Airo XP Series Manuale utente

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 „XP - XLP“

XP4 E - XP5 E - XLP5 E

XP4 E DUAL - XP5 E DUAL - XLP5 E DUAL

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

063.20.UEM-EN

2018-01

Use and Maintenance Manual - XP - XLP Series

Page 2

Revision date

Description of revision

2011-01

Issue:

05-2011

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

title transfer report”.

Inserted “Total quantity of battery electrolyte” in Technical Data. (to be checked)

2013-10

Specified instructions for harness anchoring points.

2014-01

Changed battery charger operation.

2014-09

Inserted information on maximum limits of manual forces.

Changed Name and Surname of CEO.

2015-01

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 in any way.

Added "Leaving at height”.

2018-01

Added new models DUAL.

Added pictures about fixing machines for transport.

Use and Maintenance Manual - XP - XLP Series

Page 3

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

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

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

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

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

Contents:

1. INTRODUCTION .....................................................................................................................................................................................5

1.1 LEGAL ASPECTS ..................................................................................................................................................................................5

1.1.1 Delivery of the machine ..............................................................................................................................................................5

1.1.2 Declaration of commissioning, first check, further periodical checks and transfers of ownership ..............................................5

1.1.2.1 Declaration of commissioning and first check..............................................................................................................5

1.1.2.2 Further periodical checks.............................................................................................................................................6

1.1.2.3 Transfers of ownership ................................................................................................................................................6

1.1.3 Operator training and information ...............................................................................................................................................6

1.2 TESTS PERFORMED BEFORE DELIVERY .................................................................................................................................................6

1.3 INTENDED USE ....................................................................................................................................................................................6

1.3.1 Leaving at height ........................................................................................................................................................................7

1.4 DESCRIPTION OF THE MACHINE ............................................................................................................................................................7

1.5 CONTROL PANELS ...............................................................................................................................................................................8

1.6 DRIVE POWER .....................................................................................................................................................................................8

1.7 MACHINE LIFE,DEMOLITION AND DECOMMISSIONING..............................................................................................................................8

1.8 IDENTIFICATION ...................................................................................................................................................................................9

1.9 LOCATION OF MAIN COMPONENTS.......................................................................................................................................................10

2. TECHNICAL FEATURES OF STANDARD MACHINES.......................................................................................................................11

2.1 MODEL XP4 E–XP4 EDUAL. .........................................................................................................................................................11

2.2 MODEL XP5 E–XP5 EDUAL. .........................................................................................................................................................13

2.3 MODEL XLP5 E–XLP5 EDUAL. .....................................................................................................................................................15

2.4 VIBRATIONS AND NOISE......................................................................................................................................................................17

3. SAFETY PRECAUTIONS......................................................................................................................................................................18

3.1 PERSONAL PROTECTIVE EQUIPMENT (PPE) ........................................................................................................................................18

3.2 GENERAL SAFETY NORMS ..................................................................................................................................................................18

3.3 USE INSTRUCTIONS ...........................................................................................................................................................................19

3.3.1 General .....................................................................................................................................................................................19

3.3.2 Handling.................................................................................................................................................................................... 19

3.3.3 Operating procedures ...............................................................................................................................................................20

3.3.4 Wind speed according to BEAUFORT SCALE.........................................................................................................................21

3.3.5 Pressure of the machine on ground and load-bearing capacity of ground ...............................................................................22

3.3.6 High-voltage lines .....................................................................................................................................................................23

3.4 HAZARDOUS SITUATIONS AND/OR ACCIDENTS......................................................................................................................................23

4. INSTALLATION AND PRELIMINARY CHECKS..................................................................................................................................24

4.1 BECOMING ACQUAINTED WITH THE MACHINE........................................................................................................................................24

4.2 PRELIMINARY OPERATION CHECKS......................................................................................................................................................24

5. USE INSTRUCTIONS............................................................................................................................................................................25

5.1 MACHINE MOVEMENT.........................................................................................................................................................................25

5.2 MACHINE BRAKING AND START-UP ......................................................................................................................................................26

5.3 PLATFORM ACCESS ...........................................................................................................................................................................27

5.3.1 Standard access with gate (XP4 E - XP5 E - XLP5 E) .............................................................................................................27

