Manual de Operacion Main Deck Loader

Solutions for aviation
MAIN DECK LOADER

2 PU 2000
USER MANUAL
Air Business Consultants Holding - 1 rue de la Haye 95731 Roissy CDG Cedex – France – Tel.: +33 17 379 17 17
registered in France RCS Bobigny 840047823 - TVA: FR 61 840047823 - EORI FR84004782300017
and as vocational agency under n° 326003110 60 - www.airbusiness.fr
AVIOGEI
OPERATING MANUAL
CHAPTER I
• PRESENTATION
CHAPTER II
• DESCRIPTION OF THE EQUIPMENT
CHAPTER III
• TECHNICAL SPECIFICATIONS
CHAPTER IV
• OPERATION
CHAPTER V
• HYDRAULIC SYSTEM & BRAKES
CHAPTER VI
• SPARE PARTS
CHAPTER VII
• Electrical wiring system (Vehicle)
CHAPTER VIII
• Electrical wiring system (Service)
CHAPTER IX
• Differential axle
CHAPTER X
• Amendment
CHAPTER XI
• Maintenance / Record book
AVIOGEI
INDEX
CHAPTER I
1 PRESENTATION P.
1-1 Introduction 1-1

1-2 Purpose of the operations manual and 1-2
spare parts catalogue
1-3 Amendments and additions to the 1-3
operations manual and spare parts
catalogue
1-4 Liability 1-3
1-5 Cooperation 1-3
1-6 Assistance and spare parts service 1-4
1-7 Warranty 1-5
1-8 General safety instructions 1-5
1-9 Vehicle sheet 1-6
CHAPTER II
2 DESCRIPTION OF THE EQUIPMENT P.
2-1 Base frame 2-1

2-2 Front platform and driving seat 2-3
2-3 Rear platform 2-5
2-4 Hydraulic system 2-7
2-5 Electrical wiring systems 2-8
2-6 Braking system 2-8
2-7 Safety devices 2-9
CHAPTER III
3 TECHNICAL SPECIFICATIONS P.
3-1 Description 3-1

3-2 Overall dimensions and main 3-2
specifications
3-3 Data recording 3-3
3-4 Dimensional drawing 3-4
AVIOGEI
CHAPTER IV
4 OPERATION P.
4-1 Ignition panel 4-2

4-2 Instrument panel 4-3
4-3 Operating panel 4-6
4-4 Maintenance ground control panel 4-7
4-5 Operating instructions 4-9
4-6 Emergency plates 4-24
CHAPTER V
5 HYDRAULIC SYSTEM & BRAKES P.
5-1 Hydraulic system 5-1

5-2 Braking system 5-4
CHAPTER VI
6 SPARE PARTS P.
6-1 Hydraulic system

6-4 Front stabilizer cylinder 6-1
6-5 Intermediate stabilizer cylinder 6-20
6-6 Rear stabilizer cylinder 6-22
6-7 Front axle tilt cylinder 6-24
6-8 Rear axle tilt cylinder 6-26
6-9 Front platform lifting cylinder 6-28
6-10 Rear platform lifting cylinder 6-30
6-11 Safety devices cylinder 6-32
6-12 Front wheels tilt cylinder 6-34
6-13 Rear wheels tilt cylinder 6-36
6-14 Breakaway cylinder 6-38
6-15 Cabin movement cylinder 6-40
6-16 Protrusions tilt cylinder 6-42
6-17 Rear platform roller conveyor 6-44
6-18 Front platform roller conveyor 6-46
6-19 Transverse drive wheel unit 6-48
6-20 Rear pantograph 6-51
6-21 Front pantograph 6-56
6-22 Driver’s cab 6-61
AVIOGEI
CHAPTER VII
Electrical wiring system (Vehicle)
CHAPTER VIII
Electrical wiring system (Service)
CHAPTER IX
Differential axle
CHAPTER X
Amendment
CHAPTER XI
7 MAINTENANCE/RECORD BOOK P.
11-1 Maintenance 11-1

11-2 Troubleshooting 11-16
11-3 Record book 11-20
PRESENTATION AVIOGEI
CHAPTER I
1 PRESENTATION
1-1 INTRODUCTION
1-2 PURPOSE OF THE OPERATIONS MANUAL AND SPARE PARTS CATALOGUE
1-3 AMENDMENTS AND ADDITIONS TO THE OPERATIONS MANUAL AND SPARE PARTS
CATALOGUE
1-4 LIABILITY
1-5 COLLABORATION
1-6 ASSISTANCE AND SPARE PARTS SERVICE
1-7 WARRANTY
1-8 GENERAL SAFETY INSTRUCTIONS
1-9 VEHICLE SHEET

1-1 INTRODUCTION
We are extremely pleased with your decision to purchase this equipment and we would really
like to thank you for it.
We take the opportunity to reassure you about the equipment’s operational capabilities,
resulting from the high degree of technological development achieved by our production units
as well as from the quality of the materials and commercial parts used.
1-2 PURPOSE OF THE OPERATIONS MANUAL AND
SPARE PARTS CATALOGUE
The maintenance and spare parts manual is addressed to the equipment buyers and, more
generally, to all those who for any reason are interested in its use, surveillance, maintenance,
and demolition. Its purpose is thus to:
• Describe the use of the equipment.
• Provide operating instructions.
• Describe the safety devices.
• Provide instructions for maintenance.
• Support the personnel training procedures.
• Provide instructions for filling out the record book.
• Provide spare parts lists.
• Provide scheduled maintenance plans.
This manual cannot in any way replace an adequate knowledge that operators must have
previously achieved on similar equipment or that they will be able to achieve on this
equipment, under the guidance of previously trained personnel according to the instructions in
Chapter III.
In addition to complying with the requirements contained in this manual, its use is to be made
subject to compliance with all safety standards required by the specific legislation applicable in
countries where the equipment is used.
The manual is to be considered as an integral part of the equipment and therefore must be
kept on board for any consultation, in a dry place protected from the sun's rays.
1-3 AMENDMENTS AND ADDITIONS TO THE
OPERATIONS MANUAL AND SPARE PARTS
CATALOGUE
This manual reflects the state of the art at the time of sale of the equipment, therefore it cannot
be considered inappropriate or deficient for the sole reason that subsequent amendments and
additions may have been introduced according to new legal provisions, as well as to updates
of harmonized standards and/or acquisition of new experiences.
1-4 LIABILITY
AVIOGEI as manufacturer disclaims any liability concerning the following drawbacks:
• Misuse of the equipment.
• Use by untrained personnel.
• Use contrary to the safety standards provided by the specific national legislation in
force.
• Failure to comply with the maintenance instructions and prescriptions provided in this
manual.
• Alterations not authorized by AVIOGEI.
• Use of non-original spare parts other than those indicated in the "Spare parts"
chapter.
1-5 COOPERATION
When needed, AVIOGEI will provide more detailed information to users who explicitly request
it.
The cooperation offered by buyers is always welcome. AVIOGEI will examine any proposal for
amendments that may improve our product.
In case of sale of the equipment, the user is invited to report the name of the new owner to
AVIOGEI in order to allow easy availability of the equipment, when additions to the instruction
manual and the relative technical assistance are required.
1-6 ASSISTANCE AND SPARE PARTS SERVICE
For all your needs, both during and out of the warranty period, our Customer Service is
available for the following tasks:
• Ordinary and extraordinary maintenance on our vehicles under warranty and with expired
warranty.
• Training of personnel tasked with operating with our vehicles, through the supply of
maintenance and spare parts manuals, or through instruction courses, both at our factory and
at the airport where the use of the equipment is intended.
• Supply of spare parts for airport equipment from our own production, or from third-party
manufacturers if difficult to find; supply of custom-designed or sample parts.
• For the timely intervention of our staff, or for the supply of spare parts, please use the
following addresses:
Telephone +39-06-9278251
Fax +39-06-9278505
 Mailing address AVIOGEI Airport Equipment S.r.l.
CUSTOMER SERVICE
Via Campoleone Tenuta N. 13
04010 Campoleone / Aprilia (LT)
 Website http://www.aviogei.it
 Email customerservice@aviogei.it
1-7 WARRANTY
The Warranty on our products lasts for a period of 12 months from the date of shipment.
AVIOGEI undertakes by means of this Warranty to repair or replace all parts that show defects
resulting from the manufacturing process or from the material used. The warranty does not
apply to parts subject to wear, such as: bearings, bushings, lamps, electric motor windings,
etc., for which the conditions applied by the respective manufacturers apply. The warranty is
void in the event that the buyer makes modifications to the equipment without the prior
authorization of AVIOGEI.
1-8 GENERAL SAFETY INSTRUCTIONS

The use of the equipment other than that for which it was designed releases AVIOGEI
from any liability for damage to persons and property.
The equipment is built in compliance with the Machinery Directive 2006/42/EC and
subsequent updates. It is however advisable for the personnel involved in the use of the
equipment to carry out all operations with the utmost care, as moving parts can always create
a hazard.
The equipment must be used and checked in compliance with Italian Legislative Decree
81/2008 and subsequent updates.
The equipment can operate on airport aprons with even surfaces such as concrete and
asphalt, and at air temperatures between -15 ºC and + 50 ºC.
The equipment also complies with the AHM 932 standard and UNI EN 12312-
9:2005+A1:2009.
The operators must be perfectly aware of position, function of all controls, and characteristics
of the equipment; in addition, they must also check on a daily basis the efficiency of all devices
on the equipment.
The equipment cannot in any way be used for the transport or lifting of people (excluding the
operator) or driven with cargo on board.
Access to front platform is allowed only by previous use of personal protective equipment.
Access to rear platform is allowed only when it is fully lowered (reaches ground level).
Do not inhibit or violate the safety devices installed on the equipment.
Do not perform maintenance, adjustment and setting when parts are moving.
The customer assumes responsibility for interventions not authorized by AVIOGEI, such as the
modification of parts of the equipment or the adaptation of additional devices, as such
operations can only be performed by the manufacturer.
1-9 VEHICLE SHEET
Date: 28/02/2012
Type of Equipment: CARGO LOADER
Part Number: 2PU 2000
Serial number: 10827
Serial numbers
Type Brand Code Serial number
Engine Deutz F5L 912 21055504
Displacement pump Rexroth A4VG90DA1D7/32L- 510201
NZF02F001SP
Displacement hydraulic Rexroth A2FM160/61W-VZB100 IT-0-16099931
motor
Axial piston pump Rexroth A7VO80LRH1/63L- 91866187
NZB01
Hydraulic steering Ognibene STA ON 200 G4
system
Front axle AE36L DRAWING N° 3171663 403.11.94
DESCRIPTION OF THE EQUIPMENT AVIOGEI
CHAPTER II
2 DESCRIPTION OF THE EQUIPMENT
2-1 BASE FRAME
2-2 FRONT PLATFORM AND DRIVING SEAT
2-3 REAR PLATFORM
2-4 HYDRAULIC SYSTEM
2-5 ELECTRICAL WIRING SYSTEMS
2-6 BRAKING SYSTEM
2-7 SAFETY DEVICES

2-1 BASE FRAME
The base frame is made of type "2" steel from tab. UNI 7070 and consists of a front and a rear
structure with minimal vertical development.
In addition to being the support and sliding area of the front platform’s lifting pantographs, the
front part is that portion of the equipment where all the main components are housed.
Such portion contains:
• Heat engine with hydraulic pumps.
• Front axle with steering differential axle complete with hydraulic motor. A hydraulic lifting
device installed on the axle allows to vary the minimum height of the equipment from the
ground during the vehicle transfer phase.
• Electro-hydraulic unit complete with solenoid, control and safety valves.
• Hydraulic oil tank complete with optical level, filters and filler cap.
• Fuel tank complete with level indicator and filler cap.
• Components of the service and parking braking system.
The rear part serves as support and sliding area of the main loading platform’s lifting
pantographs, as well as compartment of the vehicle’s rear axle.
An electro-hydraulic device installed on the rear axle allows the lifting of the equipment while
the vehicle is being moved.
This device is automatically engaged when retracting the stabilizers.
6 hydraulic stabilization cylinders complete with swivel foot and large support base are located
on the frame perimeter’s points of maximum stress (during use).
On the rear part there are 2 multi-stage jacks that perform the task of improving the main
platform’s initial lifting.
2-1.1 STABILIZATION SYSTEM
The stabilization system consists of six double-acting hydraulic cylinders, acting on a swivel
support foot made of steel sheet provided with a large support base designed to reduce the
maximum pressure exerted on the ground during the operating phase.
Each cylinder is bolted to the base cross members of the frame and is positioned on each
point of maximum load stress.
Each cylinder is provided with a hydraulically pilot-operated control valve which ensures
perfect sealing during the operating phase.
The rods are made of steel with thick chrome plating in order to prevent the exposed surface
from being attacked by atmospheric agents such as salt spray or other.
2-2 FRONT PLATFORM AND DRIVING SEAT
The front platform is made of type "2" steel from tab. UNI 7070. It is covered on the top by a
steel sheet platform housing idle stainless steel ball bearings and mechanisms that allow the
load handling.
A roller conveyor with metal rollers allows the longitudinal load transfer.
The handling of such components is made possible by a chain transmission controlled by

