Airo A16 J 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
SERIES „A“
A16 J A18 J
USER'S MANUAL
ENGLISH TRANSLATION OF THE ORIGINAL USER MANUAL IN ITALIAN
AIRO is a division of TIGIEFFE SRL
Via Villasuperiore, 82 - 42045 Luzzara (RE) ITALY -
[phone] -[phone]
WEB: www.airo.com
040.20.UEM-EN
2017-01

User’s Manual – A16 J A18 J Series
Page 2
Review date
Modifications Log
2010-01
Update to the new Machine Directive 2006/42/EC.
Model name updated.
2010-11
Instructions for use of bio oil added.
Oil temperature and oil list updated.
05-2011
Information on “Commissioning and first inspection, subsequent inspections and
property transfer” amended.
Additions to the Technical Data: “Total quantity of battery electrolyte” (optional
batteries for ED added)
"Max. power" diesel engine changed and "Regulated Power" added.
2011-08
Further to replacement of the 48V-12V converter on JE-JED installations, some
wiring diagrams have been upgraded and added to the second part of the manual.
2012-09
Parking brakes removed for electric and diesel/electric versions: the descriptions
and hydraulic diagrams have been changed.
2013-10
Instruction details have been added relative to the harness anchoring points.
2014-09
Information added on the maximum manual forces.
CEO name changed.
2015-01
CE Statement of Compliance updated.
Additional instructions on hands position added.
2015-10
List of recommended hydraulic oils updated.
A paragraph was added stating strictly original spare parts should be used or
alternatively the approval of the manufacturer should priory obtained.
The whole paragraph “Deboarding with the basket off the ground” is new.
The instructions for use of the battery charger and the description of overload
alarms have been updated.
2017-01
Description of the new load control system added.

User’s Manual – A16 J A18 J Series
Page 3
Tigieffe thanks you for purchasing a product of its range and reminds you to read this manual and familiarize with its
contents before using the machine. The information in this manual is crucial for the correct use of your aerial work
platform and you should be familiar and comply with these instructions for your own safety. Please store this manual in a
safe place, but at quick-reach in case of need. The contents of this manual may be modified as a result of any change or
improvement done by the manufacturer. This will involve no prior notice and no other obligations of the manufacturer to
make any upgrade, change, or improvement of the units already in the market.
Contents:
1. INTRODUCTION...........................................................................................................................6
1.1. Legal mentions.......................................................................................................................................... 6
1.1.1. Delivery of the machine............................................................................................................................... 6
1.1.2. Statements of successful commissioning, first installation test, periodical functional tests and property
transfers..................................................................................................................................................... 6
1.1.2.1. Statements of successful commissioning carried out by the first owner...................................................... 6
1.1.2.2. Periodical Functional Tests. ........................................................................................................................ 7
1.1.2.3. Transfers of ownership................................................................................................................................ 7
1.1.3. Operators training and information.............................................................................................................. 7
1.2. Tests of the manufacturer performed before the delivery..................................................................... 7
1.3. Application field ........................................................................................................................................ 7
1.3.1. Deboarding the platform off the ground....................................................................................................... 8
1.4. Description of the machine ...................................................................................................................... 8
1.5. Operator's stations.................................................................................................................................... 9
1.6. Power supply............................................................................................................................................. 9
1.7. Machine life, demolition and decommissioning..................................................................................... 9
1.8. Identification............................................................................................................................................ 10
1.9. Location of the main components......................................................................................................... 11
2. TECHNICAL FEATURES OF THE STANDARD MACHINE.......................................................12
2.1. Model A16 JE........................................................................................................................................... 12
2.2. Model A16 JED ........................................................................................................................................ 15
2.3. Model A16 JRTD...................................................................................................................................... 18
2.4. Model A18 JE........................................................................................................................................... 21
2.5. Model A18 JED ........................................................................................................................................ 24
2.6. Model A18 JRTD...................................................................................................................................... 27
2.7. Vibrations and noise............................................................................................................................... 30
3. SAFETY SIGNS..........................................................................................................................31
3.1. Personal protection devices (PPE)........................................................................................................ 31
3.2. General safety.......................................................................................................................................... 31
3.3. General..................................................................................................................................................... 32
3.3.1. Use and Operating instructions................................................................................................................. 32
3.3.2. Handling.................................................................................................................................................... 32
3.3.3. Operating procedure ................................................................................................................................. 33
3.3.4. Wind speed according to the Beaufort scale............................................................................................. 34
3.3.5. Ground pressure and load-bearing capacity. ............................................................................................ 35
3.3.6. High-voltage lines...................................................................................................................................... 36
3.4. Hazardous situations and/or accidents................................................................................................. 36
4. INSTALLATION AND PRELIMINARY CHECKS........................................................................37
4.1. Familiarizing with the machine .............................................................................................................. 37
4.2. Preliminary controls................................................................................................................................ 37
5. OPERATING INSTRUCTIONS ...................................................................................................38
5.1. Control panel on the basket................................................................................................................... 38
5.1.1. Travelling and steering.............................................................................................................................. 40
5.1.2. Basket positioning/ operation. ................................................................................................................... 41
5.1.2.1. Lifting/lowering of the first crank arm (pantograph) ................................................................................... 41
5.1.2.2. Second arm UP/DOWN............................................................................................................................. 41
5.1.2.3. Jib lifting/lowering...................................................................................................................................... 41
5.1.2.4. Extension/retraction of the telescopic boom.............................................................................................. 42
5.1.2.5. Turret slewing (rotation) ............................................................................................................................ 42

