Property of American Airlines

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2 Section 2: Operation 1. GENERAL INFORMATION Safety First! is the motto at Tesco; therefore, the first part of the Operation section begins with safety features and procedures. Operation of the Tesco CL80-20 Lift should not be conducted until the operator is familiar with all the safety features and procedures associated with the CL80-20 Lift. It is strongly advised that this manual be read completely prior to operating the vehicle. DO NOT OPERATE THE HI-LIFT DEVICE UNLESS YOU HAVE BEEN TRAINED IN THE SAFE OPERATION OF THE UNIT AND ARE FAMILIAR WITH THE INSTRUCTIONS AND SAFETY S CONTAINED IN THIS MANUAL. FAILURE TO HEED S MAY RESULT IN SERIOUS INJURY OR DEATH TO OPERATOR AND/OR CREW. DO NOT OPERATE A HI-LIFT UNIT THAT HAS DAMAGE TO STRUCTURAL OR HYDRAULIC COMPONENTS INCLUDING HOSES. FAILURE TO HEED S MAY RESULT IN SERIOUS INJURY OR DEATH TO OPERATOR AND/OR CREW. DO NOT ATTEMPT TO STABILIZE A HI-LIFT UNIT ON SOFT GROUND OR ON INCLINES BY SHIMMING STABILIZER S. FAILURE TO HEED S MAY RESULT IN SERIOUS INJURY OR DEATH TO OPERATOR AND/OR CREW. DO NOT RETRACT OR ADJUST STABILIZERS WHEN HI-LIFT UNIT IS IN RAISED POSITION. TAMPERING WITH THE STABILIZER CONTROLS OR STABILIZERS MAY CAUSE THE UNIT TO BE UNSTABLE. FAILURE TO HEED S MAY RESULT IN SERIOUS INJURY OR DEATH TO OPERATOR AND/OR CREW. DO NOT RAISE THE HI-LIFT UNIT UNLESS THE STABILIZERS HAVE BEEN DEPLOYED. FAILURE TO HEED S MAY RESULT IN SERIOUS INJURY OR DEATH TO OPERATOR AND/OR CREW. OPERATION Page 1

3 THE HI-LIFT UNIT AND COMPONENTS ARE NOT INSULATED AGAINST ELECTRICAL SHOCK. ENSURE PROPER CLEARANCE AROUND THE BODY/PLATFORM AND HI-LIFT STRUCTURE. FAILURE TO HEED S MAY RESULT IN SERIOUS INJURY OR DEATH TO OPERATOR AND/OR CREW. ENSURE ALL PERSONNEL ARE STANDING CLEAR OF STABILIZERS AND STABILIZER PAD CONTACT AREA WHEN DEPLOYING AND RETRACTING STABILIZERS. CRUSHING AND/OR PINCHING INJURY MAY RESULT. DO NOT ATTEMPT TO PERFORM ANY MAINTENANCE WORK OR REPAIRS ON A RAISED SCISSOR LIFT/PLATFORM WITHOUT ENGAGING THE MAINTENANCE PROP. FAILURE TO COMPLY COULD CAUSE DEATH OR INJURY. CAUTION DO NOT LEAVE WHEN HI-LIFT UNIT IS IN RAISED POSITION UNATTENDED. 2. SAFETY FEATURES A. Standard Features Headlights Combination tail and stoplights Back up lights Turn signals and hazard warning Parking brake Emergency lowering Handrails around platform Maintenance prop for maintenance access beneath van body B. Safety Interlocks Stabilizers and Hi-Lift will not operate unless the transmission shift lever is set on neutral and the parking brake is on. The Hi-Lift cannot be raised unless the stabilizers are fully deployed. Stabilizers cannot be retracted unless the Hi-Lift is fully lowered. The vehicle cannot be moved or driven while in lift mode. Page 2 GENERAL INFORMATION AND OPERATING INSTRUCTIONS