hydraulic motors.
Units made up of pairs of rubber wheels allow to transfer the load in the transverse direction.
The rubber wheels can in turn be activated by actuating the control device of the hydraulic
cylinders that allow them to be raised above the longitudinal plane of the roller conveyor.
The commands are grouped into two separate sections:
• A fixed section in the dashboard containing vehicle movement and stabilization commands.
• An additional section including all the operating commands.
In addition to the main in-cab controls, the vehicle is equipped with an additional operating
panel located on the frame at the front platform access ladder.
This panel contains in two separate sections all vehicle’s reset, control and emergency
operating commands.
2-2.1 FRONT PLATFORM LIFT SYSTEM
The front platform is provided with a scissor lift mechanism with simple pantograph.
The lifting pantographs are built with type "2" steel from tab. UNI 7070 and are operated by 2
single-acting hydraulic cylinders. Each cylinder is provided with a hydraulically pilot-operated
control valve which ensures perfect functionality and tightness during the operating phase.
A "lateral tilt" device acts on this system which allows the front-loading platform to tilt
transversely and adapt to the new configuration reached by the aircraft hold during the
loading/unloading of containers.
The scissor joints are made with bronze bushings and tempered steel pins, provided with
manual greaser.
The moving ends’ runways of the lifting system are contained in the base frame and in the
front platform and made of type "2" steel.
The relative sliding between scissors and runways takes place on steel wheels with bronze
bushings and tempered steel pins, provided with manual greaser.
2-3 REAR PLATFORM
The rear platform is made of type "2" steel from tab. UNI 7070. It is covered on the top by a
steel sheet platform, covered in turn by idle stainless steel ball bearings and mechanisms that
allow the load handling.
The platform is suitable for loading/unloading of all ULDs/PALLETs required by the AHM909
from the rear side and from both sides. It is equipped with mechanical locks with automatic
engagement/lowering.
A roller conveyor formed by hot galvanized metal rollers (excluding the external ones which
are coated with rubber) allows to carry out the longitudinal-load transfer.
Units made up of perimeter rubber rollers and pairs of rubber wheels allow to carry out the
transverse load and transfer. These units can be activated by actuating the control device.
A positioning guide rail system is provided for the correct containment and centering of pallets
and containers.
The equipment is provided with a specific electro-hydraulic system, combined with a manual
control for the lowering of the rear blocks, which allows the loading/unloading of ULDs to be
carried out at a height from the ground varying from 508 mm to 1600 mm.
2-3.1 REAR PLATFORM LIFT SYSTEM
The rear platform is provided with a single-acting scissor lift mechanism.
The lifting pantographs are built with type "2" steel from tab. UNI 7070 and are operated by 4
single-acting hydraulic cylinders. Each cylinder is provided with a hydraulically pilot-operated
control valve which ensures perfect functionality and tightness during the operating phase.
In the rear platform’s initial lifting section, 2 hydraulic multi-stage jacks are also activated with
the aim of improving the raising of the platform.
The scissor joints are made with bronze bushings and tempered steel pins, provided with
manual greaser.
Hence, the resulting lifting system features lifting cylinders contained between the scissors,
therefore it has no obstructions other than the overall size as such (with retracted platforms
when travelling).
• Hydraulic oil tank complete with filler and drain plug, with magnetic filter, level and
temperature sensor, discharge filters.
• Closed-circuit pump for vehicle traction.
• Piston pump for services.
• Power steering pump.
• Orbital hydraulic steering.
• A set of orbital hydraulic motors for entrainment units on platforms.
• 2 telescopic jacks to facilitate the initial lifting of the rear platform.
• 4 single-acting cylinders for rear platform lifting.
• 2 single-acting cylinders for front platform lifting.
• 6 cylinders for the stabilization of the equipment.
• 4 double-acting cylinders for front protrusions movement.
• 1 double-acting cylinder for driver's cab movement.
• A complete hydraulic installation with return filters, maximum pressure valves, electrical
distributors, control valves and everything else essential to the proper functioning of the
vehicle.
2-5 ELECTRICAL WIRING SYSTEMS
• Voltage: 24 V.
• 2 batteries 12 V - 120 A/h.
• Standard automotive systems, floodlights and end-outline marker lights.
2-6 BRAKING SYSTEM
• Hydraulic drum service brake acting on the front wheels.
• Hydraulic disengagement multi-disc parking brake acting on the front steering differential
axle.
2-7 SAFETY DEVICES
• DEVICES ENABLING TO DRIVE THE MACHINE
1. Command exchange selector located inside the ground panel, in the "IN-CAB COMMANDS"
position.
2. Parking brake disengaged.
3. Stabilizers fully retracted.
• DEVICES ENABLING TO THE DEPLOYMENT OF STABILIZERS
The command can be executed either from the maintenance ground panel or from the
driving dashboard on the platform, based on the position of the command exchange
selector.
1. Vehicle drive joystick in neutral "NEUTRAL" position.
2. Parking brake engaged.
3. Rear platform fully lowered.
• DEVICES ENABLING TO THE RETRACTION OF STABILIZERS
As to the relevant command, see above.
2. Parking brake engaged.
3. Rear platform fully lowered.
4. Front platform fully lowered.

• DEVICES ENABLING TO LIFT/LOWER THE REAR PLATFORM
As to the command, see above.
2. Stabilizers fully engaged.
3. A limit switch stops the lifting phase when the rear platform reaches the same level as the
front platform.
4. As for the lowering phase, a device prevents it when the load is positioned in an
intermediate position between the two platforms.
Furthermore, an intermittent acoustic warning is activated during the lowering phase of the
rear platform.
• RETARDER
It is positioned near the end of the stroke of the rear lifting platform in alignment with the front
platform.
• DEVICES ENABLING TO LIFTING/LOWERING AND TRANSVERSE LEVELLING OF THE

FRONT PLATFORM
The transverse levelling command can be transmitted only from the operating panel in the
driver's cab.
A limit switch stops the lowering phase when the front platform reaches the same level as the
rear platform.
Furthermore, an intermittent acoustic warning is activated during the lowering phase of the
front platform.
• ENABLING DEVICES:
Enabling to the horizontal load handling on platforms, only when the stabilizers are fully
extended.
For load handling on the rear platform: a specific device allows it only when the platform itself
is aligned with the front platform or at the lower limit position.
• SELF-LEVELLING DEVICE:
Front platform automatic self-levelling to the aircraft threshold level.
It is performed through a device connected to the aircraft that detects any equipment’s height
changes. The adjustment takes place by moving the front platform until the new threshold level
is reached. The command is activated from the cabin.
• LONGITUDINAL GUIDES FOR LOAD CONTAINMENT
On both platforms. The external guides on the rear platform can be folded down automatically.
• END-STROKE BLOCKS
Mechanical end-stroke blocks on the rear side and placed on the lifting platform. Activated as
soon as the platform leaves the lower limit position.
Hydraulic end-stroke blocks on the front side and placed on the lifting platform. Activated in
case the platforms are not aligned.
IN ADDITION:
1. Manual and electric auxiliary emergency pump.
2. Emergency stop buttons.
3. Mechanical stops to lock pantograph scissors for maintenance interventions.

TECHNICAL SPECIFICATIONS AVIOGEI
CHAPTER III
3 TECHNICAL SPECIFICATIONS
3-1 DESCRIPTION
3-2 OVERALL DIMENSIONS AND MAIN SPECIFICATIONS
3-3 DATA RECORDING
3-4 DIMENSIONAL DRAWING

3 TECHNICAL SPECIFICATIONS
3-1 DESCRIPTION
The CARGO LOADER AVIOGEI 2PU 2000 is the latest version produced by AVIOGEI in the
Cargo Loader sector.
The vehicle described in this manual allows the loading/unloading of the full range of ULDs
currently used by both commercial and military aviation with a load threshold between 1900
mm and 5500 mm above the ground.
The load carrying capacity is 20,000 kg on the rear platform and 7,500 kg on the front
platform. (The maximum allowable load-bearing values have been verified in compliance with
the Italian Legislative Decree n° 17 dated 27 January 2010).
The width of the rear-loading and front-loading platforms allows the transverse handling of
125-inch pallets.
It consists essentially of a base frame carrying two loading platforms, which can be raised by
means of simple scissor lifting devices.
The equipment is also provided with a safety belt compliant with EN360 and relative retaining
rope compliant with EN361 that the operator must use upon descent from the maneuvering
platform when the operating height is greater than 5 m.
3-2 OVERALL DIMENSIONS AND MAIN
SPECIFICATIONS
• Load capacity – Main platform (rear)

N° 2 ULD 88” x 108”
88” x 125”
96” x 125”
• Load capacity – Front platform (front)

N° 1 ULD 88” x 108”
88” x 125”
96” x 125”
• All standard containers foreseen in AHM 909
• Rear platform max. capacity: 20,000 kg
• Front platform max. capacity: 7,500 kg
• Operating platform max. capacity: N° 1 operator
• Rear platform operating range: from 508 mm to 5,500 mm
• Front platform operating range: from 1,900 to 5,500 mm
• Overall length: 13,000 mm
• Overall width: 4,850 mm
• Min. overall height: 4,050 mm
• Pitch: 6,400 mm
• Overall weight: 36,500 kg
• Front track: 2,150 mm
• Max. movement speed: 15 km/h
• ULD conveying speed: 18 m/l
• Rear platform lifting speed: loaded: 57”

unloaded: 55”
• Max. allowed inclination: 2°
• Max. allowed wind speed: 22.6 m/s
3-3 DATA RECORDING
FUNCTION OBSERVATION HYDR. PRES. TIME
(Bar) (Sec)
HIGH PRESSURE CONTROL UNIT 78-X1 250
LOW PRESSURE CONTROL UNIT 77-A 180
HIGH-FLOW PRESSURE PRESSURE RELIEF 105 8
VALVE
LOW-FLOW PRESSURE PRESSURE RELIEF 105 16
VALVE
PILOT PRESSURE – MAIN PUMP PRESSURE RELIEF 30 50
VALVE
PILOT PRESSURE CONTROL UNIT 87.M2 21
72-M1 23
REAR PLATFORM LIFTING UNLOADED Y8 71 C 120 50”
LOADED Y8 71 C 270 52”

20,000 KG
FRONT PLATFORM LIFTING UNLOADED Y11 71B 125 54”
FRONT/CENTRAL/REAR 71A-M5 40
STABILIZERS DEPLOYMENT Y7 17”
M6 130
STABILIZERS RETRACTION Y6 71A-M4 180 15”
FAST REAR PLATFORM LOWERING UNLOADED Y9 71C 50 50”
LOADED 48”
20,000 KG
SLOW REAR PLATFORM UNLOADED Y9 71C 50 54”
LOWERING LOADED Y10 86 52”
15,000 KG
FRONT PLATFORM LOWERING Y12 71B 50 55”
REAR PLAT. LONGITUDINAL UNLOADED Y30 62B 70
TRANSFER LOADED Y31 175
20,000 KG
FRONT PLAT. LONGITUDINAL UNLOADED Y15 57A 70
TRANSFER LOADED Y16 175
Y27 65A 90
UNLOADED Y28
REAR PLAT. TRANSVERSE Y29 66A
TRANSFER
Y30 65B 175
LOADED Y31
Y32 66B
FRONT PLAT. TRANSVERSE UNLOADED Y17 57B 90
TRANSFER Y18
LOADED Y19 58 175
TRAVEL PRESSURE 11-M13 410max
EQUIPMENT TRANSFER MAX.
SPEED 15 km/h
PNEUMATIC SYSTEM MAX. 7,5
PRESSURE
DRIVE SAFETY PRESSURE SWITCH 15 6,5
CALIBRATION
EMERGENCY 106 140
HYDRAULIC STEERING SYSTEM M15 175
FRONT PLATFORM MAX. LIFT 75
VALVE (LEFT)
REAR PLATFORM LOAD ROTATION 180
REDUCING VALVE FOR STARTER 72 170
PISTONS
HEAT ENGINE A:
1300 IDLE RPM

2200 RPM WITH AUTOMATIC ACCELERATOR
3-4 DIMENSIONAL DRAWING
OPERATION AVIOGEI
CHAPTER IV
4 OPERATION
4-1 IGNITION PANEL
4-2 INSTRUMENT PANEL
4-3 OPERATING PANEL
4-4 MAINTENANCE GROUND CONTROL PANEL
4-5 OPERATING INSTRUCTIONS
4-6 EMERGENCY PLATES

OPERATION AVIOGEI
4 OPERATION
The operation of the equipment is allowed by activating the relevant
commands:
• Instrument panel “Fully functional”.
• Operating panel.
• Ground control panel “Partially functional due to maintenance”.

