TIGIEFFE AIRO R Series Manual de usuario

PIATTAFORME AEREE SEMOVENTI

SELF-PROPELLED WORK-PLATFORMS

PLATES-FORMES DE TRAVAIL AUTOMOTRICES

SELBSTFAHRENDE HUBARBEITSBÜHNEN

PLATAFORMAS ELEVADORAS AUTOPROPULSADAS

ZELFRIJDENDE HOOGWERKERS

SJÄLVGÅENDE ARBETSPLATTFORMAR

SAMOKRETNE RADNE PLATFORME

“R” SERIES

R13 S R13 DC R17 S R17 DC

USE AND MAINTENANCE MANUAL

- ENGLISH - ORIGINAL INSTRUCTIONS

AIRO is a division of TIGIEFFE SRL

Via Villasuperiore, 82 - 42045 Luzzara (RE) ITALY-

+39-0522-977365 -+39-0522-977015

WEB: www.airo.com

059.20.UEM-ENG

2018-05

Use and Maintenance Manual - R13 R17 Series

Page 2

Revision date

Description of revision

2010-01

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

Model names updated.

2010-11

Added instructions for biodegradable oil kit.

Temperatures and oil list updated.

2011-02

Updated description for load control

2011-05

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

title transfer report”.

Inserted “Total quantity of battery electrolyte” in Technical Data.

Corrected "Max. power" diesel motor and inserted "Adjusted Power".

2013-01

Changed maximum drive speed due to displacement pump change

2013-10

Specified instructions for harness anchoring points.

2014-03

Specified instructions for drive on uneven surfaces and/or slopes.

2014-08

Inserted instructions for optional kit "extendible tracks".

Inserted information on maximum limits of manual forces.

2015-00

CE conformity declaration updated.

Added position of hands instruction.

2015-10

Type of usable hydraulic oil updated.

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

the machine.

Added "Leaving at height”.

2018-05

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.

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Tigieffe thanks you for purchasing a product of its range, and invites you to read this manual. Here you can find all the necessary

information for a correct use of the purchased machine; therefore, you are advised to follow the instructions carefully and to read

the manual thoroughly. The manual should be kept in a suitable place where no damage can occur to it. The content of this manual

may be modified without prior notice and further obligations in order to add changes and improvements to the units already

delivered. No reproduction or translation may take place without the written permission of the owner.

Contents:

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 R13 S ..............................................................................................................................................12

2.2. Model R13 DC ...........................................................................................................................................14

2.3. Model R17 S ..............................................................................................................................................17

2.4. Model R17 DC ...........................................................................................................................................19

2.5. Vibrations and noise ................................................................................................................................22

3. SAFETY PRECAUTIONS ..........................................................................................................................23

3.1. Personal protective equipment (PPE).....................................................................................................23

3.2. General safety norms...............................................................................................................................23

3.3. Use instructions .......................................................................................................................................24

3.3.1. General.......................................................................................................................................................................24

3.3.2. Handling......................................................................................................................................................................24

3.3.3. Operating procedures .................................................................................................................................................25

3.3.4. Wind speed according to Beaufort scale.....................................................................................................................26

3.3.5. Pressure of the machine on ground and load-bearing capacity of ground..................................................................27

3.3.6. High-tension lines .......................................................................................................................................................28

3.4. Dangerous situations and/or accidents..................................................................................................28

4. INSTALLATION AND PRELIMINARY CHECKS.......................................................................................29

4.1. Becoming acquainted with the machine ................................................................................................29

4.2. Preliminary operation checks..................................................................................................................29

5. USE INSTRUCTIONS ................................................................................................................................30

5.1. Platform control panel/wire control ........................................................................................................30

5.1.1. “Wire control” Mode: Translation, Stabilization and Widening tracks (optional)..........................................................32

5.1.1.1. Drive......................................................................................................................................................................... 33

5.1.1.2. Stabilization.............................................................................................................................................................. 34

5.1.1.2.1. Manual stabilization control...................................................................................................................................... 35

5.1.1.2.2. Automatic stabilization control (OPTIONAL) ............................................................................................................ 35

5.1.1.3. Widening or narrowing the tracks (optional)............................................................................................................. 36

5.1.2. Mode “Platform movement”: Lifting/Lowering/Rotations .............................................................................................38

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5.1.2.1. First boom lifting/lowering......................................................................................................................................... 39

5.1.2.2. Second boom lifting/lowering.................................................................................................................................... 39

5.1.2.3. Telescopic boom extension/retraction...................................................................................................................... 39

5.1.2.4. Jib lifting/lowering..................................................................................................................................................... 39