4 NOTE: When parking brake is on, it will activate the LIFT mode. With the parking brake off the unit will be in DRIVE mode. 3. SAFETY PROCEDURES DO NOT OPERATE A UNIT THAT HAS DAMAGE TO STRUCTURAL OR HYDRAULIC COMPONENTS. FAILURE TO HEED S MAY RESULT IN SERIOUS INJURY OR DEATH TO OPERATOR AND/OR CREW. Ensure operator and crew are familiar with all phases of the units operation. Follow the local station safety rules and regulations, including the safe maximum load capacities of the equipment. Visually check the vehicle s overall condition. DO NOT operate the vehicle if any defects or damage are noted. Ensure all appropriate routine maintenance and inspections have been performed. Keep hands and feet clear of the vehicle s tires and Hi-Lift mechanism. Securely fasten seat belt before driving the vehicle. Ensure the vehicle is stopped, transmission is in neutral and parking brake is set before dismounting the vehicle. DO NOT shift transmission into gear when engine speed is above idle. Ensure vehicle is at a complete stop before shifting gears. Ensure path is clear before backing up. Follow your local established procedures for alerting other personnel prior to back up. Exercise extra caution in congested areas and around blind corners. DO NOT operate the vehicle at speeds higher than conditions permit. Slow vehicle to a creep speed when approaching within 20 ft (6 m) of the aircraft. Stop vehicle when the platform s bumper is approximately 12 in (304 mm) from the aircraft. Ensure that ample overhead clearance is available, and no soft ground or obstructions are present under the stabilizers pad contact area. Always stand clear of the van body when the Hi-Lift is in operation. DO NOT sit on the vehicle s fenders when the Hi-Lift is raised. Ensure that ample overhead, front, rear, and side clearance is available before raising Hi-Lift van body. Ensure personnel are clear of the van body s path before lowering Hi-Lift. DO NOT attempt to drive the vehicle with the van body partially raised or the stabilizers deployed. OPERATION Page 3

5 PLATFORM CONTROL STATION (IF EQUIPPED) UPPER CONTROL STATION DASH MOUNTED INDICATORS (OPTIONAL) AUXILIARY HYDRAULIC PUMP SWITCH STABILIZER CONTROL STATION LOWER CONTROL STATION MANUAL OVERRIDE VALVES HYDRAULIC ENCLOSURE/TANK Figure 1 CONTROL STATION LOCATION MAIN ELECTRICAL CONTROL BOX Page 4 GENERAL INFORMATION AND OPERATING INSTRUCTIONS

6 4. CONTROLS AND INDICATORS A. Dash Mounted Indicators DO NOT DRIVE OR MOVE THE TRUCK IF ANY OF THE INDICATOR LIGHTS ON THE DASH BOARD ARE LIT. SERIOUS INJURY TO OPERATOR OR DAMAGE TO THE UNIT MAY RESULT. NOTE: Stabilizers and hi-lift will not operate unless the transmission shift lever is set to NEUTRAL and parking brake is ON. NOTE: Dash light will indicate only if engine running. (1) LIFT UP INDICATOR LIGHT (RED) when lit, indicates lift out of rest. (2) STABILIZERS EXTENDED INDICATOR LIGHT (AMBER) when lit, indicates the stabilizers are extended. (3) LIFT READY INDICATOR LIGHTS (GREEN) illuminates when the unit is in LIFT MODE (transmission is in neutral, parking brake set), and the platform can be raised or lowered Figure 2 DASH MOUNTED INDICATORS OPERATION Page 5

7 B. Lower Control Station NOTE: In the event of an emergency, depress the red mushroom head control marked EMERGENCY STOP. This cuts power to all control switches. To reset the EMERGENCY STOP, rotate the red mushroom head control clockwise until it releases. (1) UP SWITCHES two black push button switches. When both buttons are depressed simultaneously and if the stabilizers are extended, the platform will rise. NOTE: The hi-lift cannot be raised unless the stabilizers are extended. (2) DOWN SWITCH one black push button switch. When depressed, the platform will descend. (3) BEACON OFF-ON SWITCH two-position switch. When turned to ON, the beacon light will illuminate. When turned to OFF, the beacon light will extinguish. (4) EMERGENCY STOP red mushroom head push button. Cuts power to the pendant control switches when depressed. NOTE: The emergency stop button must be reset before the hi-lift functions will operate Figure 3 LOWER CONTROL STATION Page 6 GENERAL INFORMATION AND OPERATING INSTRUCTIONS