OPERATION AVIOGEI
4-1 IGNITION PANEL
4-1.1 DESCRIPTION OF COMPONENTS

1. Ignition key
2. Generator indicator light
3. Heat engine oil indicator light
4. Glow plugs indicator light

OPERATION AVIOGEI
4-2 INSTRUMENT PANEL
Drawing N° 1200-Q-0-0-1
OPERATION AVIOGEI
1. Hour meter
2. Fuel level
3. Heat engine temperature
4. Emergency push button
5. Stabilizers switch
6. Cabin movement switch (optional)
7. Front platform switch
8. Protrusions command switch
9. Heat engine temperature warning light
10. Parking brake warning light
11. “OK” indicator light to rear platform movement
12. “OK” indicator light to vehicle motion
13. Start switch
14. Vehicle drive joystick
15. Belt break switch
16. Direction indicator lights signal
17. Main beam warning light
18. Position lights warning light
19. Brake failure warning light
20. Photoelectric sensors exclusion switch
21. Emergency pump switch
22. Floodlights switch
23. Pilot pressure filter clogging indicator
24. Brake air filter clogging indicator
25. Brake filter warning light

OPERATION AVIOGEI
26. Generator warning light
27. Oil pressure warning light
28. Glow plugs warning light
29. Flashing light switch
30. Selector for protrusions programming (optional)

OPERATION AVIOGEI
4-3 OPERATING PANEL
OPERATION AVIOGEI
1. Joystick for front platform lateral inclination
2. Joystick for longitudinal/transverse movement of front platform’s roller

conveyor
3. Joystick for front platform lifting/lowering
4. Joystick for longitudinal/transverse movement of rear platform’s roller

conveyor
5. Joystick for rear platform lifting/lowering
6. Joystick for longitudinal/transverse movement of rear platform’s rear roller

conveyor
7. Emergency push button
8. Joystick for longitudinal/transverse simultaneous movement of both

platforms
4-4 MAINTENANCE GROUND CONTROL PANEL

OPERATION AVIOGEI
1. Emergency button
2. Emergency electric pump switch
3. Stabilizers engagement/disengagement switch
4. Front platform lifting/lowering switch
5. Rear platform lifting/lowering switch
6. Ground control panel/In-cab controls switch

OPERATION AVIOGEI
4-5 OPERATING INSTRUCTIONS
4-5.1 PRELIMINARY CHECKS
1. Fuel level
2. Hydraulic oil level
3. Battery electrolyte level
4. Engine oil level

OPERATION AVIOGEI
4-5.2 VEHICLE START-UP PROCEDURE
Before starting the engine, make sure that no one is too close to the engine or
the machine and proceed as follows:
1. Make sure that the drive joystick “14” is in the neutral position.
2. Make sure that the parking brake is engaged.
3. Turn the ignition key "1" clockwise bringing it to position 1 where three
control lights will light up: generator light "2", oil pressure light "3" and glow
plugs light "4".
4. Wait for the glow plug light "4" to go off and turn the key to position 2 until
the machine starts.
5. After starting, leave the key in position 1 where lights "1" and "2" turn off.
 NOTE
The machine can also be turned on from the dashboard using the switch
"13", taking care to leave the ignition key "1" in position 1.
 ATTENTION
The first daily start-up procedure shall be carried out from the ground
control panel.
Each attempt shall not last more than 15 seconds. After each attempt,
wait a few moments before repeating the procedure.
After the first daily start-up procedure, and before activating all the
services, it is necessary to bring the engine to its operating temperature
by keeping it running for at least 4/5 minutes, 15 minutes at
temperatures below 0˚ C.
4-5.3 ACCESS TO THE DRIVER CAB’S
In order to access the driver's cab, use the access ladder. For heights greater
than 5 meters, use the safety harness and the supplied fall arrest device,
positioned near the access ladder.
OPERATION AVIOGEI
4-5.4 DRIVE
From the maintenance ground control panel, make sure that the command
switch selector "6" is positioned on "IN-CAB COMMANDS, as it is essential to
carry out any operation from the instrument and the operating panels, which
we will omit to repeat for all the above operations.
Once this is done, please follow the steps below:
1. Make sure that the rear platform is fully lowered.

2. Make sure that the stabilizers are fully retracted.
3. Make sure that the parking brake is disengaged.
4. Make sure that the driver's cab is fully retracted.
5. Make sure that the Drive OK “12” warning light is on.
6. Operate the drive joystick “14” in the desired direction.
 ATTENTION
Driving is only allowed with the platforms completely unloaded.
 NOTE
Even partial release of a stabilizer leads to driving consent removal.
 NOTE
Upon reverse driving, an intermitter buzzer will be activated.

OPERATION AVIOGEI
4-5.5 U-TURN
In order to reverse direction, the vehicle must first be stopped completely,

then move the drive joystick to the opposite position while keeping the engine
idling.
 ATTENTION
Reversal of direction when the machine is being driven can cause

damage to the hydraulic and mechanical parts of the transmission.
4-5.6 STABILISERS
A. STABILISERS ENGAGEMENT
In order to engage the stabilizers, please follow the steps below:
4. Operate the stabilizers’ switch "5" until they are completely removed,
signaled by the PLATFORMS OK light "11".
B. STABILIZERS DISENGAGEMENT
In order to disengage the stabilizers, please follow the steps below:
3. Make sure that the front platform is fully lowered.
5. Operate the stabilizers’ switch "5" until they are completely retracted,
signaled by the OK DRIVE light "12".
OPERATION AVIOGEI
 ATTENTION
The engagement and disengagement of the stabilizers is only allowed

when the platforms are completely unloaded.
 NOTE
The engagement and disengagement of the stabilizers can also be

performed from the maintenance ground control panel by activating the
switch "3" and by positioning the command exchange selector "6" in
the " GROUND CONTROL PANEL" position.
4-5.7 FRONT PLATFORM
A. FRONT PLATFORM LIFTING
In order to lift the front platform, please follow the steps below:
1. Operate the front platform lifting switch "7" of the instrument panel or
the joystick "3" of the operating panel up to the desired height.
OPERATION AVIOGEI
B. FRONT PLATFORM LOWERING
In order to lower the front platform, please follow the steps below:
1. Operate the front platform lifting switch "7" of the instrument panel or the
joystick "3" of the operating panel up to the desired height.
 ATTENTION
The front platform lifting and lowering operation is allowed only when
the platform is completely unloaded.
 NOTE
During the platform lowering phase, an intermittent acoustic signal and

a flashing light are activated.
 NOTE
The front platform lowering will stop automatically when the level of the
rear platform is reached.
 NOTE
The platform lifting and lowering operation can also be performed from
the maintenance ground control panel by activating the switch "4" and
by positioning the command exchange selector "6" in the " GROUND
CONTROL PANEL" position.
OPERATION AVIOGEI
C. PLATFORM TRANSVERSE INCLINATION
In order to carry out the transverse inclination of the front platform, please
follow the steps below:
2. Operate the joystick “1” of the operating panel up to the desired inclination.
 NOTE
The transversal inclination of the platform will stop automatically when

a limit height limited to ± 2 ° is reached.
OPERATION AVIOGEI
4-5.8 REAR PLATFORM
A. REAR PLATFORM LIFTING
In order to lift the rear platform, please follow the steps below:
3. Make sure that the stabilizers are engaged (indicator light “11” on).
4. Make sure that the load (if any) is placed inside the safety load blocks.
5. Operate the rear platform lifting joystick “5” of the operating panel up to the
desired height.
B. REAR PLATFORM LOWERING
In order to perform the rear platform lowering operation, please follow the
steps below:
4. Make sure that the load (if any) is placed inside the safety load blocks.
5. Operate the rear platform lifting joystick “5” of the operating panel up to the
desired height.
OPERATION AVIOGEI
 NOTE
During the platform lowering phase, an intermittent acoustic signal and

a flashing light are activated.
 NOTE
The rear platform lifting will stop automatically when the level of the
front platform is reached.
 NOTE
The platform lifting and lowering operation can also be performed from
the maintenance ground control panel by activating the switch "5" and
by positioning the command exchange selector "6" in the "GROUND
CONTROL PANEL" position.
OPERATION AVIOGEI
4-5.9 HANDLING OF LOADS ON PLATFORMS
A. FRONT PLATFORM TRANSVERSE AND LONGITUDINAL MOVEMENT
In order to handle loads on the front platform, please follow the steps below:
4. Operate the belt conveyor joystick “2” in the desired direction.
OPERATION AVIOGEI
B. REAR PLATFORM LONGITUDINAL AND TRANSVERSE MOVEMENT
(REAR SIDE)
The rear platform roller conveyor consists of two "semi roller conveyors", one
in the front and one in the rear side, provided with separate movement
controls to allow autonomous handling of pallets.
In order to handle loads on the rear side of the rear platform, please follow the
steps below:
4. Make sure that the platform is fully lowered or aligned with the front
platform.
OPERATION AVIOGEI
C. REAR PLATFORM TRANSVERSE AND LONGITUDINAL MOVEMENT
(FRONT SIDE)
In order to handle loads on the front side of the rear platform, please follow
the steps below:
4. Make sure that the platform is fully lowered or aligned with the front
platform.
OPERATION AVIOGEI
D. SIMULTANEOUS LONGITUDINAL MOVEMENT OF BOTH PLATFORMS
In order to handle loads on both platforms, please follow the steps below:
4. Make sure that the platforms are aligned to the same loading surface
indicated by the automatic retraction of the two load blocks.
5. Operate the belt conveyor joystick “8” to handle loads from one platform to
another.
E. ROTATION OF LOADS
In order to perform the rotation of loads on the rear platform, please follow the
steps below:
1. Make sure that the drive joystick “17” is in neutral position.

4. Center the load between the two "semi-roller conveyors" without exceeding
the red delimitation strip.
5. Make sure that the retractable load guides are actually retracted.
6. Remove the side load guides to allow the load rotation.
7. Operate the two joysticks "2" and "4" in the transverse direction (one
opposite to the other) thus performing the load rotation.
OPERATION AVIOGEI
4-5.10 MOVEMENT OF FRONT PLATFORM PROTRUSIONS
In order to move the front platform protrusions, please follow the steps below:
1. Make sure that the drive joystick “14” is in neutral position.

3. Make sure that the stabilizers are disengaged (indicator light “11” on).
4. Select the width of the protrusions based on the platform loading surface
(96" or 125") by operating the selector "30".
5. Operate the protrusions switch “8” in order to lift them.
6. In order to retract the protrusions, return the selector “30” to the central
position.
OPERATION AVIOGEI
4-5.11 DRIVER’S CAB TRANSVERSE MOVEMENT
In order to perform the transverse movement of the driver’s cab, please follow
the steps below:
1. Operate the cabin movement switch “6” in the desired direction.
 ATTENTION
The movement of the cabin performed towards the inside of the platform
will be stopped immediately if it hits any object or load.
OPERATION AVIOGEI
4-6 EMERGENCY PLATES
EMERGENCY OPERATION FROM THE ELECTRO VALVES BOX
REAR PLATFORM LOWERING
1) From the electro valves box, activate the control of the electrodistributor “71C7Y9” through the
supplied hand wheel, operate the electro pump push button “29” or the hand pump “6” until the
platform is fully lowered.
2) Once the operation is complete, put the hand wheel on its initial condition.
FRONT PLATFORM LOWERING
1) From the electro valves box, activate the control of the electrodistributor “71B/Y12” through the
platform is fully lowered.
OPERATION AVIOGEI
STABILIZERS RETRACTION
1) From the electro valves box, close the valve “109”

2) From the electro valves box, activate the control of the electrodistributor “71A/Y7” through the
stabilizers are fully retracted.
PARKING BRAKE DISENGAGEMENT
1) Supply the pneumatic system for disengaging the parking brake from the outside using the quick
coupling positioned under the manual pump.
VEHICLE REMOVAL
1) From the engine compartment, open the valve “DRIVE BYPASS”.

2) Remove the vehicle.
3) Once the operation is complete, close the valve “DRIVE BYPASS”.
WARNING
Before removing the vehicle, make sure that the platforms are lowered, the stabilizers are retracted, and the parking
brake is disengaged.
CHAPTER V
5 HYDRAULIC SYSTEM & BRAKES
5-2 BRAKING SYSTEM

5-2 BRAKING SYSTEM
Drawing N° 1200/C/000.000.003
CHAPTER VI
6 SPARE PARTS

6-1.1 DESCRIPTION OF COMPONENTS & DETAIL NUMBERS
Ref. Description Detail N° Quantity

1 Double gear pump 2PB19/2PB8,3 S P28-P1 1
(HPLP B220 SMLE 5E)
2 Brass ball valve DIAM. 1" 3
3 Brass ball valve DIAM. 3/4" 1
4 Brass ball valve DIAM. 1"1/2" 1
5 Brass ball valve DIAM. 2"1/2" 1
6 Suction filter AMF60E112S1/1ECD1 1
6.A Spare filter cartridge 1ECD1 2
7 Tank bleeder vent FAS 4733.4 1
8 Filler cap TM 478 G78 1
9 Visual level indicator LVA30 1
10 Return filter RFM150MS1B810/YO 1
11 Pressure filter MHT151FV101HB3 1
11.A Spare filter cartridge CH151FV11 1
12 Return filter RFM25MS1B510/YO 1
13 BREVINI joint coupling ALREADY INDICATED, 1
POS. 11.2
14 Displacement pump A 1
4VG90DA1D7/32L-
NZF02F001SP
15 Axial piston pump A7VO80LRH1/63L-NZB01 1
16 Displacement hydraulic A2FM160/61W-VZB100 1
motor
17 Hydraulic bypass valve FT221/1-12 1
18 Throttle and modular Z2FS62-4X/2QV 1

non-return valve
19 Throttle valve FT257/2-14 1
20 Electrodistributor 4WE6J5X/AG24NZ5L 1
21 Base plate G342/1 1
22 Check valve FT260/6-38 1
28 Emergency hand pump PM 50 - COD.1060000176 1
28.1 Hand pump control lever COD.1060000176 1
29 Emergency electric pump ELP CCV24V/3000W- 1
2P6.2 COD.147.470.00627
30 Pressure relief valve VP7/1FXVM7 1
31 Throttle and modular FT257/5-14 2
non-return valve
34 Front and rear axle OVC SEC 3802 2+2
cylinders block valve
35 Rotary flow divider HDD30.43-CF+C3030 1
36 Hydraulic pilot-operated SL 10 GA1-3X 2
check valve (breakaway
cylinder)
37 Drilled block DRAWING. PM 0207 2
38 Hydraulic pilot-operated SL 10PA4-4X 2
check valve
39 Pressure relief valve DBDS6K1X/400 2
40 Braking valve SB29C-50/100 2
41 Check valve RC2 2
42 Drilled block DRAWING PM 0249 4
43 Check and release valve SL 10PA4-4X 4
44 Pressure relief valve DBDS6K1X/400 4
45 Braking valve SB29C-50/100 4
46 Right protrusion cylinder 1293/C.12 DX 2
47 Left protrusion cylinder 1293/C.12 SX 2
48 Roller conveyors EPRM 315 C25 9
hydraulic motor
49 Transverse wheel units EPRM 315 C25 12
hydraulic motor
50 Roller conveyors bypass FT221/1-14 3
valve
51 Hydraulic steering hose C 150 - COD.905400020 1
52 Hydraulic steering system STA ON 200-G4 1
53 Double-spoke steering Ø360 mm 1
wheel
54 Unit drawing 1795 - pos. FROM POS. 55 TO 58 1
4
55 Pressure-compensated 2FRM6B36-2X/10QM 1
control valve
56 Special plate DRAWING PM 0251 1
57 Electrodistributor 4WE6E5X/AG24NZ5L 2
58 Electrodistributor 4WE6D5X/AG24NZ5L 1
2
control valve
3
flow control valve
68 Sequence valve VSQ40 3802 2
69 Stabilizers cylinders block OVC SEC 3802 6
valve
70 Unit drawing PM 0453 FROM POS. 70 TO 92 1
71 Electrodistributor 4WE6J5X/AG24NZ5L -
72 Pressure reducing valve ZDR6DP2-4X/75YM -
73 Proportional valve 4WRH16W150-3XM -
74 Cover LFA25-D8-6X/F
75 Logic element LC25DR80D6X
76 Electrodistributor 4WE6H5X/AG24NZ5L
77 Cover LFA25DBU2A2-6X/420
78 Logic element LC25DB20D6X
79 Position not used -
80 Pressure reducing valve DR10DP2-3X/210Y
81 Pressure-compensated 2FRM10-3X/50L
flow control valve
82 Control valve FG32C10-2X
83 Check valve M-SR30KE05-1X
86 Electrodistributor 4WE6D5X/AG24NZ5L
87 Pressure relief valve ZDB6VB2-3X/50V
88 Pressure reducing valve DR10DP2-3X/150Y
89 Electrodistributor 4WE6J5X/AG24NZ5L
90 Pressure nipple K1AB20-11