User’s Manual – A16 J A18 J Series
Page 4
5.1.2.6. Basket rotation .......................................................................................................................................... 42
5.1.2.7. Basket levelling ......................................................................................................................................... 42
5.1.3. Other functions of the control panel on the basket.................................................................................... 43
5.1.3.1. Selection of the (OPTIONAL) electric or gasoline/diesel power ................................................................ 43
5.1.3.2. OPTIONAL electric pump starter 12V (Battery) or 230V/ 380V (in-house power)..................................... 43
5.1.3.3. Engine Starter Button (models “D” and “ED”)............................................................................................ 43
5.1.3.4. Manual horn .............................................................................................................................................. 43
5.1.3.5. Emergency stop button ............................................................................................................................. 43
5.1.3.6. Warning lights............................................................................................................................................ 44
5.1.3.6.1 Green pilot lamp (ZA), operator's station enabled..................................................................................... 44
5.1.3.6.2 Red pilot lamp (ZB): warns when the battery is out of charge. (only available on electrical models) ........ 44
5.1.3.6.3 Red pilot light (ZC): diesel engine fault or low fuel .................................................................................... 44
5.1.3.6.4 Danger warning - red pilot light (ZD) ......................................................................................................... 45
5.1.3.6.5 Red pilot: Overload (ZE)............................................................................................................................ 45
5.2. On-Ground control panel and electric control unit.............................................................................. 46
5.2.1. On-off key and control panel selector (A).................................................................................................. 47
5.2.2. Emergency stop button (B)........................................................................................................................ 47
5.2.3. Diesel/electric power selector (C).............................................................................................................. 47
5.2.4. Engine starter switch (D)........................................................................................................................... 47
5.2.5. User interface display (E).......................................................................................................................... 48
5.2.6. Battery charger warning light (F)............................................................................................................... 48
5.2.7. Enabled control panel warning light (G) .................................................................................................... 48
5.2.8. Engine pilot lights (H-L-M-N)..................................................................................................................... 48
5.2.9. Basket control levers (O P Q R S T U)...................................................................................................... 48
5.3. Boarding the platform............................................................................................................................. 49
5.4. Machine start........................................................................................................................................... 49
5.4.1. Starting of the diesel engine...................................................................................................................... 50
5.4.2. Starting the 230V single-phase electric pump (OPTIONAL)...................................................................... 51
5.4.3. Starting the 3-phase electric pump (OPTIONAL). ..................................................................................... 52
5.4.4. Starting of the12V emergency pump (OPTIONAL for D-models).............................................................. 53
5.5. Stopping the machine............................................................................................................................. 54
5.5.1. Normal stop............................................................................................................................................... 54
5.5.2. Emergency stop button ............................................................................................................................. 54
5.5.3. Stopping the diesel engine........................................................................................................................ 54
5.5.4. Optional stopper of the 380V or 230V electrical pump.............................................................................. 54
5.6. Emergency manual controls .................................................................................................................. 55
5.7. Optional socket for electric attachments (OPTIONAL)........................................................................ 56
5.8. Fuel level and re-fuelling (models “ED”, “D”)....................................................................................... 56
5.9. End of a work day.................................................................................................................................... 56
6. HANDLING AND TRANSPORTATION ......................................................................................57
6.1. Handling................................................................................................................................................... 57
6.2. Transportation......................................................................................................................................... 58
6.3. Emergency tow-away.............................................................................................................................. 60
7. MAINTENANCE..........................................................................................................................61
7.1. Cleaning................................................................................................................................................... 61
7.2. General maintenance.............................................................................................................................. 62
7.2.1. Adjustments............................................................................................................................................... 63
7.2.2. Greasing.................................................................................................................................................... 64
7.2.3. Checking and changing the hydraulic oil................................................................................................... 65
7.2.3.1 Hydraulic bio-oil (optional)......................................................................................................................... 66
7.2.3.2 Draining..................................................................................................................................................... 66
7.2.3.3 Filters ........................................................................................................................................................ 66
7.2.3.4 Washing .................................................................................................................................................... 66
7.2.3.5 Filling......................................................................................................................................................... 66
7.2.3.6 Start-up test............................................................................................................................................... 66
7.2.3.7 Mixing........................................................................................................................................................ 67
7.2.3.8 Micro-filtration............................................................................................................................................ 67
7.2.3.9 Disposal..................................................................................................................................................... 67
7.2.3.10 Topping up ................................................................................................................................................ 67