5.3.2 Standard access with gravity rod (XP4 E DUAL - XP5 E DUAL - XLP5 E DUAL)....................................................................27

5.3.3 Optional access with gate “SALOON” (XP4 E DUAL - XP5 E DUAL - XLP5 E DUAL) ............................................................28

5.4 ADJUSTING THE TELESCOPIC RAILS FOR DUAL MODELS ......................................................................................................................29

5.5 CONTROLS........................................................................................................................................................................................30

5.5.1 Emergency stop (A) ..................................................................................................................................................................30

5.5.2 Platform lifting/lowering (B-C) ...................................................................................................................................................30

5.6 GROUND CONTROL PANEL..................................................................................................................................................................31

5.6.1 Hour-meter / battery protection voltmeter (A) ........................................................................................................................... 31

5.6.2 Emergency STOP button (B) ....................................................................................................................................................31

5.6.3 Instability danger audible alarm (C) ..........................................................................................................................................31

5.6.4 Battery charger warning lights (D) ............................................................................................................................................31

5.6.5 Battery charger socket (E) ........................................................................................................................................................32

Use and Maintenance Manual - XP - XLP Series

Page 4

5.7 MACHINE START-UP...........................................................................................................................................................................32

5.8 MACHINE STOP.................................................................................................................................................................................. 32

5.8.1 Normal stop...............................................................................................................................................................................32

5.8.2 Emergency stop button............................................................................................................................................................32

5.9 MANUAL EMERGENCY LOWERING........................................................................................................................................................33

5.10 SOCKET FOR ELECTRIC TOOL CONNECTION (OPTIONAL) .......................................................................................................................33

5.11 END OF WORK ...................................................................................................................................................................................34

6. HANDLING AND CARRYING...............................................................................................................................................................35

6.1 HANDLING.........................................................................................................................................................................................35

6.2 CARRYING ........................................................................................................................................................................................36

6.2.1 Removable rails ........................................................................................................................................................................38

6.3 TOWING THE MACHINE. ......................................................................................................................................................................38

7. MAINTENANCE ....................................................................................................................................................................................39

7.1 SAFETY LOCK FOR MAINTENANCE OPERATIONS ...................................................................................................................................39

7.2 MACHINE CLEANING...........................................................................................................................................................................40

7.3 GENERAL MAINTENANCE ....................................................................................................................................................................40

7.3.1 Various adjustments .................................................................................................................................................................41

7.3.2 Greasing ...................................................................................................................................................................................42

7.3.3 Hydraulic circuit oil level check and change .............................................................................................................................43

7.3.3.1 Biodegradable hydraulic oil (Optional) .......................................................................................................................44

7.3.3.2 Emptying ....................................................................................................................................................................44

7.3.3.3 Filters .........................................................................................................................................................................44

7.3.3.4 Washing .....................................................................................................................................................................44

7.3.3.5 Filling..........................................................................................................................................................................44

7.3.3.6 Commissioning / check ..............................................................................................................................................44

7.3.3.7 Mix .............................................................................................................................................................................45

7.3.3.8 Micro-filtration ............................................................................................................................................................ 45

7.3.3.9 Disposal .....................................................................................................................................................................45

7.3.3.10 Topping up .................................................................................................................................................................45

7.3.4 Suction filter replacement .........................................................................................................................................................46

7.3.5 Pressure relief valve operation check.......................................................................................................................................47

7.3.6 Braking system adjustment and operation check .....................................................................................................................48

7.3.6.1 Pedal brakes ..............................................................................................................................................................48

7.3.6.2 Automatic brakes .......................................................................................................................................................49

7.3.7 Inclinometer operation check....................................................................................................................................................50

7.3.8 M1 microswitch efficiency check...............................................................................................................................................51

7.4 BATTERY ..........................................................................................................................................................................................51

7.4.1 General warning instructions ....................................................................................................................................................51

7.4.2 Battery maintenance.................................................................................................................................................................52

7.4.3 Battery recharge .......................................................................................................................................................................52

7.4.4 Battery charger: fault report ......................................................................................................................................................53

7.4.5 Battery replacement..................................................................................................................................................................53

8. MARKS AND CERTIFICATIONS..........................................................................................................................................................54

9. PLATES AND STICKERS.....................................................................................................................................................................55

10. CHECK REGISTER...............................................................................................................................................................................57

11. WIRING DIAGRAM - STANDARD MACHINES....................................................................................................................................71

12. HYDRAULIC DIAGRAM - STANDARD MACHINES ............................................................................................................................73

13. DECLARATION OF CONFORMITY EC FACSIMILE. ..........................................................................................................................75

Use and Maintenance Manual - XP - XLP Series

Page 5

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

Original EC Declaration of conformity

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.

