Airo XS Series User manual

037.20.UEM-EN 2010-00
PIATTAFORME AEREE SEMOVENTI
SELF-PROPELLED WORK-PLATFORMS
PLATES-FORMES DE TRAVAIL AUTOMOTRICES
SELBSTFAHRENDE HUBARBEITSBÜHNEN
PLATAFORMAS ELEVADORAS AUTOPROPULSADAS
ZELFRIJDENDE HOOGWERKERS
SERIE „XS“
XS7 E - XS8E - XS9E
USE AND MAINTENANCE MANUAL
- ENGLISH -
AIRO is a division of TIGIEFFE SRL
Via Villasuperiore, 82 - 42045 Luzzara (RE) ITALY -
'[phone] - 7+39-0522-977015
WEB: www.airo.it

Use and maintenance manual Self-propelledaerial platforms Page 2
Tigieffe thanks you for purchasingaproduct of itsrange, and invitesyouto readthismanual. Hereyou can find all thenecessary
information for acorrect use of the purchased machine; therefore, you are advised to followthe instructionscarefullyand to read
the manualthoroughly. Themanual should be kept in a suitable placewhereno damagecan occur toit.Thecontentof this manual
may be modified withoutpriornotice and further obligations in order to add changesand improvements to the units already
delivered. No reproduction or translation may take placewithout the written permission of the owner.
Contents:
1. INTRODUCTION.........................................................................................................................................................................................4
1.1 LEGALASPECTS ..................................................................................................................................................................................4
1.1.1 Delivery of the unit.....................................................................................................................................................................4
1.1.2 Declaration of commissioning, first inspection, further periodical inspections and transfers of ownership.................................4
1.1.2.1 Declaration of commissioning and first inspection.......................................................................................................4
1.1.2.2 Further periodical inspections......................................................................................................................................5
1.1.2.3 Transfers of Ownership................................................................................................................................................5
1.2 INTENDED USE.....................................................................................................................................................................................5
1.3 DESCRIPTION OFTHE UNIT...................................................................................................................................................................6
1.4 CONTROLSTATIONS ............................................................................................................................................................................6
1.5 POWERSUPPLY...................................................................................................................................................................................6
1.6 IDENTIFICATION...................................................................................................................................................................................7
1.7 LOCATION OFMAIN COMPONENTS.........................................................................................................................................................8
2. TECHNICALFEATURES OFSTANDARD MACHINES..............................................................................................................................9
3. SAFETY PRECAUTIONS...........................................................................................................................................................................11
3.1 POWER SUPPLY......................................................................................................................................................................................11
3.2 WORK ANDMAINTENANCE RULES........................................................................................................................................................11
3.3 SAFETYRULES..................................................................................................................................................................................12
3.3.1 General.....................................................................................................................................................................................12
3.3.2 Handling....................................................................................................................................................................................12
3.3.3 Operating procedures...............................................................................................................................................................13
4. INSTALLATION AND PRELIMINARY CHECKS.......................................................................................................................................17
4.1 BEFORE USING THE MACHINE .............................................................................................................................................................17
5. GENERALUSE INSTRUCTIONS..............................................................................................................................................................18
5.1 PLATFORMCONTROLPANEL...............................................................................................................................................................18
5.1.1 Drive and steering.....................................................................................................................................................................19
5.1.2 Platform Lifting / Lowering.........................................................................................................................................................20
5.1.3 Manual platform extension (optional)........................................................................................................................................21
5.2 OTHER FUNCTIONS OFTHEPLATFORM CONTROLPANEL .......................................................................................................................21
5.2.1 Manual horn (D)........................................................................................................................................................................21
5.2.2 Emergency brake (STOP) (E)...................................................................................................................................................21
5.2.3 Green warning light: control station enabled (G).......................................................................................................................21
5.2.4 Red warning light: run-down battery (H)...................................................................................................................................21
5.2.5 Red warning light: overload (L).................................................................................................................................................22
5.2.6 Red warning light: danger due to instability or malfunctioning of the electrical system (M)......................................................22
5.2.7 Red warning lights (H+L+M): danger due to isolation loss of the electrical system..................................................................22
5.2.8 Mode selector (1 person / 2 persons) – ONLY XS9 E..............................................................................................................22
5.3 GROUNDCONTROLSTATION...............................................................................................................................................................23
5.3.1 Hour meter / battery-protection voltmeter (A)............................................................................................................................24
5.3.2 Emergency stop button (B).......................................................................................................................................................24
5.3.3 Main key: ignition / selection of control station (C)...................................................................................................................24
5.3.4 Warning light: control station enabled (D).................................................................................................................................24
5.3.5 Lever platform lifting / lowering (E)............................................................................................................................................24
5.3.6 Movement audible alarm (F)....................................................................................................................................................24
5.3.7 Warning light: battery charger (G).............................................................................................................................................25
5.4 PLATFORMACCESS ...........................................................................................................................................................................25
5.5 START-UP.........................................................................................................................................................................................25
5.6 MACHINE STOP..................................................................................................................................................................................26
5.6.1 Normal stop...............................................................................................................................................................................26
5.6.2 Emergency stop........................................................................................................................................................................26
5.7 MANUALEMERGENCYLOWERING........................................................................................................................................................27
5.8 SOCKETFORELECTRIC TOOLCONNECTION .........................................................................................................................................27