91 Nozzle -
92 Light plugs for Z5L/G24
electrodistributors
93 Front platform lifting 1195/C.1 2
cylinder
94 Rear platform lifting 1195/C.2 4
cylinder
95 Rear platform breakaway 8840 2
cylinder
96 Front stabilizer cylinder 1293/C/005.000.000 2
97 Central stabilizer cylinder 1239/C/005.000.000 2
98 Rear stabilizer cylinder 1293/C.6.93 2
99 Steering cylinder Supplied with differential 1
axle
100 Rear axle tilt cylinder 1195/C.8 2
101 Transverse load wheel tilt 1195/C.9 5
cylinder
101.A Transverse load wheel tilt 1195/C.7 7
cylinder
102 Changeover valve RS 417 1
103 Sequence cylinder 1375 2
104 Stabilizer plate Drawing N° 1195/C.5.7.93 6
105 Pump max high/low-flow Z2DB 6 VC2-4X/50V 1
control valve
106 Max emergency valve VP72FX 1
107 Front axle tilt cylinder 1195/C.10 2
108 Front/Rear axle FT221/1-14 1
emergency valve
108.A Parking brake emergency FT221/1-14 1
valve
109 Front/Rear axle FT221/1-14 1
emergency valve
109.A Front platform max. VP72FX 1
levelling valve
109.B Front platform levelling FT 257/5-12 1
throttle and non-return
valve
109.C Stabilizers max. retraction VP72FX 1
valve
123 Rear platform breakaway DR 10 G5-5X/200YM 1
cylinder pressure
reducing valve
124 Breakaway cylinder check FT 260/6-12 1
valve reducing valve
160 Hydraulic motor radiator HPLMA205DMLG4G4BST 1
fan
161 Flow control valve RFA-VLP 1012 1
162 Hydraulic pump radiator HPLPA206SSVG4G4BST 1
fan
BRAKE SYSTEM
135 Pressure filter MHT 152-RD-1C1-HB3+ 1
CH152RD11
135.1 Spare filter cartridge CH152RD11 1
136 S6 vertical brake pedal COD.123046/G 1
137 Batteries charge pressure COD.MO15957/120 - 120 1
switch BAR
138 Battery COD. MO15558 (0,75) 1

CALIBRATED AT 60 BAR
139 Battery COD. MO15558 (0,75) 1
CALIBRATED AT 60 BAR
140 Stop pressure switch COD.MO15298 2-10 N.A. 1
141 Disc parking brake DROMOS DIFFERENTIAL 1
AXLE INCL.
142 Parking brake pressure COD.MO15200/25 – 1
switch CALIBRATED AT 25 BAR
143 Negative proportional COD.202412/35 1
valve
FRONT/REAR PLATFORM
INTERMEDIATE
HYDRAULIC UNIT
148 Front platform rear 1022.97/C.61.1 1
cylinders
151 Rear platform front 1022.97/C.61.1 1
cylinders
FRONT PLATFORM
PROTRUSIONS MOVEMENT
110 Ext. cylinders 4WE6J5X/AG24NZ5L 1
electrodistributor
111 Int. cylinders 4WE6J5X/AG24NZ5L 1
electrodistributor
113 Check valve VSO-DE-L-14 4
COD.055303370901000
114 Right/Left protrusions See section 6-18 4
cylinder
DRIVER CAB’S MOVEMENT
121 Cylinder See section 6-17 1
122 Check valve VSO-DE-L-14 1
COD.055303370901000
SPARE PARTS AVIOGEI
6-4 FRONT STABILIZER CYLINDER
Drawing N° 1293/C/005.000.00DX-SX
SPARE PARTS AVIOGEI
6-4.1 DESCRIPTION OF COMPONENTS AND DETAIL NUMBERS
Ref. Detail N° Description Quantity

1 275236 1 BALSELE 1
3 OVC60-C OVERCENTER VALVE 1
4 WRM 236267 SLUDGE SCRAPER 1
5 1293/C/005.001.00DX- JACKET 1
SX
6 OR 223 O-RING 1
7 1204/C.3.4 BODY SEAL GROOVE 1
8 1204/C.3.3.93 CAP 1
9 1204/C.3.5 HEAD SEAL GROOVE 1
10 OR 241 O-RING 1
11 1293/C/005.002.000 ROD 1
12 1293/C/005.004.000 PLATE 1
13 OR 340 O-RING 1
14 D11W374295-1 BALSELE 1
15 UNI 5927 - M8 X 20 HEXAGON SOCKET 1
HEAD CAP SCREW
16 1293/C/005.003.000 SPACER 1
SPARE PARTS AVIOGEI
6-5 INTERMEDIATE STABILIZER CYLINDER
Drawing. N° 1293/C/005.000.00DX-SX
SPARE PARTS AVIOGEI

1 275236 1 BALSELE 1
5 1293/C/005.001.00DX- JACKET 1
SX
6 OR 223 O-RING 1
8 1204/C.3.3.93 CAP 1
10 OR 241 O-RING 1
11 1293/C/005.002.000 ROD 1
12 1293/C/005.004.000 PLATE 1
13 OR 340 O-RING 1
14 D11W374295-1 BALSELE 1
15 UNI 5927 - M8 X 20 HEXAGON SOCKET 1
HEAD CAP SCREW
16 1293/C/005.003.000 SPACER 1
SPARE PARTS AVIOGEI
6-6 REAR STABILIZER CYLINDER
Drawing N° 1293/C/006.000.00DX-SX
SPARE PARTS AVIOGEI

1 275236 1 BALSELE 1
2 1293/C/006.005.000 SPACER 1
5 1293/C/005.001.00DX- JACKET 1
SX
6 OR 223 O-RING 1
8 1204/C.3.3.93 CAP 1
10 OR 241 O-RING 1
11 1293/C/006.002.000 ROD 1
12 1293/C/005.004.000 PLATE 1
14 OR 340 O-RING 1
15 D11W374295-1 BALSELE 1
16 UNI 5927 - M8 X 20 HEXAGON SOCKET HEAD 1
CAP SCREW
SPARE PARTS AVIOGEI
6-7 FRONT AXLE TILT CYLINDER
Drawing N° 1195/C.10
SPARE PARTS AVIOGEI

1 1195/C.10.1 JACKET 1
2 1195/C.10.2 ROD 1
3 1195/C.10.3 CAP 1
6 1195/C.10.6 SPACER 1
7 1195/C.10.92.9 BUSHING 1
8 D11W472393 SEAL 1
9 B 377314 SEAL 1
10 WRM.314362 SCRAPER 1
11 OR 623 O-RING 1
12 OR 229 O-RING 1
1195/C.110.K SEALS KIT 1
SPARE PARTS AVIOGEI
6-8 REAR AXLE TILT CYLINDER
SPARE PARTS AVIOGEI

1 1195/C.8.1 JACKET 1
2 1195/C.8.2 ROD 1
3 1195/C.8.3 CAP 1
6 1195/A.6.9 FRONT JOINT BEARING 1
7 GE 40 ES – 2RS RADIAL SPHERICAL 1
BEARING
8 Ø 62 UNI 7437-75 CIRCLIP 1
9 B 374295 SEAL 1
10 E/DWR 95 GUIDE RING 1
11 I/DWR 60 SEAL RING 1
12 WRM 236267 SCRAPER 1
13 2901 – 3/8” SILENCER 1
14 OR 223 SEAL 1
15 M8X15 UNI 5927-67 GRUB SCREW 1
SPARE PARTS AVIOGEI
6-9 FRONT PLATFORM LIFTING CYLINDER
SPARE PARTS AVIOGEI

1 189.09.0.80 JACKET 1
2 189.09.0.81 ROD 1
3 189.09.0.70 CAP 1
4 50.10.24.3302 GUIDE RING 1
5 50.00.01.1514 ANTI-EXTRUSION RING 1
6 50.00.02.1515 O-RING 1
7 50.25.05.2901 SEAL 2
8 50.10.22.2901 DUST SCRAPER 1
9 51.26.01.1702 RADIAL SPHERICAL 2
BEARING
1293/C.2.K SEAL KIT 1
SPARE PARTS AVIOGEI
6-10 REAR PLATFORM LIFTING CYLINDER
SPARE PARTS AVIOGEI

1 189.09.0.80 JACKET 1
2 189.09.0.81 ROD 1
3 189.09.0.70 CAP 1
4 50.10.24.3302 GUIDE RING 1
5 50.00.01.1514 ANTI-EXTRUSION RING 1
6 50.00.02.1515 O-RING 1
7 50.25.05.2901 SEAL 2
8 50.10.22.2901 DUST SCRAPER 1
9 51.26.01.1702 SPHERICAL JOINT 2
1293/C.2.K SEAL KIT 1
SPARE PARTS AVIOGEI
6-11 SAFETY DEVICES CYLINDER
Drawing N° 1375 UNI
SPARE PARTS AVIOGEI

1 1375/1 JACKET 1
2 M12X1,5 NUT 1
3 TPL 118078 SEAL 1
4 OR 014 O-RING 1
5 CT 000300 PISTON 1
6 1375/2 ROD 1
7 OR 120 O-RING 1
8 B 094063/A SEAL 1
9 WRM 062087 SCRAPER 1
10 CG040030 GUIDE HEAD 1
11 1375/3 CONTROL PIN 1
1375/K SEALS KIT 1
SPARE PARTS AVIOGEI
6-12 FRONT WHEELS TILT CYLINDER
SPARE PARTS AVIOGEI

1 658 JACKET 1
2 609 ROD 1
3 133 CAP 1
4 153 HEAD 1
5 -------------- SPACER 1
6 221 SELF-LOCKING NUT 1
7 093 BARREL 2
9 2000000 FIXED JOINT BEARING 2
10 408 SEAL 1
11 OR117 O-RING 1
12 OR 826 O-RING 1
13 408 SEAL 1
14 409 SCRAPER 1
15 OR 132 O-RING 1
658/k SEALS KIT 1
SPARE PARTS AVIOGEI
6-13 REAR WHEELS TILT CYLINDER
SPARE PARTS AVIOGEI

1 658 JACKET 1
2 609 ROD 1
3 133 CAP 1
4 153 HEAD 1
5 -------------- SPACER 1
7 093 BARREL 2
9 2000000 FIXED JOINT BEARING 2
10 408 SEAL 1
11 OR117 O-RING 1
12 OR 826 O-RING 1
13 408 SEAL 1
14 409 SCRAPER 1
15 OR 132 O-RING 1
658/k SEALS KIT 1
SPARE PARTS AVIOGEI
6-14 BREAKAWAY CYLINDER
Drawing N° 8840
SPARE PARTS AVIOGEI

1 COD. 67.61.5 SCRAPER (SECOND 1
COMPONENT)
2 COD. 69.61.8 SEAL (SECOND 1
COMPONENT)
3 COD. 82.76.5 SCRAPER (THIRD 1
COMPONENT)
4 COD. 84.76.8 SEAL (THIRD 1
COMPONENT)
5 COD. 97.91.5 SCRAPER (FOURTH 1
COMPONENT)
6 COD. 99.91.8 SEAL (FOURTH 1
COMPONENT)
7 COD. 113.107.5 SCRAPER (FIFTH 1
COMPONENT)
8 COD. 132.126.5 OUTER JACKET SCRAPER 1
9 COD. 115.107.8 SEAL (FIFTH 1
COMPONENT)
10 COD. 134.126.8 OUTER JACKET SEAL 1
11 Ø 91 THIRD COMPONENT 1
12 Ø 76 SECOND COMPONENT 1
13 Ø 61 FIRST COMPONENT 1
14 Ø 107 FOURTH COMPONENT 1
15 Ø 126 FIFTH COMPONENT 1
16 Ø 156 OUTER JACKET 1
17 -------- CIRCLIP (SECOND 1
COMPONENT)
18 -------- CIRCLIP (THIRD 1
COMPONENT)
19 -------- CIRCLIP (FOURTH 1
COMPONENT)
20 -------- CIRCLIP (FIFTH 1
COMPONENT)
21 OR 867 CASE BACK SEAL RING 1
(OUTER JACKET)
22 -------- CASE BACK (OUTER 1
JACKET)
658/K SEALS KIT 1
SPARE PARTS AVIOGEI
6-15 CABIN MOVEMENT CYLINDER
SPARE PARTS AVIOGEI