5.1.2.5. Turret orientation (rotation)....................................................................................................................................... 39

5.1.2.6. Platform rotation (OPTIONAL).................................................................................................................................. 40

5.1.2.7. Platform level compensation .................................................................................................................................... 40

5.1.3. Other functions of the platform control panel ..............................................................................................................41

5.1.3.1. Electric / thermic power selector (F) (OPTIONAL) ................................................................................................... 41

5.1.3.2. Electric motor start / stop button (E) (OPTIONAL) ................................................................................................... 41

5.1.3.3. Enabled electric pump warning light (T) (OPTIONAL).............................................................................................. 41

5.1.3.4. Heat motor starting switch (G).................................................................................................................................. 41

5.1.3.5. Horn (B).................................................................................................................................................................... 41

5.1.3.6. Emergency STOP button (P).................................................................................................................................... 41

5.1.3.7. Warning lights........................................................................................................................................................... 42

5.1.3.7.1. Enabled control panel warning light (ZB).................................................................................................................. 42

5.1.3.7.2. Central turret warning light (ZC) ............................................................................................................................... 42

5.1.3.7.3. Enabled warning light Diesel motor fault / low fuel level (ZD) (DIESEL motor only)................................................. 43

5.1.3.7.4. Danger warning light (unsteady position and faults indicator)(ZE) ........................................................................... 43

5.1.3.7.5. Overload alarm warning light (ZF)............................................................................................................................ 43

5.1.3.7.6. Outriggers position warning lights (ZA) .................................................................................................................... 43

5.2. Ground control panel (electric control unit)...........................................................................................44

5.2.1. On-off key / control panel selector (A).........................................................................................................................45

5.2.2. Emergency stop button (B) .........................................................................................................................................45

5.2.3. Thermic or electric work power selector (C) (OPTIONAL)..........................................................................................45

5.2.4. Heat motor start button (D) .........................................................................................................................................46

5.2.5. User interface display (E)............................................................................................................................................46

5.2.6. Machine warning light on (G)......................................................................................................................................46

5.2.7. Heat motor warning lights (H,L,M and N) (DIESEL motor only)..................................................................................46

5.2.8. Platform control levers (O,P,Q,R,S,T,U) .....................................................................................................................46

5.3. Platform access........................................................................................................................................47

5.4. Machine start-up.......................................................................................................................................48

5.4.1. Heat motor start-up.....................................................................................................................................................49

5.4.2. Starting the 230V electric pump (OPTIONAL) ............................................................................................................49

5.5. Machine stop.............................................................................................................................................51

5.5.1. Normal stop.................................................................................................................................................................51

5.5.2. Emergency stop button..............................................................................................................................................51

5.5.3. Heat motor stop ..........................................................................................................................................................51

5.5.4. Stopping the 230V single-phase electric pump (OPTIONAL). ....................................................................................52

5.6. Emergency manual controls....................................................................................................................53

5.7. Socket (OPTIONAL) for electric tool connection and single-phase electric pump powering

(OPTIONAL) 55

5.8. Fuel level and re-fuelling..........................................................................................................................55

5.9. End of work...............................................................................................................................................56

6. HANDLING AND CARRYING....................................................................................................................57

6.1. Handling....................................................................................................................................................57

6.2. Carrying.....................................................................................................................................................57

7. MAINTENANCE.........................................................................................................................................60

7.1. Machine cleaning......................................................................................................................................60

7.2. General maintenance ...............................................................................................................................61

7.2.1. Various adjustments ...................................................................................................................................................62

7.2.2. Greasing .....................................................................................................................................................................63

7.2.3. Hydraulic circuit oil level check and change................................................................................................................64

7.2.3.1 Biodegradable hydraulic oil (Optional)...................................................................................................................... 65

7.2.3.2 Emptying .................................................................................................................................................................. 65

7.2.3.3 Filters........................................................................................................................................................................ 65

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7.2.3.4 Washing ................................................................................................................................................................... 65

7.2.3.5 Filling........................................................................................................................................................................ 65

7.2.3.6 Commissioning / check ............................................................................................................................................ 65

7.2.3.7 Mix............................................................................................................................................................................ 66

7.2.3.8 Micro-filtration........................................................................................................................................................... 66

7.2.3.9 Disposal.................................................................................................................................................................... 66

7.2.3.10 Topping up ............................................................................................................................................................... 66

7.2.4. Hydraulic filter replacement ........................................................................................................................................67

7.2.4.1. Suction filters............................................................................................................................................................ 67