Use and Maintenance Manual - XP - XLP Series

Page 6

1.1.2.2 Further periodical checks

Yearly checks are compulsory. In Italy 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 other qualified public or private services) at least twenty days before the

expiry of the year from the last check.

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

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

for the annual check.

1.1.2.3 Transfers of ownership

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

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

Declaration of conformity issued by the manufacturer.

Declaration of commissioning carried out by the first owner.

1.1.3 Operator training and information

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

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

1.2 Tests performed before delivery

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

Braking test

Overload test

Operating test

1.3 Intended use

The machine described in this use and maintenance manual is a manual drive aerial platform (moving is not power-driven)

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.

-Any remaining load is represented by the work materials.

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 platform. 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.

It is forbidden to move the machine with platform raised. To move the machine it is necessary that the work platform is in the

access position (fully lowered). No operator must be on board the platform during the displacement of the machine.

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.

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

following a specific request on the part of the user.

Use and Maintenance Manual - XP - XLP Series

Page 7

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 Manual Drive Elevating Work Platform equipped with:

-Chassis equipped with wheels.

-Vertical scissor lifting structure operated by one or more hydraulic cylinders (the number of cylinders varies according to

machine model).

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

The chassis is equipped with four idle wheels of which two rear pivoting and two front fixed (non steering). The rear wheels are

equipped with pedal parking brake; on front wheels there is a device for automatic braking which intervenes when the work platform

is in a position other than the access one.

The hydraulic cylinder moving the extensible structure is provided with a solenoid safety valve 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 is equipped with rails and toe-boards of a prescribed height (the height of the rails is 1100 mm; the height of the

toe-boards is 150 mm). For basic models XP4 E –XP5 E –XLP5 E the platform perimeter corresponds to the rails perimeter,

while for DUAL models it is possible to adjust the maximum platform size by adjusting the rails on two fixed positions. In the "open"

position, the rails make the whole platform floor available to the operator; in the "closed" position the rails reduce its perimeter

dimensions allowing the operator on board to fit the platform into confined spaces such as the panels of false ceilings.

To access the platform the following access systems are available:

-Entrance area with one-door reclosing gate and automatic lock in the closed position (standard for basic models XP4 E –XP5

E –XLP5 E);

-Entrance area with gravity rod (standard for "DUAL” models);

-Entrance area with two-door gate ("saloon” type) with automatic reclosing and locking system in closed position (optional for

"DUAL” models).

When no motive power is available, the manual emergency lowering can be controlled enabling the knob manually from the ground

(see instructions plates).

Use and Maintenance Manual - XP - XLP Series

Page 8

1.5 Control panels

The machine is provided with a single control panel on the platform for the normal use of the machine.

On the ground there is an emergency stop device and the device for manual emergency lowering.

1.6 Drive power

The machines are powered by an electro-hydraulic system consisting of rechargeable accumulators and electric pump.

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.

Use and Maintenance Manual - XP - XLP Series

Page 9

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

SFXX.XX.XXX

Use and Maintenance Manual - XP - XLP Series

Page 10

1.9 Location of main components

Alongside is a diagram showing the machine and its

components.

1) Platform control push-button panel

2) Box components

3) Control panel

4) Hydraulic control unit

5) Steering wheels with pedal parking brake

6) Fixed wheels with automatic parking brakes

7) 230V plug (optional)

8) Spirit level for visual check of machine levelling

(optional)

9) Lifting cylinders

10) Lowering control valves

11) Battery

12) Battery charger

13) Inclinometer

14) Manual device for emergency lowering

15) Platform height control M1 microswitch

16) Stopping levers of the lifting structure

17) Document box

18) Battery charger power cable location

19) Wheel chocks for forklift truck

20) Transport fixing holes.

FIG.2

3,4,11

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