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5.9 END OFWORK...................................................................................................................................................................................28
6. HANDLING AND CARRYING....................................................................................................................................................................29
6.1 HANDLING.........................................................................................................................................................................................29
6.2 CARRYING.........................................................................................................................................................................................30
6.2.1 Fold-down rails..........................................................................................................................................................................31
6.3 EMERGENCY TOWING.........................................................................................................................................................................32
7. MAINTENANCE .........................................................................................................................................................................................33
7.1 MACHINE CLEANING...........................................................................................................................................................................34
7.2 GENERALMAINTENANCE....................................................................................................................................................................34
7.2.1 Various adjustments..................................................................................................................................................................35
7.2.2 Greasing....................................................................................................................................................................................36
7.2.3 Hydraulic circuit oil level check and change..............................................................................................................................37
7.2.4 Hydraulic filter cleaning / replacing...........................................................................................................................................37
7.2.4.1 Suction filter: cleaning / replacement........................................................................................................................37
7.2.4.2 Return filter: replacement...........................................................................................................................................38
7.2.5 Adjustment and efficiency check of inclinometer.....................................................................................................................39
7.2.6 Adjusting and checking the pressure relief valve of the lifting circuit........................................................................................40
7.2.7 Operation check and adjustment of platform overload controller..............................................................................................41
7.2.7.1 Overload controller with deformation transducer. ......................................................................................................41
7.2.7.2 Control system by-pass..............................................................................................................................................43
7.2.8 Adjusting and efficiency check of pressure relief valve.........................................................................................................44
7.2.9 Adjusting and efficiency control ofbraking valves (counterbalancingvalves)...........................................................................45
7.2.10 Efficiency check of safety microswitches..................................................................................................................................46
7.2.11 Efficiency check of control deviceof electrical system isolation............................................................................................47
7.2.12 “Dead-man”switch operation check..........................................................................................................................................48
7.2.13 Battery.......................................................................................................................................................................................48
7.2.13.1 General instructions...................................................................................................................................................48
7.2.13.2 Battery maintenance.................................................................................................................................................48
7.2.13.3 Battery recharge.........................................................................................................................................................49
7.2.13.3.1 Battery charger: faults report...............................................................................................................................50
7.2.13.4 Battery replacement..................................................................................................................................................50
8. MARKS AND CERTIFICATIONS..............................................................................................................................................................51
9. CONTROLREGISTER..............................................................................................................................................................................51
Annexes: hydraulic andelectric circuit diagrams
control register
conformity declaration
spare parts manual
troubleshooting guide