1 658 JACKET 1
2 609 ROD 1
3 133 CAP 1
4 153 HEAD 1
5 ----- SPACER 1
7 093 BARREL 2
8 252 JOINT BEARING 2
9 408 --- TPM 196133 SEAL 1
10 OR 117 SEAL 1
11 OR 826 SEAL 1
12 408 --- TSE 137098 SEAL 1
13 408 --- GHM 098129 SCRAPER 1
14 OR 132 SEAL 1
SPARE PARTS AVIOGEI
6-16 PROTRUSIONS TILT CYLINDER
SPARE PARTS AVIOGEI

1 658 JACKET 1
2 609 ROD 1
3 133 CAP 1
4 153 HEAD 1
5 ----- SPACER 1
7 093 BARREL 2
8 252 JOINT BEARING 1
9 COF 2000000 FIXED JOINT BEARING 1
10 408 --- TPM 196133 SEAL 1
11 OR 117 SEAL 1
12 OR 826 SEAL 1
13 408 --- TSE 137098 SEAL 1
14 408 --- GHM 098129 SCRAPER 1
15 OR 132 SEAL 1
SPARE PARTS AVIOGEI
6-17 REAR PLATFORM ROLLER CONVEYOR
Drawing N° 1362/R
SPARE PARTS AVIOGEI

1 MPR15-15R 76J IDLER ROLLERS 72
2 1195/A.4.M.S.92 METAL ROLLER 13
3 UCP/205SY 25 TF FLANGED HOUSING 26
UNIT
4 1195/A.5.5.1.92 PINION (LONGL. 24
ROLLERS -
TRANSMISSION)
Z=12-¾” X 7/16”
5 OMR 315 HYDRAULIC MOTOR 1
6 1195/A5.5. PINION (LONGL. 2
ROLLERS - MOTORS)
REV.91 Z=12-¾” X 7/16”
7 UCF 205 FLANGED HOUSING 2
UNIT
8 Drawing 1362/B.1.1 RUBBER ROLLERS 2
9 ASA 60 CHAIN (LONGL. ROLLERS 20 M
-TRANSMISSION)
14 UNI 6604 - 69 LUG A 8 X 7 X 63 28
SPARE PARTS AVIOGEI
6-18 FRONT PLATFORM ROLLER CONVEYOR
Drawing N° 1362/R
SPARE PARTS AVIOGEI

1 MPR15-15R 76J IDLER ROLLERS 13
2 1195/A.4.M.G.S.92 RUBBER ROLLERS 1
(LONGL.)
3 Drawing PALLET-ENVELOPING 2
1353.95/A.3.15.3. ROLLERS
4 Drawing 1362/C.4 CYLINDER FOR 1
PALLET ROTATION
5 SPR 45 BALLS 60
6 1195/A.4.M.S.92 METAL ROLLERS 10
(LONGL.)
7 OMR315 HYDRAULIC MOTOR 1
8 Drawing PINION ON RUBBER 2
1353.95/A.3.15.4 ROLLER Z 12 ¾
9 Drawing PINION ON ROTATION 2
1006.95/B.2.1.4 ROLLER MOTOR
10 Drawing LONGL. ROLLERS 1
.1195/A.5.5.rev.91 MOTOR PINION
11 Drawing PINION ON LONGL. 11
.1195/A.5.5.1.92 ROLLERS
ASA 60 CHAIN 12 M
SPARE PARTS AVIOGEI
6-19 TRANSVERSE DRIVE WHEEL UNIT
Drawing N° 1195/B
SPARE PARTS AVIOGEI
SPARE PARTS AVIOGEI
1 1195/B.1.1 Support for transverse 1
drive wheels
2 1195/B.1.2 Right rocker arm 1
3 1195/B.1.3 Left rocker arm 1
4 Ø55 UNI 7438-75 Circlip 4
5 1195/B.1.4 Drive wheel axle 2
6 1195/B.1.5 Drive wheel axle 2
7 1195/B.1.6 Tilt rod axle 2
8 1195/B.1.7 Rear bearing tilt 1
cylinder axle
9 1195/B.1.8 Front bearing tilt 1
cylinder axle
10 1195/B.1.9 Wheel pinion 2
11 1195/B.1.10 Motor pinion 1
12 1195/B.1.11 Hydraulic motor mount 1
13 35/45X40-55X5 Sintered bushing 4
14 30/40X30-50X5 Sintered bushing 2
15 63006-2RS1 Ball bearing 4
16 UCFC 205 Flanged housing unit 1
17 T.C.E.I. M10X30 UNI Screw 4
5932
18 UNI 1751 Elastic washer 2
19 T.E. M12X30 UNI 5737- Screw 2
65
21 T.S.E.I. M10X35 UNI Screw 4
5933
22 UNI 5588-65 Hex nut 4
24 T.E. M12X30 UNI 5737-65 Screw 8
25 Ø12.5 UNI 1751 Elastic washer 8
26 T.E. M12X50 UNI 5737- Screw 2
65
27 T.E. M10X30 UNI 5737- Screw 4
65
29 UNI 6604-69 Lug 1
30 UNI 6604-69 Lug 2
31 Ø35 UNI 7435-75 Circlip 43
32 UNI 6604-69 Lug 2
33 UNI 5928-67 Grub screw 3
34 UNI 5588-65 Hex nut 2
35 ASA 60 Roller chain 2X1.1m
36 1195/C.9 Wheels tilt cylinder 1
37 OMR 200 Transverse wheels 1
hydraulic motor
38 1195/B.1.13 Rocker arms flush 2
bracket
39 1195/B.1.15.92 Cylinder front bearing 1
SPARE PARTS AVIOGEI
6-20 REAR PANTOGRAPH
Drawing N° 1316/A.3
SPARE PARTS AVIOGEI
SPARE PARTS AVIOGEI
SPARE PARTS AVIOGEI

1 1195/A.3.1 Rear pantograph outer 1
arms
2 1195/A.3.2 Rear pantograph inner 1
arms
3 1195/A.3.3 Support rocker arm 1
4 1195/A.1 Base frame 1
5 1195/A.5 Rear platform 1
6 1195/A.3.4 Lower joints pins 2
7 1195/A.3.5 Lower joint pin bushing 2
8 1195/A.3.6 Lower joint washer 4
bushings
9 Ø10X1 Straight grease nipple 22
10 T.E. M10X25 UNI 5737- Screw 12
65
12 1195/A.3.7 Upper joints pin 2
13 1195/A.3.8 Upper joint pin bushing 2
14 1195/A.3.9 Upper joint washer 4
bushing
15 1195/A.3.10 Lower cylinder bearing 4
pin
16 GE-60.ES.2RS Cylinder joint bearing 8
17 1195/C.2 Rear lifting cylinder 4
18 1195/A.3.11 Upper cylinder bearing 4
pin
19 1195/A.3.12 Central pin 2
20 1195/A.3.13 Central pin bushing 2
21 1195/A.3.14 Inner wear bushing 2
22 1195/A.3.15 Outer wear bushing 2
23 M8X2 Self-locking ferrule 4
24 1195/A.3.16 Upper wheel pin 1
25 1195/A.3.17 Rocker arm sintered 2
bushing
26 1195/A.3.18 Sliding wheel 1
27 1195/A.3.19 Sliding wheel bushing 2
28 T.E. M8X10 UNI 5737- Screw 2
65
29 T.E. M12X50 UNI 5737- Screw 4
65
31 1195/A.3.20 Lower wheel unit pin 1
32 T.P.S.E.I. M12X50 UNI Screw 2
5933
33 1195/A.3.21 Rocker arm roller 1
34 1195/A.3.22 Rocker arm roller axle 1
SPARE PARTS AVIOGEI
35 40/50X50-60X5 Self-locking sintered 2
bushing
36 T.E. M8X20 UNI 5737- Screw 4
65
SPARE PARTS AVIOGEI
6-21 FRONT PANTOGRAPH
Drawing N° 1316/A.2
SPARE PARTS AVIOGEI
SPARE PARTS AVIOGEI
SPARE PARTS AVIOGEI
SPARE PARTS AVIOGEI
1 1293/A.2.1 Outer arm 1
2 1293/A.2.2 Inner arm 1
3 1293/A.2.3 Bushing 2
4 1293/A.2.4 Central pin 2
6 1293/A.2.6 Central wear bushing 2
7 M90X2 Self-locking ferrule 4
8 Ø10X1 Straight grease nipple 10
9 1195/A.2.7 Cylinder joint bearing 2+2
pin
10 GE60ES.2RS Joint bearing 2
11 1195/A.2.7 Cylinder joint bearing 2+2
pin
12 T.E. M10X25 UNI 5737- Screw 4
65
14 1195/A.2.8 Inner arms wheel pin 2
15 1195/A.2.9 Pantograph sliding 4
wheel
16 1195/A.2.10 Sliding wheel bushing 4
5933
18 PROF. 00319 Guide on front platform 2
(Pantograph wheels)
19 PROF. 00319 Guide on base frame 2
(Pantograph wheels)
20 1195/A.2.11 Outer arms wheel unit 2
pin
21 1195/A.2.12 Arm joints pin 4
22 GE60ES.2RS Joint bearing 4
23 1195/A.2.13 Joint bearing spacer 8
24 1195/A.2.14 Spacer stop flange (Joint 4
bearing)
25 1195/A.2.15 Joint bearing stop 4
flange
5933
5933
28 1195/A.1 Base frame 1
29 1195/A.4 Front platform 1
SPARE PARTS AVIOGEI
6-22 DRIVER’S CAB
Drawing N° 1293/A7 - COD. 5001076
SPARE PARTS AVIOGEI
A 2010308 DOOR SEAL -
1 4000618 SLIDING GLASSES RIGHT 1
FRAME
2 3003095 LATERAL REAR SLIDING 1
GLASS
3 3003100 LATERAL FIXED GLASS 1
4 3003094 LATERAL FRONT 1
SLIDING GLASS
5 4000617 SLIDING GLASSES LEFT 1
FRAME
6 3003094 LATERAL SLIDING GLASS 1
7 3003100 LATERAL FIXED GLASS 1
8 3003095 LATERAL SLIDING REAR 1
GLASS
9 3003090 UPPER REAR GLASS 1
10 - DRIVER’S CAB DOOR 1
11 3003091 LOWER REAR GLASS 1
12 3003089 DRIVER’S CAB DOOR 1
LOWER GLASS
13 5005514 + 2005544 LOCK + HANDLE 1+1
14 3003088 DOOR UPPER GLASS 1
15 400619 FRONT SLIDING GLASS 1
FRAME
16 3003093 LOWER FRONT FIXED 1
GLASS
17 3003092 UPPER FRONT SLIDING 1
GLASS
ELECTRICAL WIRING SYSTEM (VEHICLE)
Drawing N° 1293/EA
Pos. Description Code Quantity

