - 42045 Luzzara (RE) ITALY-
[phone] -[phone]
WEB: www.airo.com
053.20.UEM-EN
2020 - 01

Use and Maintenance Manual –A12 JE A15 JE A17 JE A12 JED A15 JED Series
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Revision date
Description of revision
01-2011
•Manual issue.
05-2011
•Corrected “Total quantity of battery electrolyte” in Technical Data.
•Inserted motor generator: data "Max power." and "Adjusted Power" diesel engine,
generator current data.
04-2013
•Edit to insert second battery charge indicator.
10-2013
•Specified instructions for harness anchoring points
01-2014
•Deleted timer circuit, second battery charger
07-2014
•Updated technical data of batteries and battery charger.
•Inserted information on maximum limits of manual forces.
•CE conformity declaration updated.
00-2015
•CE conformity declaration updated.
•Added position of hands instruction
10-2015
•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”.
05-2018
•Data sheets were added with units of measurement of the international system and US unit
of measurement.
•Changed Name and Surname of CEO.
•Unified First and Second Part.
12-2018
•Added “AIRO SENTINEL” secondary safety system description;
•“Tilt alarm” description updated;
•“ZC” warning light description (drive controller alarm) updated;
•Edit to insert a “Battery indicator” and “Battery compartment access”;
•EC Declaration of Conformity updated in 8 languages;
•Updated “Electric diagram”.
05-2019
•New model A17 JE added.
•Updated procedure description of commissioning declaration in Italy.
01-2020
•Updated normative references and certifying body
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.

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Contents:
1. INTRODUCTION..........................................................................................................................................6
1.1. Legal aspects............................................................................................................................................................. 6
1.1.1. Delivery of the machine ............................................................................................................................................... 6
1.1.2. Declaration of commissioning, first check, further periodical checks and transfers of ownership................................ 6
1.1.2.1. Declaration of commissioning and first check.............................................................................................................. 6
1.1.2.2. Further periodical checks............................................................................................................................................. 7
1.1.2.3. Transfers of ownership ................................................................................................................................................ 7
1.1.3. Operator training and information ................................................................................................................................ 7
1.2. Tests performed before delivery .............................................................................................................................. 7
1.3. Intended use............................................................................................................................................................... 7
1.3.1. Leaving at height.......................................................................................................................................................... 8
1.4. Description of the machine....................................................................................................................................... 8
1.5. Control panels............................................................................................................................................................ 9
1.6. Drive power ................................................................................................................................................................ 9
1.7. Machine life, demolition and decommissioning. .................................................................................................... 9
1.8. Identification............................................................................................................................................................. 10
1.9. Location of main components................................................................................................................................ 11
2. TECHNICAL FEATURES OF STANDARD MACHINES............................................................................12
2.1. Model A12 JE............................................................................................................................................................ 12
2.2. Model A15 JE............................................................................................................................................................ 15
2.3. Model A17 JE............................................................................................................................................................ 18
2.4. Model A12 JED......................................................................................................................................................... 21
2.5.Model A15 JED......................................................................................................................................................... 24
2.6. Vibrations and noise................................................................................................................................................ 27
3. SAFETY PRECAUTIONS ..........................................................................................................................28
3.1. Personal protective equipment (PPE).................................................................................................................... 28
3.2. General safety norms.............................................................................................................................................. 28
3.3. Use instructions....................................................................................................................................................... 29
3.3.1. General...................................................................................................................................................................... 29
3.3.2. Handling..................................................................................................................................................................... 29
3.3.3. Operating procedures ................................................................................................................................................ 30
3.3.4. Wind speed according to Beaufort scale.................................................................................................................... 31
3.3.5. Pressure of the machine on ground and load-bearing capacity of ground................................................................. 32
3.3.6. High-voltage power lines............................................................................................................................................ 33
3.4. Dangerous situations and/or accidents................................................................................................................. 33
4. INSTALLATION AND PRELIMINARY CHECKS.......................................................................................34
4.1. Becoming acquainted with the machine................................................................................................................ 34
4.2. Preliminary operation checks................................................................................................................................. 34
5. USE INSTRUCTIONS ................................................................................................................................35
5.1. Platform control panel............................................................................................................................................. 35
5.1.1. Drive and steering...................................................................................................................................................... 37
5.1.2. Platform positioning movements................................................................................................................................ 38
5.1.2.1. Pantograph (lower boom) lifting/lowering................................................................................................................... 38
5.1.2.2. Upper boom lifting/lowering ....................................................................................................................................... 38
5.1.2.3. Jib lifting/lowering....................................................................................................................................................... 38
5.1.2.4. Telescopic boom extension/retraction ....................................................................................................................... 38
5.1.2.5. QUICK UP/QUICK DOWN (optional)........................................................................................................................ 39
5.1.2.6. Turret orientation (rotation) ........................................................................................................................................ 39
5.1.2.7. Jib rotation (optional) ................................................................................................................................................. 39
5.1.2.8. Platform rotation......................................................................................................................................................... 39
5.1.2.9. Platform levelling........................................................................................................................................................ 39
5.1.3. Other functions of the platform control panel ............................................................................................................. 40