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1. INTRODUCTION
This Use and MaintenanceManual provides general instructionsconcerning the completerange of unitsindicatedon the cover.
Therefore, the description of their components, as well ascontrol and safety systems, mayinclude parts not presentonyour unit
sincesuppliedon requestor not available. In order tokeeppace withthe technicaldevelopment AIRO-Tigieffe s.r.l. reserves the
right to modify the product and/or the use and maintenance manualat any time without updating the units already delivered.
1.1 Legal aspects
1.1.1 Delivery of the unit
Within EU(European Union) member countries the machine is delivered complete with:
-Use and Maintenance manual in your language;
-CE mark applied on the unit;
-CE conformity declaration;
-Guarantee certificate;
Only for Italy:
-Specimen for commissioning declaration to ISPESL;
-List of ISPESL departmentsby territory;
-Statement of inside testing.
1.1.2 Declaration of commissioning, first inspection, further periodical inspections and transfers of ownership
The legalobligationsof theowner of the machine vary according tothe countryof commissioning.It istherefore recommended to
inquiryabout theproceduresinforce in your countryfromtheboardsresponsible for industrial safety.Thismanualcontains afinal
section called"Check register" for a better filing of documents and recording of any modifications.
1.1.2.1 Declaration of commissioning and first inspection
In ITALY the owner of the Aerial Platformmust notifythe useof the unit to the local competent ISPESL (National Institute for the
prevention of accidentsattheworkplace) and submit it toperiodical compulsoryinspections. Thefirst one ofthese inspectionsis
carried out byISPESL, while the followingones bythe territorial inspection boards (ASL/USL or ARPA). The inspections are on a
payment basisandthemachine ownerwillbecharged for them. For theseinspections,the territorialinspectionboards(ASL/USL
or ARPA) and ISPESL can be supportedby authorized public or private subjects. The authorized private subjects acquire the
qualification of responsibles ofthe public service and referdirectly to the public structure that controls this function.
To declarethe commissioningof the unit in Italy,send theformthatissupplied together withotherdocumentsupon machine
delivery, by registered letter with advice ofreceipt.
Within one year of the declaration, ISPESL will assign aSerial Number and during the FirstInspection will issuea"Checkbooklet"
indicatingonlythedetectable data ofthe machine alreadyin use or inferablefromthe relative User Manual.AfterwardsISPESL will
send acopyof thesame booklet tothe territorialinspectionboards (ASL/USL or ARPA) which willcarryout the furtherperiodical
mandatory inspections (every year).

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1.1.2.2 Further periodical inspections
Yearly inspectionsare compulsory.InItalytheownerof theAerialPlatformmustapply for aperiodicalinspectionby sendinga
registered letter tothelocal competentinspection board(ASL/USL or ARPA) at leasttwentydays before the expiryoftheyear from
the last inspection.
NB: If amachine withoutavalid controldocument should be movedin an area outsidethe competenceof the usualinspection
board, theowner of the machine mustaskthe inspection board, competentfor thenewterritory wherethe machine istobe used,
for the annual inspection.
1.1.2.3 Transfers of Ownership
In caseof transfer of ownership (in Italy)the newowner ofthe AerialPlatformmust notify the ownership of the unit tothe local
competent inspectionboard (ASL/USL or ARPA) by enclosing a copy of:
-Conformity declaration issuedby the manufacturer;
-Declaration of commissioning carried out bythe first owner.
1.2 Intended use
The machine described in thisuse and maintenance manual is aself-propelled aerialplatform intendedfor lifting persons and
materials (equipmentandbuilding materials)inorderto carry outmaintenance,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;
-any remaining load is represented by the material being worked.
In any caseNEVERexceed the maximum capacity allowed as indicated in paragraph "Technical features”.
All loadsmust bepositioned inside the platform.Donot lift loads (even if complyingwith the maximumcapacity allowed) hanging
from the platform or the lifting structure.
Do not carry large-sized panels since they increase theresistance towind force thus causing the machine to overturn.
While de-placingtheunitwithliftedplatformdo not loadhorizontalloadsontotheplatform(theoperators on board must notpull
ropes, wires, etc.).
Aload controlsystem interrupts the operation of the unit if the load on the platformexceeds by 30%approx. therated load (see
chapter "General use instructions”) andthe platform is lifted.
The unit cannot be used in areas where road vehicles operate. Always surround the working area by means of suitable signs when
the unit is used in publicareas.
Do not use the machine to towtrucks or other vehicles.