7.2.4.2. Return filter............................................................................................................................................................... 67

7.2.5. Drive reduction gear oil level check and change.........................................................................................................68

7.2.5.1 Checks in the use of synthetic biodegradable oil in drive reduction gears ............................................................... 68

7.2.6. Telescopic boom sliding blocks clearance adjustment ...............................................................................................69

7.2.7. Tracks condition and tension check............................................................................................................................70

7.2.8. Pressure relief valve adjustment and operation check................................................................................................71

7.2.9. Inclinometer operation check......................................................................................................................................72

7.2.10. Operation check of M1 microswitches ........................................................................................................................73

7.2.11. MRT microswitch operation check..............................................................................................................................73

7.2.12. M2A-M2B microswitches operation check. .................................................................................................................73

7.2.13. STP1-STP2-STP3-STP4 microswitches operation check...........................................................................................73

7.2.14. “Dead-man” safety system operation check................................................................................................................74

7.2.14.1. "Dead-man" pedal”................................................................................................................................................... 74

7.2.14.2. "Dead-man" button................................................................................................................................................... 74

7.3. Starter battery...........................................................................................................................................76

7.3.1. Starter battery maintenance........................................................................................................................................76

7.3.2. Starter battery recharge..............................................................................................................................................76

7.3.3. Battery block...............................................................................................................................................................77

7.3.4. Battery charger: fault report ........................................................................................................................................77

7.3.5. Battery replacement....................................................................................................................................................78

8. MARKS AND CERTIFICATIONS...............................................................................................................79

9. PLATES AND STICKERS..........................................................................................................................80

10. CHECK REGISTER ...................................................................................................................................82

11. HYDRAULIC DIAGRAM ............................................................................................................................97

12. WIRING DIAGRAM....................................................................................................................................99

13. DECLARATION OF CONFORMITY EC FACSIMILE. .............................................................................110

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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

Only for Italy:

Declaration of commissioning to INAIL

List of local INAIL departments

Declaration of internal testing

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 responsibles of the public service and refer directly to the public structure that controls

this function.

To declare the commissioning of the machine in Italy, send the form that is supplied together with other documents upon machine

delivery, by registered letter with advice of receipt.

The INAIL will assign a serial number when the First Check is performed before completing the “technical identification sheet” on

which it indicates only the details obtained from the already-operating machine or obtainable 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 it is necessary that the owner of the Aerial Platform must apply for a periodical check by

sending a registered letter to the local competent inspection board (ASL/USL or ARPA or other qualified public or private services)

at least twenty days before the expiry of the year from the last check.

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

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

for the annual check.

1.1.2.3. Transfers of ownership

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

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

Declaration of conformity issued by the manufacturer.

Declaration of commissioning carried out by the first owner.

1.1.3. Operator training and information

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

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

1.2. Tests performed before delivery

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

Braking test

Overload test

Operating test

1.3. Intended use

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

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

blasting, welding operations, etc.

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

80 Kg for each person on board.

40 Kg for equipment.

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

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

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

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

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

from the platform or lifting structure.

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

The machine is not equipped with an overload controller as in the design phase we considered stability and overload criteria

increased as reported by the EN280 in paragraphs 5.4.1.5 and 5.4.1.6 .

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.

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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.

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 aerial platform equipped with:

motorized chassis equipped with rubber tracks and outriggers;

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 consists of sheeting, box-type structures and electrically welded structural forms of different thickness. It is motorised

to allow the machine to move (see "General use instructions"). The 2 tracks are controlled by independent motors and equipped

with hydraulic parking brake, positive logic type (when drive controls are released brakes are automatically activated). On the

chassis there are four outriggers operated by hydraulic double acting cylinders that are controlled by solenoid valves directly

flanged on the same. The outriggers are held in position by non-return valves directly piloted and flanged on the same.

Upon request, the machine can be equipped with a system of tracks widening to widen the track width and increase stability in the

event of use on rough terrain.

The turret rests on a turntable fixed to the chassis and can be oriented (rotated) by 320° 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 one, consists of a "simple parallelogram" system (R13) or a "double parallelogram" (R17) and named

"pantograph".

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

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

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

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One cylinder for the “pantograph” extension.

One cylinder for the boom extension.

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

One cylinder for the “jib” extension.

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 120° totally (60° on the right and 60° on the left) by means of an

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

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

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

(“Jib” inclination excluded).

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 are powered by a dual powered system:

heat motor (standard petrol motor; optional diesel motor);

electric pump (standard 230V single-phase; optional 380 three-phase).

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

circuit diagrams annexed 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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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 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

SC XXXXXX

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