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5.1.3.1. Manual horn............................................................................................................................................................... 40
5.1.3.2. Emergency stop button............................................................................................................................................. 40
5.1.3.3. Motor generator operation mode selector.................................................................................................................. 40
5.1.3.4. Warning lights............................................................................................................................................................ 40
5.1.3.4.1. Enabled control panel green warning light (ZA)......................................................................................................... 40
5.1.3.4.2. Red warning light: flat battery (ZB) ............................................................................................................................ 40
5.1.3.4.3. Drive controller fault warning light / Diesel motor generator fault / low fuel red warning light - OPTIONAL (ZC)....... 41
5.1.3.4.4. Danger red warning light (ZD).................................................................................................................................... 41
5.1.3.4.5. Overload red warning light (ZE)................................................................................................................................. 41
5.1.4. “AIRO SENTINEL” Anti-Trapping System - OPTIONAL ............................................................................................ 42
5.1.4.1. SENTINEL logic movements ..................................................................................................................................... 43
5.2. Ground control panel and electric control unit..................................................................................................... 44
5.2.1. On-off key and control panel selector (A)................................................................................................................... 45
5.2.2. Emergency stop button (B) ........................................................................................................................................ 45
5.2.3. Diesel motor generator start button (C) (models A12 JED - A15 JED) ...................................................................... 45
5.2.4. User interface display (D) .......................................................................................................................................... 45
5.2.5. Powered-on machine warning light (E)...................................................................................................................... 46
5.2.6. Battery recharge indicator (F) .................................................................................................................................... 46
5.2.7. Diesel motor generator warning lights (G H L M) - OPTIONAL.................................................................................. 46
5.2.8. Levers of movement of the platform (N O P Q R S T U)............................................................................................ 46
5.3. Platform access ....................................................................................................................................................... 47
5.4. Machine start-up...................................................................................................................................................... 47
5.4.1. Diesel motor generator start-up ................................................................................................................................. 48
5.5. Machine stop............................................................................................................................................................ 48
5.5.1. Normal stop................................................................................................................................................................ 48
5.5.2. Emergency stop button.............................................................................................................................................. 48
5.5.3. Diesel motor generator stop....................................................................................................................................... 49
5.6. Emergency manual controls................................................................................................................................... 49
5.7. Socket for electric tool connection (Optional) ...................................................................................................... 50
5.8. Level and refuelling (models A12 JED - A15 JED)................................................................................................ 51
5.9.End of work .............................................................................................................................................................. 51
6. HANDLING AND CARRYING....................................................................................................................52
6.1. Handling ................................................................................................................................................................... 52
6.2. Carrying.................................................................................................................................................................... 53
6.3. Emergency towing of the machine......................................................................................................................... 54
7. MAINTENANCE.........................................................................................................................................55
7.1. Machine cleaning..................................................................................................................................................... 55
7.2. General maintenance............................................................................................................................................... 56
7.2.1. Various adjustments .................................................................................................................................................. 57
7.2.2. Greasing .................................................................................................................................................................... 58
7.2.3. Hydraulic circuit oil level check and change............................................................................................................... 59
7.2.3.1 Biodegradable hydraulic oil (Optional)....................................................................................................................... 60
7.2.3.2 Emptying.................................................................................................................................................................... 60
7.2.3.3 Filters......................................................................................................................................................................... 60
7.2.3.4 Washing..................................................................................................................................................................... 60
7.2.3.5 Filling ......................................................................................................................................................................... 60
7.2.3.6 Commissioning / check.............................................................................................................................................. 60
7.2.3.7 Mix ............................................................................................................................................................................. 61
7.2.3.8 Micro-filtration ............................................................................................................................................................ 61
7.2.3.9 Disposal..................................................................................................................................................................... 61
7.2.3.10 Topping up................................................................................................................................................................. 61
7.2.4. Hydraulic filter replacement ....................................................................................................................................... 62
7.2.4.1. Suction filter............................................................................................................................................................... 62
7.2.4.2 Return filter ................................................................................................................................................................ 62
7.2.5. Drive reduction gear oil level check and change........................................................................................................ 63
7.2.5.1 Checks in the use of synthetic biodegradable oil in drive reduction gears (Optional)................................................ 63
7.2.6. Telescopic boom sliding blocks clearance adjustment .............................................................................................. 64
7.2.7. Circuit movements pressure relief valve operation check.......................................................................................... 65