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1.3 Description of the unit
The machine described in this use andmaintenance manualis a self-propelled aerial platform equipped with:
-motorized chassis equipped with wheels;
-vertical liftingstructure,scissors type, activated by one orseveral hydrauliccylinders(the number of cylindersdependson the
model of the machine);
-operator platformwithmanually sliding appendix (the max.capacityvaries accordingto the model -seechapter "Technical
features”).
The chassis is motorized to allowthe machine to be moved (see “General use instructions”). The chassisis equipped withtworear
idle wheelsandtwofront steering and driving wheels.Therear wheels haveahydraulicparking brake of thepositive logictype,
(when drivecontrols are released brakes are automatically activated).
The hydraulic cylinders which move the pivot structure areprovided with safetyelectrovalves directly flanged on thesame. These
devices allowthebooms to remain in position even if one of the supply tubesaccidentallybreaks.
The platform, which can be manuallyextended fromthe front side (optional),is fitted withguardrailsand toe boards of prescribed
height (the guardrails height ≥1100 mm; the toe boards height ≥150 mm).
Should the motive power beabsentthemanual emergencylowering canbe controlledby activatingmanually the knob fromthe
ground according tothe plate instructions.
The machine can be equippedwith two types of load controlupon customer’s request:
-1: single load control systemwhere the extension ofthe mobileplatform (optional) reduces the platformcapacitytothe
capacity indicated on the extensible part;
-2: double load control system where the max. platform capacity is not reduced withthe mobile platform extension (optional).
1.4 Control stations
The machine is equipped with two controlstations:
-at platform for normaluse of the unit;
-at thechassis for emergencycontrolsto lower orstop the unitinemergencysituations.The groundcontrolstation isalso
equipped with a key-selector to select thecontrol stationandto start the unit.
1.5 Power supply
The machines can be powered by an electro-hydraulic system composed of rechargeable accumulators and electric pump.
The hydraulicandelectrical systemsare equipped withall necessaryprotections (seeelectricandhydraulic diagramsattachedto
this manual)
D
o not use the machine for purposes different from those it was intended for.
If disposalof theunit is necessary, comply with current local regulations. Themachine is built mainly with metal
parts easy to be identified (mostly steel, andaluminiumfor the hydraulic blocks); therefore we can statethat the
machine can be recycled by 75%.

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1.6 Identification
In order to identifythe machine, when spareparts and service arerequired, alwaysmention the information giveninthe serial
number plate.Shouldthis plate(as well asthevariousstickers appliedon the unit) belostor illegible, it istobe replacedas soon
as possible. In order toidentifythemachinewhen no plate isavailable the serialnumber isalso stamped onthechassis.To locate
the plate and the stamp of the serial number, see the following picture. It is recommended to copysuch data in the following boxes.
Model.................................………….. Chassis:..................................………... Year:...................................…………...
Fig. 1
SFXX.XX.X

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1.7 Location of main components
Belowis a diagram showing the machine and its components.
1) Control panel at platform;
2) Electric power unit;
3) Hydraulic power unit;
4) Hydraulic drive engines;
5) Parking brakes;
6) 230V socket;
7) Bubble level for visual checkof
machine levelling;
8) Lifting cylinders;
9) Lowering controlvalves;
10) Battery;
11) Battery charger;
12) Steering cylinder;
13) Inclinometer;
14) Control deviceof electrical system
isolation;
15) Manualdevicefor emergency
lowering;
16) Pothole guards;
17) Microswitch M1 platform height
control;
18) Microswitch M3A +M3B (only
XS9 E) electric limitswitchfor
lifting inmode “2 persons”–
inhibition ofdrivecontrol in mode
“1 person” withplatform ata
height over 6 m;
19) Microswitch M5 control of mobile
platform position (optional) –drive
control inhibited with extended
platform(optional);
20) Microswitches MPT1 –MPT2
position control of pothole system;
21) Deformation trasducer;
22) Monitoring circuit board ofthe
control load system at platform.
Fig.2
1
2,3
3
5,15
6,7
8
8
9
9
4
10,14
11
12
13,22
17,18
19
16,20
21 21