User’s Manual – A16 J A18 J Series
Page 5
7.2.4. Hydraulic filter replacement....................................................................................................................... 68
7.2.4.1. Suction filters............................................................................................................................................. 68
7.2.4.2. Return filter................................................................................................................................................ 68
7.2.5. Check the oil level in the main reduction gear (for travel) and change it, if needed. ................................. 69
7.2.5.1 Periodical check-ups of synthetic biooil in the main (travel) reduction gears ............................................ 69
7.2.6. Air purging from the locking cylinder of the floating axles. ........................................................................ 70
7.2.7. Adjustment of the clearance of the sliding pads under the telescopic boom............................................. 71
7.2.8. Efficiency check, and adjustment of the pressure relief valve (in the main travel system)........................ 72
7.2.9. Efficiency check of the pressure relief valve in the operating line. ............................................................ 73
7.2.10. Checking the efficiency and calibration of the brake valves...................................................................... 74
7.2.11. Checking the efficiency of the inclinometer............................................................................................... 75
7.2.12. Operation check and adjustment of the load controller on the platform. ................................................... 77
7.2.13. Overload controller by-pass –ONLY FOR EMERGENCY OPERATIONS................................................ 79
7.2.14. Functional control of the microswitches M1............................................................................................... 80
7.2.15. Dead-man safety system, functional check............................................................................................... 80
7.3. Starter battery.......................................................................................................................................... 81
7.3.1. Starter battery models “D”“ED”................................................................................................................. 81
7.3.2. Starter type battery for models “E”............................................................................................................ 81
7.3.3. Starter battery maintenance...................................................................................................................... 81
7.3.4. Starter battery recharge ............................................................................................................................ 81
7.4. Battery-operated “TRAVEL” system for models “E” and “ED”.......................................................... 82
7.4.1. General instructions for the MAIN TRAVEL BATTERY............................................................................. 82
7.4.2. Maintenance of the battery-operated travel system .................................................................................. 82
7.4.3. TRAVEL battery recharge. ........................................................................................................................ 83
7.4.4. Battery charger trouble-shooting............................................................................................................... 84
7.4.5. Battery replacement .................................................................................................................................. 84
8. MARKS AND CERTIFICATIONS................................................................................................85
9. PLATES AND LABELS ..............................................................................................................86
10. TEST RECORDS ........................................................................................................................88
11. WIRING DIAGRAMS.................................................................................................................105
12. HYDRAULIC DIAGRAM ...........................................................................................................118
13. CERTIFCATE CEE .................................................................................................................125