1 Battery 236-1BT 120 AH 300 A 2
4 Fuse holder 8 slots 0030903 1
5 Light switch 01.154.000.01 1
6 High-beam headlights P9MLLD+P9PDNVO 1+1
indicator
6A Position lights P9MLVD+P9PDNVO 1+1
indicator
7 Parking brake warning P9MLRD+P9PDNVO 1+1
light
7A Direction indicator P9MLVD+P9PDNVO 1+1
lights signal
8 Generator warning P9MLRD+P9PDNVO 1+1
light
8A Engine temperature 310.474/39/3KHD190°C 24V 1
tool
9 Ignition lock 0342.309.010 1
10 Dashboard light 02.212.000 1
11 Hour meter 2460.2399 24V 1
12 Float 0051.0049 1
13 Fuel level tool 63.1603.9932 1
15 Intermittence 55W – 24V 1
16 Acoustic signal KE125 – 24V 1
17 Overall dimensions 35.413.000 1
light
18 Engine oil pressure P9MLRD+P9PDNVO 1+1
light
19 Floodlight 05.261.000 4
20 Right front headlight + 05.115.000+32.026.000 2+1
direction light
21 Right left headlight + 05.115.000+32.027.000 2+1
direction light
22 Right rear light 0001.0017 1
23 Left rear light 0001.0017 1
24 Microcontact filter In the hydraulic system 1
clogging
25 Electromagnet engine With Deutz engine 1
stop
26 Cylinder head With Deutz engine 1
temperature sensor
27 Oil pressure sensor With Deutz engine 1
28 Cylinder head max. With Deutz engine 1
temperature sensor
29 Ceiling light under “Turtle shell” type 1
front and rear
platforms
30 Filter clogging warning P9MLRD+P9PDNVO 1
light
31 Belt break sensor See Deutz engine 1
32 Brakes’ failure sensor On brake inverter 2
33 Left brakes’ failure P9MLRD+P9PDNVO 1+1
sensor
34 Right brakes’ failure P9MLRD+P9PDNVO 1+1
sensor
35 Windshield wiper 0.390.617.551.850/2 W76° 1
motor 24V
36 Windshield wiper Big 22” 7 550mm 1
blade
37 Windshield wiper arm 034.291 1
38 In-cab lights 07.22.071 1
39 Console ceiling light 02.012.000 1
F1A-B-C Fuse holder (with fuse, SAKS 1 3
20A)
I1-3 Floodlights and 080.SMLDV+080ADV+080B20V 2+2+2
windshield wiper
switch
MT1 Console ceiling light Z – 15G Q21 1
microcontact
PR Reset button P9MPNNG+P9B10VN 1+1
PE2-3 Emergency stop push P9MER4RN+P9B01VN 1+1
button
ST Battery cut-off 08 099 100 1
T1-2 Contactor T0922 24V 40A 2
T5 Microcontactor 18.0249.0000 1
T3-4-7-8-9 Microcontactor 18.0235.0000 5
ST1-2 Relay box 01.00665 4 slots 2
ST2 Closed metal box Size 19V (253X217X95) 1
ELECTRICAL WIRING SYSTEM (SERVICES)
Drawing N° 1293/ES
RAC Anti-shearing photoelectric sensor + E3B2-R5M4-G+E39R2 1+1
reflector
RAC Anti-shearing relay + socket MK2P+S 24V + PF083A-E 1+1
PEF1 Photoelectric sensor exclusion P9MPNNG+P9B10VN 1+1
button
PS1 Parking brake pressure switch 91.532.001+81513.507+ 31.680.604 1+1+1
RF1 Parking brake relay + socket MK3P5-24V+PF113A-E 1+1
FCP1 Platform levelling inductive sensor XS1N30PC410 1
FCP2 Levelling proximity inductive sensor XS4P30PA340 1
FCP6 Automatic levelling inductive sensor XS4P30PA340 1
FCL Truck levelling photoelectric sensor RRX10-30VDC NAPDA2 1
RP1 Platforms’ levelling relay MK3P5-S 24V + PF113A-E 1+1
RP2 Rear platform slow lifting relay MK2P-S 24V + PF083A-E 1+1
RP2A Rear platform automatic levelling 18.0235.0000 1
relay
RP2B Levelling proximity relay 0332.015.002 1
RP3 Rear platform slow lowering relay MK2P-S 24V + PF083A-E 1+1
RP6 Rear platform automatic levelling 18.0249.0000 1
relay
S1 Up/down commands selector switch P9MSLDOV+P9PDNV0+P9B10VN+P9B01VN 1+1+1+1
L3 Command down indicator P9MLVD+P9PDNVO 1+1
M1 Drive joystick 077MTS2422B 1
M2 Stabilizers joystick P9MMB2T+P9B10VN 1+2
M3 Front platform joystick P9MMB2T+P9B10VN 1+2
M4 Front platform joystick P9MMB2T+P9B10VN 1+2
M5 Lateral tilt joystick P9MMB2T+P9B10VN 1+2
M6 Rear platform joystick P9MMB2T+P9B10VN 1+2
M7 Front rollers/wheels joystick P9MMB4T+P9B11VN+PACFS5 1+4+1
M8 Rear rollers/wheels joystick P9MMB4T+P9B11VN+PACFS5 1+4+1
M9 Rear + int. rollers/wheels/int. P9MMB4T+P9B11VN+PACFS5 1+4+1
wheels joystick
M10 Paired rollers joystick P9MMB2T+P9B10VN 1+2
M11 Tot. protrusions joystick P9MMB2T+P9B10VN 1+2
M12 Side protrusions joystick P9MMB2T+P9B10VN 1+2
M13 Cabin extension joystick P9MMB2T+P9B10VN 1+2
I1 Stabilizers toggle switch 647HK 1
I2 Front platform toggle switch 647HK 1
I3 Rear platform toggle switch 647HK 1
FC1 Retracted stabilizers limit switch 9007BD10L 1
FC2 Extended stabilizers limit switch 9007BD10L
FC3 Rear platform down limit switch BM61B2+HA1 1+1
FC4 Front platform max. height limit 9007BD10+HA1 1+1
switch
FC5 Front platform max. height limit 9007BD10+HA1 1+1
switch
FC6 Front platform down limit switch 9007BD10+HA1 1+1
FCM1 Max. left inclination limit switch Mercury AS431A 1
FCM2 Max. right inclination limit switch Mercury AS431A 1
PS2 Brake pressure pressure switch 81532001+81513507+31680604 1+1+1
PS3 Pneumatic edge (30 mm) L = 2000 with contact N.A. 1+1
L1 OK DRIVE indicator P9MLVD+P9PDNVO 1+1
L2 REAR PLATFORM OK indicator P9MLVD+P9PDNVO 1+1
D1 Diode 600K 1
R1 Forward drive relay MK2P-S+BF083A-E 1+1
R2 Reverse drive relay MK2P-S+BF083A-E 1+1
R3 Stabilizers up relay MK3P5-S+BF113A-E 1+1
RT1 Axles tilting time relay H3Y-2-24VDC5A+PYF08A 1+1
R3A Axles tilting time relay 0332.015.002 1
R4 Axles tilting relay MK3P5-S+PF113A-R 1+1
RT2 Stabilizers time relay H3Y-2-24VDC5A+PYF08A 1+1
R4A Stabilizers time relay 0332.015.002 1
R5 Front platform lifting relay MK3P5-S+BF113A-E 1+1
R6 Front platform lowering relay MK3P5-S+BF113A-E 1+1
R6A Front platform lowering signal relay 18.0235.0000 1
R7 Left side tilt relay MK3P5-S+BF113A-E 1+1
R8 Right side tilt relay MK3P5-S+BF113A-E 1+1
R9 Rear platform lifting relay MK3P5-S+PF113A-E 1+1
R10 Rear platform lowering relay LY4+PTF14A 1+1
R11 Front rollers forward relay 55.34.9.024.0040+94.74 1+1
R12 Front rollers reverse relay 55.34.9.024.0040+94.74 1+1
RP12 Rear platform automatic levelling 18.0235.0000 1
relay
R13 Right front wheels relay LY4+PTF14A 1+1
R14 Left front wheels relay LY4+PTF14A 1+1
R15 Rear rollers forward relay MK3P5-S+BF113A-E 1+1
R16 Rear rollers reverse relay MK3P5-S+BF113A-E 1+1
R17 Right rear wheels relay LY4+PTF14A 1+1
R18 Left rear wheels relay LY4+PTF14A 1+1
R19 Int. rollers relay + rear forward LY4+PTF14A 1+1
R20 Int. rollers relay + rear reverse LY4+PTF14A 1+1
R21 Right intermediate wheels relay LY4+PTF14A 1+1
R22 Left intermediate wheels relay LY4+PTF14A 1+1
R23 Paired rollers forward relay 55.34.9.024.0040+94.74 1+1
R24 Paired rollers reverse relay 55.34.9.024.0040+94.74 1+1
R25 Tot. protrusions up relay LY4+PTF14A 1+1
R26 Tot. protrusions down relay LY4+PTF14A 1+1
R27 Side protrusions up relay 55.34.9.024.0040+94.74 1+1
R28 Side protrusions down relay 55.34.9.024.0040+94.74 1+1
R29 Right cabin extension relay 55.34.9.024.0040+94.74 1+1
R30 Left cabin extension relay 55.34.9.024.0040+94.74 1+1
RRC Cabin retraction relay 18.0249.0000 1
R37 Automatic accelerator relay 0332.204.201 24V 1
F1 Command fuse holder ASK1 with fuse 8A 1
F2 Power fuse holder ASK1 with fuse 16A 1
F3 Drive fuse holder ASK1 with fuse 6A 1
F4 Stabilizers fuse holder ASK1 with fuse 8A 1
F5 Front platform fuse holder ASK1 with fuse 6A 1
F6 Lateral tilt fuse holder ASK1 with fuse 6A 1
F7 Rear platform fuse holder ASK1 with fuse 8A 1
F8 Front rollers/wheels fuse holder ASK1 with fuse 8A 1
F9 Intermediate rollers/wheels fuse ASK1 with fuse 8A 1
holder
F10 Rear rollers/wheels fuse holder ASK1 with fuse 10A 1
F11 Press./rev. fuse holder ASK1 with fuse 8A 1
F12 Side/Int. protrusions fuse holder ASK1 with fuse 8A 1
P3 Emergency pump button 080PRG+080BF20V 1+1
C1 Rear platform lowering signaling SE129 24V 1
device
C2 Front platform lowering signaling SE129 24V 1
device
C3 Reverse gear signaling device SE129 24V 1
LR1 Rear platform lowering rotating F0220502 yellow + F0272102 basic 1
beacon
LR2 Front platform lowering rotating F0220502 yellow + F0272102 basic 1
beacon
E1 Automatic accelerator ET5-6V/100 24V 1
electromagnet
FCP7 Photoelectric sensor exclusion limit XS4P30PA340 1
switch
FP1-2- Photoelectric sensor E3B-R5M4-G+E39R2 3
3
PR Reset 080PNG+080BF11V 1+1
44 Molded lamp 24V 1
RFP Relay MK2P-S24V 1
RP7 Relay MK2 24V+PY08A 1+1
Airtight panel (520x650x250) Art. 16.121 1
Profile device columns (pair) Art. 16.463 1
Device column asymmetrical profile Art. 16.502 2
Device column asymmetrical profile Art. 16.507 2
Tilted rack Art. 11.530 1
Symmetrical dynamic profile Art. 17.955 1
Asymmetrical dynamic profile Art. 17.960 1
Sliding guides Art. 16.457 1
Inner door Art. 16.447 1
Brackets (4) Art. 16.460 1
Handles (pair) Sides C – D for case 13.10 1
Rif. Relay
R11= Front rollers forward relay
R12= Front rollers reverse relay
RP12= Rear platform automatic levelling relay
R13= Right front wheels relay
R14= Left front wheels relay
R15= Rear rollers forward relay
R16= Rear rollers reverse relay
R17= Right rear wheels relay
R18= Left rear wheels relay
R19= Int. + rear rollers forward relay
R20= Int. + rear rollers reverse relay
R21= Right interm. wheels relay
R22= Left interm. wheels relay
R23= Paired rollers forward relay
R24= Paired rollers reverse relay
R25= Inner protrusions up relay
R26= Inner protrusions down relay
R27= Outer protrusions up relay
R28= Outer protrusions down relay
R29= Right cabin extension relay
R30= Left cabin extension relay
RRC= Cabin retraction relay
R37= Automatic accelerator relay
RAC= Anti-shearing relay
RF1= Parking brake relay
RP1= Platforms levelling relay
RP2= Rear platform slow lifting relay
RP2A= Rear platform automatic levelling relay
RP2B= Levelling proximity relay
RP3= Rear platform slow lowering relay
RP6= Rear platform automatic levelling relay
R1= Drive forward relay
R2= Drive reverse relay
R3= Stabilizers up relay
RT1= Axles tilting down time relay
R3A= Axles tilting up time relay
R4= Axles tilting up relay
RT2= Stabilizers down time relay
R4A= Stabilizers up time relay
R5= Front platform lifting relay
R6= Front platform lowering relay
R6A= Front platform lowering signal relay
R7= Left side tilt relay
R8= Right side tilt relay
R9= Rear platform lifting relay
R10= Rear platform lowering relay
MAIN-DECK CARGO LOADER 2PU 2000
USE AND MAINTENANCE MANUAL N° 1293 AVIOGEI

DIFFERENTIAL AXLE
Drawing N° 1293/D

DIFFERENTIAL AXLE
Drawing N° 1293
POS. DESCRIPTION
A DIFFERENTIAL AXLE (BODY)

B JUNCTION
C REDUCER
D DIFFERENTIAL GEAR
E STEERING COMPONENTS
F BRAKE UNIT

DIFFERENTIAL AXLE: BODY
DRAWING

DIFFERENTIAL AXLE: A BODY
SPARE PARTS LIST

1 AXLE BODY 3115783 1
2 SLEWING RING 3111963 4
4 BUSHING 3125863 4
5 SEAL RING 3115603 2
6 BUSHING 3125843 2
7 RELIEF VALVE 70052 1
8 CAP 70048 2
9 SEAL 70051 2
10 NUT M 12 70286 2
11 SCREW M 12 X 50 70276 2
12 GREASE NIPPLE 70055 2
13 REFERENCE PIN 70445 2

DIFFERENTIAL AXLE: B JUNCTION
DRAWING

DIFFERENTIAL AXLE: B JUNCTION
SPARE PARTS LIST

2 FERRULE 3112233 2
3 SPACER 3124013 2
4 SLEEVE (COMPLETE) 3112013 2
5 AXLE SHAFT WITH DOUBLE JOINT 3115883 2
6 SEAL RING 70026 4
7 O-RING 70275 2
8 SOCKET 3111893 2
9 RIGHT JUNCTION BODY 3126053 1
10 ADJUSTMENT SHIM 1 mm 3125883 *
ADJUSTMENT SHIM 0.5 mm 3125893 *
11 PIN 3125853 4
12 CAP 70049 8
13 SEAL RING 3125933 4
14 SCREW M 16 x 1.5 x 45 70336 24
15 LEFT JUNCTION BODY 3126063 1
16 NUT M 16 x 1.5 70340 2
17 STEERING WHEEL ADJUSTMENT SCREW 3117923 2
18 BUSHING 70079 4
N.B. QUANTITY TO BE DEFINED BEFORE ASSEMBLY


DIFFERENTIAL AXLE: C REDUCER
DRAWING

DIFFERENTIAL AXLE: C REDUCER
SPARE PARTS LIST

1 O-RING 70247 6
2 PIN 3113003 6
3 UPRIGHT 3125833 2
4 SCREW M 12 x 35 70294 46
6 ROLLERS 3113023 276
7 SPACER 3113033 6
8 PLANETARY GEAR 3113013 6
9 CAP 70105 2
10 SEAL 70111 2
11 CAP 70169 2
12 SEAL 70278 2
13 FASTENING PIN 70248 6
14 ADJUSTMENT SHIM 0.1 mm 3109853 *
15 PLATELET 3112993 2
16 CIRCLIP 70045 2
17 COGWHEEL 3108683 2
18 CROWN GEAR 3109803 2
19 CROWN GEAR HOLDER 3112243 2
20 CIRCLIP 3109893 2
21 BEARING 70020 2
22 WHEEL HUB 3112223 2
23 BEARING 70019 2
24 SEAL RING 70527 2
25 NUT 3112283 20
26 RIM 3112273 20
27 SPHERICAL WASHER 70018 20
28 WASHER 3100653 20
29 COVER 3125823 2
30 SCREW M 8 x 16 70434 12