8 C. Upper Control Station with Engine Stop Switch - Standard NOTE: In the event of an emergency, depress the red mushroom head control marked EMERGENCY STOP. This cuts power to all control switches. To reset the EMERGENCY STOP, rotate the red mushroom head control clockwise until it releases. (1) UP SWITCHES two black push button switches. When both buttons are depressed simultaneously and if the stabilizers are extended, the platform will rise. (2) DOWN SWITCH one black push button switch. When depressed, the platform will descend. (3) ENGINE STOP one red push button switch. Turns off vehicle s engine. (4) EMERGENCY STOP red mushroom head push button. Cuts power to the pendant control switches when depressed. NOTE: The emergency stop button must be reset before the hi-lift functions will operate Figure 4 UPPER CONTROL STATION, W/ENGINE STOP SWITCH - STANDARD OPERATION Page 7

9 D. Upper Control Station with Engine Stop/Start Switch - Optional NOTE: In the event of an emergency, depress the red mushroom head control marked EMERGENCY STOP. This cuts power to all control switches. To reset the EMERGENCY STOP, rotate the red mushroom head control clockwise until it releases. (1) UP SWITCHES two black push button switches. When both buttons are depressed simultaneously and if the stabilizers are extended, the platform will rise. (2) DOWN SWITCH one black push button switch. When depressed, the platform will descend. (3) ENGINE OFF-ON-START three-position spring return from right to center switch. When turned to the START position, the vehicle's engine will engage. When turned to the OFF position, the vehicle's engine will turn off. (4) EMERGENCY STOP red mushroom head push button. Cuts power to the pendant control switches when depressed. NOTE: The emergency stop button must be reset before the hi-lift functions will operate Figure 5 UPPER CONTROL STATION, WITH ENGINE STOP/START SWITCH - OPTIONAL Page 8 GENERAL INFORMATION AND OPERATING INSTRUCTIONS

10 E. 2-Way Platform Control Station - Optional (1) ENABLE SWITCH black push button switch. This button must be depressed to activate the PLATFORM extend/retract or left/right. (2) RETRACT-EXTEND three-position momentary switch (center position = off). When placed in the EXT position while depressing the ENABLE SWITCH, the platform will extend. When placed in the RET position while depressing the ENABLE SWITCH, the platform will retract to its stowed position. NOTE: Platform can be operated with ignition on with platform control switch. Figure 6 2-WAY PLATFORM CONTROL STATION - OPTIONAL F. 4-Way Platform Control Station - Optional 1 2 (1) ENABLE SWITCH black push button switch. This button must be depressed to activate the PLATFORM extend/retract or left/right. (2) LEFT-RIGHT three-position momentary switch (center position = off). When placed in the LEFT position while depressing the ENABLE SWITCH, the platform will move to left. When placed in the RIGHT position while depressing the ENABLE SWITCH, the platform will move to right. (3) RETRACT-EXTEND three-position momentary switch (center position = off). When placed in the EXT position while depressing the ENABLE SWITCH, the platform will extend. When placed in the RET position while depressing the ENABLE SWITCH, the platform will retract to its stowed position. NOTE: Platform can be operated with ignition on with platform control switch Figure 7 4-WAY PLATFORM CONTROL STATION - OPTIONAL OPERATION Page 9

11 G. Stabilizer Control Station (Ref. Figure 8) (1) STABILIZER RETRACT black push button switch. When depressed, returns stabilizers to stowed position. (2) STABILIZER EXTEND black push button switch. When depressed, the stabilizers are deployed so that the platform can be raised. NOTE: All stabilizers must be fully extended before raising lift. 5. HI-LIFT VEHICLE OPERATING PROCEDURE A. Preliminary Checks Figure 8 STABILIZER CONTROL STATION The following preliminary check list shall be performed before driving the vehicle. (1) FUEL LEVEL DO NOT operate vehicle if fuel level is below ¼ tank. (2) WHEEL BRAKES DO NOT operate vehicle if the service brake pedal is resting low near the floorboard or if brake pedal is spongy when brake is applied. (3) TIRES DO NOT operate this vehicle if tire pressure is low. (4) OIL LEVEL Visually check the level of the hydraulic oil on the hydraulic oil reservoir s sight gauge. (5) GENERAL CONDITION Perform a general walk around visual inspection of the vehicle s overall condition. DO NOT operate vehicle or Hi-Lift if any damage to the vehicle or structure is seen. 1 2 Page 10 GENERAL INFORMATION AND OPERATING INSTRUCTIONS