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7.2.7.1. Pressure relief valve of proportional movement circuit .............................................................................................. 65
7.2.7.2. Pressure relief valve of ON-OFF movement circuit.................................................................................................... 66
7.2.8. Operation check of the turret inclinometer................................................................................................................. 67
7.2.9. Adjustment of the overload controller (load cell)........................................................................................................ 69
7.2.10. Overload controller by-pass –ONLY FOR EMERGENCY OPERATIONS ................................................................ 70
7.2.11. Operation check of M1 microswitches ....................................................................................................................... 71
7.2.12. Operation check of microswitches MPT1-MPT2 for A12 JE - A12 JED - A15 JE - A15 JED..................................... 72
7.2.13. Operation check of MPT1-MPT2 microswitches and PS1A-PS1B proximity sensors for A17 JE.............................. 73
7.2.14. Operation check of dead-man pedal safety system................................................................................................... 75
7.3. Battery ...................................................................................................................................................................... 75
7.3.1. General instructions for battery.................................................................................................................................. 75
7.3.2. Battery maintenance.................................................................................................................................................. 76
7.3.2.1. Accessing the battery compartment........................................................................................................................... 76
7.3.2.2. Closing the battery compartment............................................................................................................................... 77
7.3.2.3. Battery maintenance.................................................................................................................................................. 77
7.3.3. Battery recharge ........................................................................................................................................................ 77
7.3.4. Battery charger: fault report ....................................................................................................................................... 79
7.3.5. Battery replacement................................................................................................................................................... 79
8. MARKS AND CERTIFICATIONS...............................................................................................................80
9. PLATES AND STICKERS..........................................................................................................................81
10. CHECK REGISTER ...................................................................................................................................83
11. WIRING DIAGRAM..................................................................................................................................101
12. HYDRAULIC DIAGRAM ..........................................................................................................................110
13. DECLARATION OF CONFORMITY.........................................................................................................112

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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.

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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 Aerial Platform new owner 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 aerial 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.

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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 work elevating 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 an anchoring 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 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 self-propelled 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 motorised to allow the machine to move even with lifted platform (see "Use instructions”) and has two rear driving
wheels and two front idle steering wheels. The rear wheels are equipped with parking brakes, positive logic type (when drive
controls are released brakes are automatically activated). On the chassis there are two pot-hole guards automatically activated by
the platform control panel (depending on the rotating turret position) when the platform is raised.
The turret rests on a turntable fixed to the chassis and can be oriented (rotated) by 370° 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 a terminal boom called "Jib" (the Jib is fixed as a standard, as an option it is rotating of about 130°
totally).
The hydraulic cylinders which move the articulated structure are provided with over-center 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 “jib”, can be rotated by 180° totally (90° on the right and 90° on the left) by means of a
rotary actuator fitted with over-centre valve. It is fitted with rails and toe boards of prescribed height (the rails height 1100 mm; the
toe boards height 150 mm; in the access area the toe board height is 100 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).

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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. Drive power
The machines can be powered by:
▪Electro-hydraulic system composed of rechargeable batteries, electric pump and electric drive motors equipped with
automatic parking brake.
▪Hybrid system composed of rechargeable batteries, electric pump and electric drive motors equipped with automatic
parking brake and additional Diesel motor generator. Hybrid machines are identified by the initials "ED".
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.

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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