DIFFERENTIAL AXLE: D DIFFERENTIAL GEAR
DRAWING

DIFFERENTIAL AXLE: D DIFFERENTIAL GEAR
SPARE PARTS LIST

1 NUT 3143623 1
2 SPACER 3100323 1
3 FLANGE (COMPLETE) 3111613 1
4 SEAL RING 70267 1
5 BEARING 70266 1
ADJUSTMENT SHIM 1 mm 3111643 *
7 SPACER 3111363 1


DIFFERENTIAL AXLE: E STEERING CYLINDER
DRAWING

DIFFERENTIAL AXLE: E STEERING CYLINDER
SPARE PARTS LIST

1 PISTON ROD WITH PLUNGER 3118043 1
2 LINER 3112103 1
3 RING 3112293 2
4 O-RING 70282 2
5 FLANGE 3125073 2
6 OIL SCRAPER 3112143 2
7 SEAL 3125063 2
8 PLATELETS 3113863 2
9 NUT M 39 x 1.5 RIGHT 3113843 1
10 SWIVEL HEAD RIGHT 3113803 1
11 GREASE NIPPLE 70053 2
12 SCREW M 14 x 35 70307 8
13 SLUDGE SCRAPER 3112133 2
14 FASTENING PIN 70284 4
15 RING 3112213 4
16 LOWER PISTON ROD 3130553 2
17 SPHERICAL JOINT 70285 4
18 UPPER PISTON ROD 3130543 2
19 NUT M 39 xx 1.5 LEFT 3113853 1
20 SWIVEL HEAD LEFT 3113813 1
21 LABEL 3163973 1
22 RIVET 70287 2
23 SEAL 3112123 1

DIFFERENTIAL AXLE: F BRAKE UNIT
DRAWING

DIFFERENTIAL AXLE: F BRAKE UNIT
SPARE PARTS LIST

1 PLATTER (COMPLETE) 3185753 2
2 GUARD 3185763 2
3 GUARD 3185773 2
4 CIRCLIP 3185693 16
5 SCREW TE M 5 x 8 3185623 16
6 CAP 3185633 4
7 CAP 3185783 4
8 BRAKE CYLINDER 65 (VEGETABLE OIL) 3181793 2
9 CIRCLIP 3174193 4
10 SCREW TE M 12 x 25 3174183 4
11 BRAKE SHOE (DIA 420 x 90) 12459.10-04 4
12 PIN (DIA 10 x 55) 3185823 4
13 SPRING 3185833 2
14 SPRING 3185673 2
15 LONG DRAIN SCREW 3144483 2
16 ADJUSTABLE FITTING 3111903 2
17 SCREW FOR FITTING 3144193 2
18 SEAL 70170 4
19 BRAKE DRUM 3176543 2
20 SCREW M 8 x 1.5 x 20 70296 4
COMPLETE BRAKE (DIA 420 x 90) 2
10.1 Assisted process to approach the aircraft
The AHM 913 (amended during the IATA 37th edition 2017) requires all newly
produced equipment to be provided with a control system when approaching the
aircraft.
Such system operates by reducing the speed of the vehicle during the approach
process as well as when it is driven on safety areas established in IATA AHM 913.
However, even for means of production prior to the issue of the AHM 913 standard,
IATA suggests to provide installations of approach systems that comply as far as
possible with the safety requirements stated by the AHM 913 2017, taking into
consideration both the technical and economic aspects that such an implementation
would require.
This amendment attached to the Manual moves about within this scope.
10.1.1 Approaching the aircraft

The machine is equipped with two optical proximity sensors located in the front part
of the platform that stop its advancement as soon as they measure a distance
(preset) useful to prevent any contact with the aircraft.
As a result of the detection of the minimum distance (preset) from the obstacle, a
red light placed on the right railing of the driver's seat warns the operator to
prepare for a controlled approach.
By pressing the bypass button, it is possible to allow the advancement of the
machine by proceeding with a visual approach performed under the full
responsibility of the user.
 NOTE
By pressing both bypass buttons, it is possible to travel by bypassing the safety

devices. This function can be used in case of sensor malfunction and/or to further
approach the aircraft under the full responsibility of the user.
 ATTENTION
Travel block occurs in the following cases:

• Parking brake engaged
• Aircraft approach sensor reading
In order to move forward, it is necessary to press the bypass buttons as specified

in this manual with regard to the different conditions.
10.1.2 Proximity sensors calibration
1. The distance photoelectric sensors have two

status signaling LEDs
- Green Led (1): Device ON
- Orange Led (3): Contacts switching
Before starting the calibration, make sure that

the sensor is powered and working, clean the
laser emission surface and check the contact
switching (LED 3) placing an obstacle in front of
the laser.
2. Adjust the switching distance of the contacts

through the potentiometer (2) on the device.
The orange LED change status indicates that
the contacts have been switched.
- Rotation to the right: the distance
switching increases
- Rotation to the left: the distance

switching decreases
3. Check the set distance by performing some
tests.
 ATTENTION
The distance set on the sensors may be

less than the contact distance.
Perform tests at reduced speed while

paying the utmost attention.
 NOTE
Sensors do not require maintenance.

Regularly clean the optical surface and check the electrical connections.
MAINTENANCE/RECORD BOOK AVIOGEI
CHAPTER XI
11 MAINTENANCE/RECORD BOOK
11-1 MAINTENANCE
11-2 TROUBLESHOOTING
11-3 RECORD BOOK

11-1 MAINTENANCE
11-1 GENERAL INFORMATION
All operations described in this chapter are essential for an efficient and safe use of the
machine.
Such operations represent the minimum requirements to maintain the machine in a state of
efficiency.
Mechanical, hydraulic, and electrical units and components therefore need routine
maintenance.
Maintenance is a preventive safety. Non-compliance with the instructions or maintenance

intervals can lead to decreased performance and damage to the machine, as well as to the
loss of the right to raise warranty claims.
The data relating to third-party units installed on the machine can be found in the attached
technical documentation. Please refer to it in before carrying out any maintenance work.
 ATTENTION
The inspection and maintenance operations require in-depth knowledge of the machine;
therefore, they must only be carried out by qualified and trained personnel.
The authorization grant for carrying out maintenance interventions is attributed to the
user who assumes all responsibility.
11-2 DELIMITATION AND DESCRIPTION OF WORK
Preventive maintenance work includes the following stages:
• Machine cleaning.
• Monitoring of levels.
• Check the correct operation of the machine in all functions as described in the
operation chapter.
• Place the machine in a suitable place to proceed with maintenance.
• Make sure that there are no obstacles in the upper part of the machine hindering the
full elevation.
• Stop the machine. It is good practice to lock the drive wheels with wedges.
• Insert the safety systems/latches before getting underneath the machine structures
• Disconnect the batteries from the electrical system
• The hydraulic components, rigid pipes, hoses, valves, etc., must be protected with caps
and kept up to installation after disassembly.
 ATTENTION
Before starting any maintenance work, follow the instructions laid down in the
paragraph “Injury prevention”.
 ATTENTION
For machines equipped with PLC: Before welding, disconnect the electrical control
units.
11-3 LUBRICANTS
The important requirement for proper operation and durability of the machine is the use of
original spare parts and suitable lubricants.
The table below shows the types of lubricants that must be used according to the ambient
temperature.
 NOTE
Where not possible, only equivalent products listed in the table must be used due to
internal reasons.
BRAND HYDRAULIC OIL GREASE

ISO Viscosity: VG 46 H. LP Din. 51825
DIN. 51525
AGIP OSO 46 (1) Arnica 22* GR. MU 2

Mobil DTE 22 DTE 25* Mobilux 2
Shell Tellus 46 Alvania Fett. R 2
Esso Nuto H 46 Nuto H 22* Beacon 2
BP HLP 46 HLP 46* Energrease LS 2
*Use only in extremely low temperatures
(1) Original equipment hydraulic oil
DIFFERENTIAL OIL
AGIP: ROTRA SAE 80W90 (1): MOBIL: DELVAC SUPER
ENGINE OIL
AGIP: Superdiesel SAE 15W/40 (1): MOBIL: DELVAC SUPER
BRAKE FLUID
AGIP: DOT 4
 NOTE
Engine lubricants can be found in the manufacturer's attached documentation.
Damage to the environment:
The replaced lubricants and the discarded materials must be disposed of

according to the applicable regulations.
11-1.1 INJURY PREVENTION
In order to avoid accidents that can cause injury to people, maintenance work must be carried
out by trained personnel and the following rules must be observed:
• The heat engine must be switched off.

• Safety devices must be inserted before getting underneath the machine.
• The main battery switch must be turned off
• Do not open or close pressure pipes.
• For operations on hydraulic systems, wear a mask and protective goggles.
• Any oil leaks must be covered immediately with binding powder, in order to avoid the
risk of damage caused by slipping.
• Mark out the risk areas around the machine.
• Keep at safe distance from rotating or moving parts.
• Use extraction systems for exhaust gases (if any) or ventilate the premises.
• Do not smoke or use open flame in the presence of highly flammable materials.
• Secure the machine from accidental movement through the use of special wheel block
wedges.
• Always have a fire extinguisher nearby.
 ATTENTION
Before starting maintenance operations, equip yourself with the appropriate personal
protective equipment PPE.
 ATTENTION
Some maintenance phases may not fully comply with injury prevention; in these
particular exceptions, the responsibility for any accidents is to be considered
responsibility of the maintenance technician.
During the test performance of the hydraulic system, it is necessary to proceed with the
utmost caution, in order to avoid accidents to people caused by possible leaks in the
high-pressure area.
 ATTENTION
If it is necessary to access the front platform, there are special housings “Fig. 1” to
which anti-fall devices can be attached.
11-1.4 HEAT ENGINE
WORK TO BE PERFORMED 20 oh 50 oh 200 oh 500 oh YEAR

See the maintenance list in the Manufacturer's
Use and Maintenance Manual (attachment)
ENGINE
Check for oil leaks
THROTTLE
Check connecting parts and movements by
means of linkages and couplings
ENGINE
Check moving parts for smooth running
EXHAUST SYSTEM
Screw the parts as required
COMBUSTION SYSTEM
Check for leaks and screw as required
11-1.5 AXLES
WORK TO BE PERFORMED EVERY N° HOURS: 20 50 200 500 YEAR
Steering differential:
Check the oil level of the lateral planetary
gearboxes
Differential body oil level check.
Oil replacement of planetary reduction gears and
differential unit.
Transverse linkages and steering differential

housing.
Tires and wheels:

Inflators’ conditions and pressure.
Tires and wheels:

Screw all bolts and nuts daily upon inspection and
every 20 hours of operation.
Steering cylinder and axle joints fixing.

11-1.6 STEERING WHEEL
Steering wheel:
Functionality test.
Steering cylinder:
Check for leaks and make sure that it is supported
properly.
Hydraulic hoses:
Inspect signs of wear or damage; check for any
leaks.
Steering system pressure control.

11-1.7 THROTTLE AND BRAKE SYSTEM
Brakes:
Adjustment and functionality tests.
Throttle:
Check for correct operation.
Parking brake:
11-1.8 LIFTING SYSTEMS
Clean the sliding guides of the pantograph wheels

(Frame and platforms).
Make sure that all housings work correctly.
Pantograph scissor weld joints:

Check for any cracks.
Lifting cylinders:
Check for any leaks.
Tubes and hoses:

Check for any cracks or deformations.
All housings with threaded fittings to be

greased:
Spread the grease adequately.
11-1.9 DRIVER’S CAB
Control lights:
Control panel:
Check all switches for defective or corroded parts.
Check the cabin body, access area, gates, ladder,

and guard rail.
11-1.10 LOAD HANDLING SYSTEM
Load handling wheels
Load handling rollers
Drag chains:
Check tension and lubricate.
Check and lubricate bearing housings.
Check and lubricate sliding bearings.
Check the wheel, cylinder, and linkage housing

systems.
Check hydraulic motor fasteners.

11-1.11 HYDRAULIC SYSTEM
Hydraulic oil level check.
Hydraulic oil change:

First change
Second change
Filter cartridge replacement:

First replacement
Later
System:
Check for leaks
Hydraulic, electric, and solenoid valves:

Functionality test.
Pipes:
Check for wear/damage, screw the fittings and
change them if necessary.
System pressure:
Check and adjust if necessary.
Emergency hand pump:

Functionality tests.
Emergency electric pump:

Functionality tests.
Check for leaks in all hydraulic cylinders and

motors.
11-1.12 ELECTRICAL WIRING SYSTEM
Batteries:
Check liquid level, clean and screw the clamps if
deemed necessary.
Check the operation, the overall conditions, the

presence of oxidation and the tightening of all
switches, buttons and joysticks.
Check the operation, conditions and installation of

all fuses and relays.
Check start-up, water resistance and any corrosion

of instrument panel’s connectors.
Check the condition and operation of the vehicle

electrical system components.
11-1.13 TIGHTENING TORQUES
11-2 TROUBLESHOOTING
GENERAL INFORMATION
The causes of possible failures listed below cannot be considered complete or definitive.
Before troubleshooting according to this list, try to eliminate all functional and mechanical
failures. Make a preselection to identify the cause of the possible failure.
All hydraulic solenoid valves are provided with luminous socket plugs that allow to see if the
failure is located inside the valve.
Furthermore, all solenoid valves can be activated manually, so in most cases it can be
determined whether the failure is electrical or hydraulic.
Before looking for failures in the electrical system, make sure that:
• The warning lights are working
• The fuses are intact
• The batteries that provide the required performance are charged
• The emergency stop buttons are off.
FAILURE/CAUSE SOLUTION
Heat engine See manufacturer’s use and maintenance
manual
The engine revolutions will not adjust
automatically.
• Relay failure • Check, replace if necessary.