12 B. Driving the Vehicle (1) Ensure the preliminary checklists have been performed before boarding the driver s cab and operating the vehicle. (2) Drive vehicle according to the vehicle operator s manual and applicable laws. C. Hi-Lift (Body) Control Station Operating Procedures Normal Operation Sequence to Raise Unit (1) Slow vehicle to a creep speed when approaching within 20 ft (6 m) of the aircraft. (2) Position vehicle on level ground with a space of at least 12 in (304 mm) between the aircraft and work platform. DO NOT make contact with any part of the aircraft. NOTE: An assistant may be required when positioning the vehicle by the aircraft. (3) Shift transmission into neutral and set parking brake. NOTE: The stabilizers and Hi-Lift functions will not operate unless the transmission is in neutral and the parking brake is set. NOTE: Parking brake will activate the LIFT mode. (4) Dismount the vehicle and extend the stabilizers. Refer to Figure 8. NOTE: All stabilizers must be fully extended before raising lift. (5) Set chocks per operational requirements. DO NOT ATTEMPT TO STABILIZE A HI-LIFT UNIT ON SOFT GROUND OR ON INCLINES BY SHIMMING STABILIZER S. FAILURE TO HEED S MAY RESULT IN SERIOUS INJURY OR DEATH TO OPERATOR AND/OR CREW. STAND CLEAR OF STABILIZERS PAD, WHILE OPERATING THE STABILIZER CONTROLS. CRUSHING INJURY TO OPERATORS FEET COULD RESULT. DO NOT ATTEMPT TO RAISE THE VAN BODY UNLESS THE STABLIZERS ARE EXTENDED AND SET. SERIOUS INJURY OR DEATH TO OPEATOR MAY RESULT IF UNIT UPSETS. (6) With the vehicle securely positioned, board the van body via the boarding steps located at the rear of the unit. (7) Enter the catering body and set the interior lights to the desired condition. The interior lights are controlled by timer circuit, located at the rear, has been installed to prevent drain on the OPERATION Page 11

13 battery if the lights are left on. Set the timer to the desired operation time before switching the interior lights on. NOTE: The front Spot lights will NOT illuminate when the body is in the down position. The rear Spot light will work all the time when needed. The spot light control switches are located at both ends of the truck body. (8) Locate the upper control station (ref. Figure 1). (9) Raise the van body by pushing both UP, UP buttons together. Refer to Figure 4. (10) Adjust the 2 or 4-way platform (if equipped) by depressing the ENABLE switch and place the RETRACT-EXTEND or the LEFT-RIGHT switch to the desired location. Refer to Figure 7 NOTE: Platform can be operated with ignition on with platform control switch. THE HI-LIFT UNIT AND COMPONENTS ARE NOT INSULATED AGAINST ELECTRICAL SHOCK. ENSURE PROPER CLEARANCE AROUND THE BODY/PLATFORM AND HI-LIFT STRUCTURE. FAILURE TO HEED S MAY RESULT IN SERIOUS INJURY OR DEATH TO OPERATOR AND/OR CREW. DO NOT OVERLOAD HI-LIFT UNIT, DO NOT EXCEED THE RATED CAPACITY. SERIOUS DAMAGE TO THE HI-LIFT WILL RESULT, WITH POSSIBLE INJURY TO OPERATORS. CAUTION MAINTAIN A SPACE OF AT LEAST 12 IN (304 MM) BETWEEN THE AIRCRAFT AND WORK PLATFORM. DO NOT MAKE CONTACT WITH ANY PART OF THE AIRCRAFT. NOTE: In the event of an emergency, depress the red mushroom head control marked EMERGENCY STOP. This cuts power to all control switches. To reset the EMERGENCY STOP, rotate the red mushroom head control clockwise until it releases. (11) Once the van body is at desired height, the vehicle's engine may be turned off. Shut off the truck using the ENGINE STOP button switch or rotate the ENGINE OFF-ON-START switch to the OFF position (optional). Normal Operation Sequence to Lower Unit (12) Ensure all personnel are away from under the platform before proceeding. (13) If the engine has been turned off, rotating the engine switch to the START position (optional ENGINE OFF-ON-START switch) will restart the chassis engine. (14) From the upper control station push DOWN button, and lower the unit until it is in its full resting position. Page 12 GENERAL INFORMATION AND OPERATING INSTRUCTIONS