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2.TECHNICALFEATURESOFSTANDARDMACHINES
Description XS7 EXS8 E XS9 E
“2 persons”
“1 person”
Max. working height – m - 6.61 7.96 89.27
Max. platform height – m - 4.61 5.96 67.27
Ground clearance (pothole guards up) – mm - 72 72 72
Ground clearance (pothole guards down) – mm - 15 15 15
Inside turning radius – m - 000
Outside turning radius – m - 1.48 1.48 1.48
Max. capacity - Kg -250 250 200 120
Max. No. of people on platform2221
Max. platform extension - optional – m - 111
Max. capacity on the extended part - optional – Kg - 120 120 120
Max. No. of people on the extended part – optional 111
Max. drive height (1) – m - 4.61 5.96 6
Max. platform dimensions – standard – mm -740x1650 740x1650 740x1650
Max. hydraulic pressure - bar - 240 240 240
Tyre dimensions - mm - Ø 300 Ø 300 Ø 300
Tyre type (2)300-115-240 300-115-240 300-115-240
Max. operating temperature - °C - +50° +50° +50°
Min. operating temperature - °C - -5° -5° -5°
Stability limits:
Longitudinal inclination - degrees - 1.5° 1.2° 1°
Transversal inclination - degrees -1.5° 1° 1°
Max. wind force - m/s - 000
Battery voltage and capacity –V/Ah- 6x4/190 6x4/190 6x4/190
Battery weight – kg - 33x4 33x4 33x4
Single-phase battery charger - V/A - 24/30 HF24/30 HF24/30 HF
Max. power absorbed by battery charger -A- 555
Electropump power - KW - 333
Max. current absorbed – A - 160 160 160
Max. drive speed - m/s - 111
Safety drive speed - m/s -0.1 0.1 0.1
Oil tank capacity - l - 20 20 20
Max. gradeability - %-30 27 25
Cubic volume with rails in work position - m3 -2.9 33.2
Cubic volume with rails down – standard- m3 -2.3 2.4 2.6
Height / Length with folded down rails - standard – m - 1.65 / 1.805 1.76 / 1.805 1.87 / 1.805
Cubic volume with rails down – optional- m3 -2.8 2.9 3.1
Height / Length with rails down - optional – m - 1.65 / 2.15 1.76 / 2.15 1.87 / 2.15
Machine weight (unloaded) (3) - Kg - 1310 1395 1540

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(1) Translation with platform lifted up to the indicated limit possible only if the machine is fitted with automatic or manual pothole guards in
lowered position (reduced height of the machine from the ground). Otherwise, translation is possibleonly with platform completely lowered (until
the activation of the microswitch that automatically prevents the operation after 1mapprox. of lifting)or upto the limit shown in the table. With
sliding platform (optional) extended drive control is prevented.
(2) Cushion tyres (full rubber).
(3) In some cases different limits can be fixed. It is recommended to comply with the data shown on the machine plate.
Noise testshave been carried out under the most unfavourable conditions to studythe effectsonthe operator. The level of acoustic pressure
weighed (A) at work places doesnot exceed 75,2dB(A).
As to vibrations in ordinary working conditions:
- the rms. value weighed according to acceleration frequency relevant to the upper limbs is lower than 2.5 m/sec2;
- the rms. value weighed according to acceleration frequency relevant to the body is lower than 0.5 m/sec2.