• Rear platform lifting joystick failure • Check, replace if necessary.
Loader cannot be moved.
• Stabilizers not fully retracted • Remove stabilizers.

• Parking brake engaged • Remove.
• Drive solenoid valve not working • Check, replace if necessary.
• Drive joystick defective • Check and/or replace.
• Selector set on ground control position • Restore the operating controls position.
• Drive motor not reaching the proper • Contact the Customer service.
pressure
• Drive bypass valve is open • Close.
Loader is slowed down.
• Heat engine not reaching the required • See manufacturer’s use and maintenance
RPM manual.
• The brake cannot be completely released • Adjust the wheel brake.
• Uneven displacement pump’s flow rate • Lack of hydraulic oil, add.
• Filter clogged, replace.
Loader moves without operating the
accelerator.
• The solenoid valve cannot be reset • Activate manually and/or replace.

Loader power steering is low.
• Front tire air pressure too low • Proper tire pressure needed.
• Steering pump defective • Replace.
• Oil leakage from the steering cylinder or • Restore the cylinder or the broken pipe.
from the system
• Hydraulic steering unit defective • Replace.
Braking system.
• Abrupt braking • Reduce the pressure by acting on the adjuster

under the pedal, check the pressure with a
pressure gauge.
• Weak braking • Increase the pressure by acting on the adjuster
underneath the treadle, check the pressure
with a pressure gauge: be careful not to exceed
the pressure levels allowed by the brakes.
• Non-constant braking pressure. • Check the nitrogen pressure, recharge if
necessary.
• Continuous battery charge • Pump capacity depleted, replace.
• Supply pump constantly running under • Dirt in the valve, carefully check the sliding of
pressure. the parts and their integrity.
• Batteries not charging. • Check the sliding parts of the inlet valve.
• Braking function constantly activated. • The system cannot discharge freely and the
pressure affects the brakes.
• Check that the pedal stop adjuster leaves a
• Loud bangs on pedal. slight gap between the transmission and the
• Dashboard warning light always on or fails to operating piston.
illuminate • Too high exhaust flow. Contact the
manufacturer.
• Check pressure switch adjustment.
Low/Insufficient brakes.
• Wheel brake not adjusted or worn out • Adjust and/or repair.

• Low or leaky system pressure • Check the system and stop any leaks.
• Brake treadle valve defective. • Replace.
• Brake mass seals impregnated with oil, • Clean the seals and replace if necessary.
leaky brake cylinders. Repair the defective components.
Stabilizers cannot be extended.
• Drive joystick in drive position • Shift the joystick into neutral position.
• Parking brake disengaged • Engage.
• Low hydraulic pressure • Detect the failure in the control unit.
• Control unit electrodistributor not • Check the electrical connections.
activating or defective
• Relay not activating • Replace.
• Joystick control not working or defective • Check and clean the contacts and/or
replace.
Stabilizers cannot be retracted.
• Front and rear platforms not completely • Completely lower the platforms.
lowered • Detect the failure in the control unit
• Low hydraulic pressure • Engage.
• Parking brake disengaged • Replace.
• Relay not activating • Clean the contacts and/or replace.
• Control joystick not working or defective
Front platform cannot be lifted.
• Control unit electrodistributor not • Check the electrical contacts and/or

activating or defective. replace the valve.
• Control joystick not working or defective • Clean the contacts and/or replace.
• Control relay not energizing • Replace.
• Low system pressure. • Check the calibration of the relief valve.
and/or contact the Customer service.
• Check valve on cylinders set too low • Contact the Customer service.
Front platform cannot be lowered.
• Control joystick defective • Check the electrical contacts and/or

replace.
• Control unit electrodistributor not • Check the electrical contacts and/or
energizing replace the defective components.
• Control relay not energizing • Contact the Customer service.
Rear platform cannot be lifted.
• Stabilizers not completely engaged • Engage the stabilizers.

• Control joystick sending no electrical • Clean the contacts and/or replace
impulse • Replace.
• Relay not activating • Check the electrical contacts and/or
• Electrodistributor not energizing replace the valve.
• Low/Insufficient system hydraulic • Contact the Customer service.
pressure
Load transfer is too slow or keeps abruptly

stopping.
• Low/insufficient system pressure • Check or contact the Customer service.

• Section emergency command open • Close.
• Flow adjuster not properly adjusted • Adjust.
• Hydraulic motor defective • Replace.
11-3 RECORD BOOK
11-3.1 REFERENCE LEGISLATIVE FRAMEWORK

This record book is issued by AVIOGEI to the user of the Cargo Loader 2PU 2000, pursuant to
Directive 2006/42/EC.
11-3.2 STORAGE INSTRUCTIONS

This record book is to be understood as an integral part of the 2PU 2000 and must accompany
it throughout its lifetime, until it is finally dismantled.
11-3.3 COMPILATION INSTRUCTIONS

These instructions are provided in accordance with the provisions on the date of the first sale
of the 2PU 2000. New provisions may intervene to modify the user's obligations.
The register is developed to record the following events concerning the useful life of the Cargo
Loader:
• Transfers of ownership.
• Replacement of mechanisms, structural elements, electrical components, hydraulic
components, safety devices and their related components.
• Major failures and related repair actions.
• Routine inspections.
 NOTE
If there are insufficient sheets in the register, the necessary sheets must be added by
drawing them up like those attached below.
On the additional sheets, the user will indicate the type of Cargo Loader, the
manufacturing serial numbers and the year of construction.
The additional sheets will be considered as part of this register.
11-3.4 REGISTER SHEETS
11-3.4.1 Ownership of Cargo Loader 2PU 2000
DELIVERY OF CARGO LOADER TO THE FIRST OWNER

The Cargo Loader AVIOGEI 2PU 2000 serial number n° ....……....……..., year of
construction....……....……... referred to in this Record Book, was handed over by the AIRPORT
EQUIPMENT S.r.l. on ....……....……..., to the Company
............................................................................................... according to the mutually agreed
terms, provided with the technical, dimensions and functions specified in the instruction manual
and in the summary contained in this Register.
AIRPORT EQUIPMENT S.r.l.
________________________________________________________________________________________________
SUCCESSIVE TRANSFERS OF OWNERSHIP

The ownership of the Cargo Loader 2PU 2000 is transferred to the Company
............................................. Airport ................................................ on .............................. It is
hereby certified that, on the aforementioned date, the technical, dimensions and functions of the
Cargo Loader 2PU 2000 comply with those originally predicted and that any changes have been
recorded in this Register.
Transferor Transferee
…………………………………………………… ……………………………………………………
________________________________________________________________________________________________
SUCCESSIVE TRANSFERS OF OWNERSHIP

The ownership of the Cargo Loader 2PU 2000 is transferred to the Company
............................................. Airport ................................................ on .............................. It is
hereby certified that, on the aforementioned date, the technical, dimensions and functions of the
Cargo Loader 2PU 2000 comply with those originally predicted and that any changes have been
recorded in this Register.
Transferor Transferee
…………………………………………………… ……………………………………………………
________________________________________________________________________________________________
11-3.4.2 Replacement and/or repair of pumps
REPLACEMENT AND/OR REPAIR OF PUMPS

Date..................................... Replacement..................................... Repair..........................................
PUMP...................D/N.................................... Manufacturer.................................... REPLACED
WITH PUMP D/N...................................................
Manufacturer........................................................................................................................................
Reason for replacement.......................................................................................................................
Company Representative Customer

.................................................... ....................................................
________________________________________________________________________________________________

WITH PUMP D/N...................................................
Manufacturer........................................................................................................................................

.................................................... ....................................................
________________________________________________________________________________________________

WITH PUMP D/N...................................................
Manufacturer........................................................................................................................................

.................................................... ....................................................
________________________________________________________________________________________________
11-3.4.3 Replacement and/or repair of mechanisms
REPLACEMENT AND/OR REPAIR OF MECHANISMS
Date.................................. Component description...................................... D/N................................................

Manufacturer......................................................... Delivered by................................……………………………..
Reason for replacement.......................................................................................................................................

.................................................... ....................................................


.................................................... ....................................................


.................................................... ....................................................


.................................................... ....................................................
11-3.4.4 Replacement and/or repair of structural elements
REPLACEMENT AND/OR REPAIR OF STRUCTURAL ELEMENTS


.................................................... ....................................................


.................................................... ....................................................


.................................................... ....................................................


.................................................... ....................................................
11-3.4.5 Replacement and/or repair of hydraulic components
REPLACEMENT AND/OR REPAIR OF HYDRAULIC COMPONENTS


.................................................... ....................................................


.................................................... ....................................................


.................................................... ....................................................


.................................................... ....................................................
11-3.4.6 Replacement and/or repair of electrical components
REPLACEMENT AND/OR REPAIR OF ELECTRICAL COMPONENTS

.................................................... ....................................................


.................................................... ....................................................


.................................................... ....................................................


.................................................... ....................................................
11-3.4.7 Replacement and/or repair of safety devices and components
REPLACEMENT AND/OR REPAIR OF SAFETY DEVICES AND COMPONENTS

.................................................... ....................................................


.................................................... ....................................................


.................................................... ....................................................


.................................................... ....................................................
11-3.4.8 Serious failures and repairs
SERIOUS FAILURES AND REPAIRS
Failure
description............................................................................................................................................
.............................................................................................................................................................
Cause(s)...............................................................................................................................................
.............................................................................................................................................................
Repairs………………………………………………………………………………………………………….

.................................................... ....................................................
Place Date
.................................................... ..............................................
Failure
description............................................................................................................................................
.............................................................................................................................................................
Cause(s)...............................................................................................................................................
.............................................................................................................................................................
Repairs………………………………………………………………………………………………………….

.................................................... ....................................................
Place Date
.................................................... ..............................................
Failure
description............................................................................................................................................
.............................................................................................................................................................
Cause(s)...............................................................................................................................................
.............................................................................................................................................................
Repairs………………………………………………………………………………………………………….

.................................................... ....................................................
Place Date
.................................................... ..............................................
Failure
description............................................................................................................................................
.............................................................................................................................................................
Cause(s)...............................................................................................................................................
.............................................................................................................................................................
Repairs………………………………………………………………………………………………………….

.................................................... ....................................................
Place Date
.................................................... ..............................................
11-3.4.9 Routine inspections
The user is obliged to comply with the maintenance and control program described in this
instruction manual
N° DATE DESCRIPTION SIGN
10
11
12
13
2PU 2000

Manual de Operacion Main Deck Loader

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual de Operacion Main Deck Loader

Uploaded by

Copyright:

Available Formats

Solutions for aviation

MAIN DECK LOADER

1-1 Introduction 1-1

2 DESCRIPTION OF THE EQUIPMENT P.

2-1 Base frame 2-1

3-1 Description 3-1

4-1 Ignition panel 4-2

5 HYDRAULIC SYSTEM & BRAKES P.

5-1 Hydraulic system 5-1

6-1 Hydraulic system

11-1 Maintenance 11-1

1-2 PURPOSE OF THE OPERATIONS MANUAL AND SPARE PARTS CATALOGUE

1-6 ASSISTANCE AND SPARE PARTS SERVICE

1-8 GENERAL SAFETY INSTRUCTIONS

1-9 VEHICLE SHEET

• Describe the use of the equipment.

• Provide operating instructions.

• Describe the safety devices.

• Provide instructions for maintenance.

• Support the personnel training procedures.

• Provide instructions for filling out the record book.

• Provide spare parts lists.

• Provide scheduled maintenance plans.

• Misuse of the equipment.

• Use by untrained personnel.

• Alterations not authorized by AVIOGEI.

1-8 GENERAL SAFETY INSTRUCTIONS

Do not inhibit or violate the safety devices installed on the equipment.

1-9 VEHICLE SHEET

2-1 BASE FRAME

2-2 FRONT PLATFORM AND DRIVING SEAT

2-3 REAR PLATFORM

2-4 HYDRAULIC SYSTEM

2-5 ELECTRICAL WIRING SYSTEMS

2-6 BRAKING SYSTEM

2-7 SAFETY DEVICES

Such portion contains:

• Heat engine with hydraulic pumps.

• Electro-hydraulic unit complete with solenoid, control and safety valves.

• Fuel tank complete with level indicator and filler cap.

• Components of the service and parking braking system.

This device is automatically engaged when retracting the stabilizers.

The handling of such components is made possible by a chain transmission controlled by

The commands are grouped into two separate sections:

• An additional section including all the operating commands.

• Closed-circuit pump for vehicle traction.

• Piston pump for services.

• Power steering pump.

• Orbital hydraulic steering.

• A set of orbital hydraulic motors for entrainment units on platforms.

• 2 telescopic jacks to facilitate the initial lifting of the rear platform.

• 4 single-acting cylinders for rear platform lifting.

• 2 single-acting cylinders for front platform lifting.

• 6 cylinders for the stabilization of the equipment.

• 4 double-acting cylinders for front protrusions movement.

• 1 double-acting cylinder for driver's cab movement.

• 2 batteries 12 V - 120 A/h.

• Standard automotive systems, floodlights and end-outline marker lights.

2-6 BRAKING SYSTEM

• Hydraulic drum service brake acting on the front wheels.

• DEVICES ENABLING TO DRIVE THE MACHINE

2. Parking brake disengaged.

3. Stabilizers fully retracted.

• DEVICES ENABLING TO THE DEPLOYMENT OF STABILIZERS