14 CAUTION THE HI-LIFT MUST BE PROPERLY STOWED BEFORE ATTEMPTING TO DRIVE THE VEHICLE. INDICATOR LIGHTS WILL BE LIT IF THE HI-LIFT IS NOT IN THE STOWED POSITION. SERIOUS DAMAGE CAN OCCUR IF THE VEHICLE IS MOVED WITHOUT PROPERLY STOWING THE HI- LIFT. D. Returning Vehicle to Normal Driving Condition (1) Ensure the Hi-Lift is fully lowered, and all stabilizers are fully retracted. NOTE: Stabilize the engine by allowing it to idle before retracting the stabilizers. (2) Mount vehicle cab and release parking brake. Check the dash mounted warning lights. They should all be extinguished. (e.g., stabilizer and lift are retracted and brake is released.) NOTE: Attempting to drive the vehicle while in LIFT MODE (parking brake on) will lock transmission in neutral. Return the gear selector to NEUTRAL, and releases the parking brake to activate DRIVE MODE. Refer to step (1). 6. MAINTENANCE PROPS OPERATION DO NOT ATTEMPT TO PERFORM ANY MAINTENANCE WORK OR REPAIRS ON A RAISED SCISSOR LIFT/PLATFORM WITHOUT ENGAGING THE MAINTENANCE PROP. FAILURE TO COMPLY COULD CAUSE DEATH OR INJURY. The maintenance pros must be used during all service and maintenance where the lift must be raised and personnel must be under the lifted platform. The maintenance props are at the center of the Hi-Lift on both sides. The maintenance props are designed to be quick and easy so as not to discourage maintenance personnel from using it. 1. Raise the scissor sufficiently to swing up prop. (Both sides) 2. Swing both props up. 3. Lock the maintenance props into position by inserting the Lock pin through the locking tabs and props (ref. Figure 9). 4. Lower the scissor securing the maintenance props in the support position. 5. To remove the maintenance props, raise the scissor high enough to disengage the maintenance props and provide clearance for the maintenance props to swing down. 6. Remove the Lock pin (ref. Figure 9). 7. Swing props down to their stowed position. OPERATION Page 13

15 MAINTENANCE PROP LOCKING PIN MAINTENANCE PROP STOWED Figure 9 MAINTENANCE PROP MAINTENANCE PROP ENGAGED Page 14 GENERAL INFORMATION AND OPERATING INSTRUCTIONS

16 7. EMERGENCY FEATURES OPERATING PROCEDURES HANDPUMP HANDLE Figure 10 EMERGENCY OVERRIDE PROCEDURE A. Manual Emergency Handpump Retracting (Stowing) Stabilizers (OPTIONAL) 12VDC AUXILIARY HYDRAULIC PUMP SWITCH ENSURE THAT THE HI-LIFT IS FULLY LOWERED BEFORE ATTEMPING TO RETRACT STABILIZERS. (1) Insert handle into Handpump (ref. Figure 10). (2) Press an hold valve (A) and pump handle to retract stabilizers. B. Emergency 12VDC Power Pack Retracting (Stowing) Stabilizers (Optional) B A HANDPUMP ENSURE THAT THE HI-LIFT IS FULLY LOWERED BEFORE ATTEMPING TO RETRACT STABILIZERS. OPERATION Page 15

17 (1) Press an hold valve (A) and press the hydraulic pump switch to retract stabilizers (ref. Figure 10). C. Emergency Hi-Lift Lowering CAUTION STAND CLEAR OF DESCENDING HI-LIFT. SERIOUS INJURY TO OPERATOR MAY OCCUR IF STRUCK BY DESCENDING LIFT. (1) Close the valve (B) in the hydraulic box (ref. Figure 10) by loosening locknut and turning fully clockwise. (2) Go under the truck and reach up to the under side of the lift cylinders (ref. Figure 11). (3) Locate the red manual operation knobs (E). (4) Push in and turn the red knob counter-clockwise until it pops out. (5) Return to the box and slowly open the flow control as necessary to bring the lift down safely. (6) Once down, the valve (E) must be reset by pushing in & twisting clockwise until it locks. (7) Readjust valve (B) per Hydraulic Adjustment Section 2-2 when unit is functioning again. E Figure 11 EMERGENCY HI-LIFT CYLINDER LOWERING Page 16 GENERAL INFORMATION AND OPERATING INSTRUCTIONS

18 8. OPTIONAL- AIRCRAFT CONTACT SENSING BUMPER DO NOT PLACE OBJECTS OR STEP ON PLATFORM BUMPER - LIFT WILL LOWER AUTOMATICALLY. OPERATION Page 17

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