User’s Manual – A16 J A18 J Series
Page 6
1. INTRODUCTION
This is a general manual applicable to all models stated on the cover page. Therefore, the description of the machine
and its components, as well as control and safety systems, may include parts that are not actually available on your
machine depending on model and date of purchase. In order to keep pace with the technical development, AIRO-
Tigieffe s.r.l. reserves itself the right to modify the product and/or the user's manuals as needed and without any
obligation to prior updates of already existing manuals.
1.1. Legal mentions
1.1.1. Delivery of the machine
Deliveries to any member country of the EC (European Union) are always accompanied by the following documents:
User's Manual in the native language of the country of use.
CE-plate attached to the machine
EC Statement of Compliance
Warranty certificate
Only for Italy:
Declaration of commissioning to INAIL
List of the competent local INAIL departments
Statement of in-house testing
Please note: this manual is an integral part of the machine. The original manual or copy thereof must be available on
board of the machine along with the original reports (or copies thereof) of all periodical tests conducted by the user.
Should you sell, lease or elsehow transfer the ownership the machine, make sure that a copy of the manual is handed
over with the machine.
1.1.2. Statements of successful commissioning, first installation test, periodical functional tests and
property transfers.
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 "Test Records" for a better filing of documents and recording of any
modifications.
1.1.2.1. Statements of successful commissioning carried out by the first owner.
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 tests. 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 tests are carried out by the already-mentioned parties
within thirty days from a request being made. In the event of such time passing without these tests being made, the
employer can call in qualified public or private services. The employer (machine owner) is to bear all costs of the afore
mentioned check-ups and tests. The local inspection Authorities (ASL/USL, ARPA and INAIL) may appoint any other
qualified public or private service to carry out the test. In this case, the appointed private Authorities will act on behalf of
Inail (State Authority) by the same powers and qualification of the latter.
Italian Customers using the machine in Italy: please notify successful commissioning of the machine to the competent
INAIL department using the special form found with the other delivery documents and send it by registered letter with bill
of receipt.
INAIL will assign the machine a serial number and fill out a “Technical Data Sheet” on the day of
the first installation test. The Data Sheet will exclusively contain the main details of the equipment
as-is that will be checked off against the information contained in the instruction manual. The
“Technical Data Sheet” will form an integral part of the machine.

User’s Manual – A16 J A18 J Series
Page 7
1.1.2.2. Periodical Functional Tests.
Yearly overhauls are compulsory. In Italy, the owners of an Aerial Platform must apply for a periodical check by sending
a 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.
PLEASE NOTE: 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 other qualified public or private services) by enclosing a copy of:
Statement of compliance issued by the manufacturer.
Statements of successful commissioning carried out by the first owner.
1.1.3. Operators 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 of the manufacturer performed before the delivery.
Before being placed on the market, each MEWP undergoes the following tests:
Braking test
Overload test
Functional test
1.3. Application field
The machine described in this user’s 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. (load) capacity varies according to the model (see paragraph “Technical
features”) and would be normally assigned as follows:
80 Kg for each person on board
40 Kg for tools and equipment
The remaining load is represented by the materials to be handled.
NEVER exceed the maximum capacity as indicated in paragraph "Technical features”. Persons, tools and work materials
can be loaded on the platform only from the initial boarding position (platform all-down). It is absolutely forbidden to load
persons, tools and work materials on the platform when it is not in the boarding position.
Any load must be put inside the cage. Do not lift any load (even if within the maximum capacity) hanging off the platform
or lifting structure.
Do not carry large-sized panels since they increase the resistance to wind force thus causing the machine to tilt over.
Do not load anything on the platform while the platform is UP and the machine travels (operators on board are not
allowed to pull wires or ropes, etc...)
An overload controller stops the machine if the load on the platform exceeds the nominal load by approx. 20% (see
chapter "General Use and Operation”) and platform is lifted.
The machine cannot be used in areas where road vehicles operate. Make sure to alert the presence of the platform by
means of suitable signs when the machine is used in public areas.
Do not use the machine to tow trucks or other vehicles.

User’s Manual – A16 J A18 J Series
Page 8
Any other use different than those for which it was designed must be approved in writing by the manufacturer following a
specific request on the part of the user.
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. Deboarding the platform off the ground
The risk of deboarding the Aerial Work Platform when the platform is off the ground has not been accounted in our
design safety because the only possible deboarding configuration is the one with the platform completely lowered on
ground. For this reason, boarding or leaving a raised platform is absolutely prohibited.
However, operators do happen to incur certain situations where they need to leave or access the platform in different
positions than the initial boarding one. These situations are commonly referred to as “Boarding the platform off the
ground”.
The risks relative to “boarding a platform off the ground” depend on the configuration of the platform, but also from the
risk assessment analysis carried out by the employer before authorizing any such condition. However, the following
circumstances should always be taken in due account:
Site/area characteristics;
Use of the machine as an anchoring point for other operators and other applications, which should be prevented
and never be possible for no reasons;
Use of the machine at xx% of the its performance to prevent additional stress resulting from specific operations,
or flexural bending of the chassis which may force the platform away from the boarding area. In this case, it is
recommendable to perform a few trials and define these limit conditions;
Implementation of a special emergency evacuation procedure (for instance having a man on the platform;
another one at the control station on ground, while a third one leaves a raised platform);
Administration of extensive training of the persons involved (both operators and passengers);
Installation of all implements needed at the point of boarding/deboarding to prevent falling of the persons
leaving the platform.
This paragraph should not be interpreted as a formal approval by the manufacturer to deboard the platform off-the-
ground, which remains a strictly prohibited action. The Employer is the ultimate person responsible for making any such
decision and this paragraph is merely meant to supply additional information and help.
1.4. Description of the machine
The machine described in this user's manual is a Mobile Elevating Work Platform equipped with:
A motorized wheeled chassis;
A rotating, hydraulic turret;
A lifting system operated by means of hydraulic cylinders and joints whose number will change based on
machine type;
An operator platform (the max. capacity of which varies based on machine type - see chapter "Technical
features”).
The chassis is motorised to allow the machine to move (see "General use instructions"). All machines are available with
any of the following drive options:
Two driving wheels and two idle steering wheels; or
Four driving wheels, out of which two are steering and two are fixed.
Moreover, all the above variants can be equipped with an optional full floating axle with locking differential.
All driving wheels are equipped with hydraulic parking brakes, positive logic type (when drive controls are released
brakes are automatically activated).
The turret is assembled on a turntable mounted to the chassis and can be stepwise rotated by 360° around the central
axle of the machine by means of irreversible endless screw.
The lifting system, with articulated boom, is composed of three main assemblies:
The first is a vertical assembly made of two “parallel four-bar linkages” called “crank arm” or “pantograph”.
The second is an articulated boom lift with telescopic extension.
The third is the jib which is the tip of the boom that extends out or telescopes.

User’s Manual – A16 J A18 J Series
Page 9
The above three lifting assemblies are operated by 4 hydraulic double-acting cylinders as follows:
One for “arm” operation;
One for “boom” operation;
One for sliding the telescopic boom in and out;
One for “jib” operations.
The hydraulic cylinders controlling all the crank arm operations (except boom incline sensor) are provided with face-
mounted over-centre valves. This special design allows the keeping of the booms in the same position even in the
unlikely case of a hydraulic line failure.
The platform is hinged to the end of the “jib” and can be swivelled 140° (70° to the right and 70° to the left) by means of
a rotary actuator fitted with over centre valve. The platform has also got guard rails and toe boards of a predefined height
(1100 mm /433 in for the guard rails and 150 mm /59 in for the toe boards). The levelling of the platform is automatic
and is ensured by mechanical ties and two cylinders in closed circuit. A manual adjustment is strictly possible by means
of a special control on condition that the boom is fully DOWN (closed) and the “Jib” inclination against the plane ranges
between +10° and –70°.
1.5. Operator's stations
The machine is equipped with two operator's stations, respectively located:
on the platform for normal operations; and
and on the tower (or on ground). The latter contains the emergency controls (to lower or stop the machine in
case of emergencies), a key-selector to select the active control panel and to start the machine.
1.6. Power supply
The machines can be powered by:
an electric-hydraulic system composed of rechargeable batteries and electrical pump;
an engine (diesel engine models are identified by the abbreviation “D”; gasoline engine models are identified by
the abbreviation “B”);
a combination-power system (Electric/Diesel models are identified by the abbreviation “ED”; Combi models with
electric/gasoline power are identified by the abbreviation “EB”).
Both hydraulic and electric systems are equipped with all the necessary protections and safeties (see wiring and
hydraulic circuit diagrams).
1.7. Machine life, demolition and decommissioning
The machine has been designed to last for 10 years in normal operating conditions, 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 is made from 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 is 90% recyclable.
The European standards and those transposed by the member countries relating to environmental
safety and waste disposal 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.

User’s Manual – A16 J A18 J Series
Page 10
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 without a plate or a label, please check the production
number punched underneath the chassis. The exact location of the plate and the number punched on the chassis is
shown on the following label. Please check and copy them here below for your easier convenience in future.
MODEL: _________________
CHASSIS: __________________
YEAR: __________________
Fig. 1