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1 - GASOLINE MANUAL NUMBER EFFECTIVITY: 09/26/02 GASOLINE POWERED Scissor Lift Vehicle -1036S thru -1037S REV 00 CORPORATION 9501 SOUTH CENTER ROAD MUNCIE, IN P.O. BOX 2645 MUNCIE, IN Phone Number (765) Fax Number (765)

2 OPERATION This Operations Manual is to be used as a quick reference only. Complete Operations instructions along with Parts, Lubrication, Maintenance, Troubleshooting, Repair, and Warranty information are located in the Full Manual. Consult the Full Manual or the Factory when any question arises that is not covered within this Operations Manual. Electrocution Hazard: Platforms of Lift-A-Loft units are not electrically insulated. Therefore, contact with or proximity to any wires or other potential electrical conductors must be considered highly dangerous. A minimum distance of 10 feet must be maintained between potential conductors and the operator or platform, whichever is closer. Check local codes and facility directives for the possibility of additional requirements. Surface Conditions: The gradeability characteristics of Lift-A-Loft units are intended for travel between overhead work locations only. Do not raise the unit on a ramp or incline. Death or serious personal injury may result. The travel path and supporting surfaces must be sufficiently firm to safely hold both the unit and its rated load. Platform Capacity: Operators must continually be aware of the load being imposed upon the platform. This load must not exceed the maximum rated capacity of the platform. The maximum rated capacity for each unit is the total combined weight of all personnel, tools, supplies and equipment carried on the platform for raising, holding, lowering or traveling. The maximum rated capacity of each unit can be seen both on the Serial Number Plate as TOTAL PLATFORM CAPACITY and on decals placed on the unit. The rated load capacity for each unit must not be exceeded under any circumstances - raising, holding, lowering, or traveling. Lift-A-Loft encourages personnel in the platform to wear safety harness and have provided attachment points for connecting the safety harness (Lanyard Attachment). Check local codes and facility directives. Safety harness may be mandatory at your site. Never attach harness to an adjacent structure when working from the platform. Following are several basic rules that are a must for good platform safety. PLATFORM SAFETY RULES Never use the unit without the platform railings or with only partial railings. Do not use ladders, boxes, or similarly dangerous objects to gain additional reach on the platform. Also keep platform clear and free of oil and debris. Never lean out over the railings. If the work cannot be safely reached, re-position the unit for safe access. Make sure personnel on the platform have their hands, arms, etc. within the perimeter of the platform when in motion. Do not climb on the elevating mechanism. Never work inside the elevating mechanism or under the platform, unless precautions have been taken to support the mechanism, and the controls have been completely shut off. Do not use the railings to support and carry material and loads. Do not permit any materials to overhang the platform. Do not attach overhanging loads or increase platform size. Do not transfer from the platform to another structure when working aloft. Before lowering the platform, be sure the area surrounding the platform is clear of personnel and other hazards. Before raising the platform, be certain that the area above and around the unit is free of obstructions and hazards and that the platform remains a safe distance from electrical lines and other conductors. Page 1

3 Do not attempt to adjust any of the factory set pressure, or descent rate controls; and do not attempt to circumvent or override any other controls installed on the unit. These controls are incorporated on the unit for operator safety and equipment protection. Driving Conditions: The APX was designed for travel in and around the airport. Do not drive the vehicle in areas intended for licensed high speed traffic. PRE-USE INSPECTION On a daily basis before the unit is placed in service; it must be given a thorough inspection by the operator or other designated person to determine readiness for safe use. Additionally, each subsequent user should also check the unit before operating it even though a prior user may have checked it during the workday. 1) Components of Pre-Use Inspection: The following items constitute the minimum elements of the Pre-Use Inspection. 2) After-Inspection Action: After completion of the required Pre-Use Inspection any items not meeting inspection standards, codes, or directives shall be reported immediately. Items determined to be detrimental to safety must be corrected before the unit is placed in service. Do not release or operate any unit if the Pre-Use Inspection discloses items that affect safe use. Report such deficient items for correction by trained and qualified personnel. During operation, be alert for signs and indications of improper unit functioning, such as sluggish or erratic control, excessive noise, or other possible indications of the need to re-check the unit before continued operation and use. Check for overall appearance and cleanliness. Labels and placards must be in place and operation manual properly attached. Examine platform area to be sure that all guardrails and kick plates are in place and that platform is free of debris, oil, or loose items. Examine hydraulic fittings and connections for any signs of leakage, and check hoses for scrapes, cuts, scuffs, or abrasions. Examine unit for telltale signs that lubrication and other preventative maintenance has been performed. Check the unit in all operating modes to establish that all functions are operating correctly and are free from damage. DAILY PRE- USE INSPECTION Examine cam roller tracks and cylinder rods to determine that they are free of dirt and debris. Clean off rods as required. Check unit to be sure that the protective covers for components (valves etc.) are installed and free from any external damage. Visually check overall unit condition to verify it is free from damage to structural members and from cracked welds and other signs of misuse or abuse. Check tires for scrapes, cuts, or other damage that could adversely affect unit operation and safety. Check that entrance chains are securely fastened after entering platform. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. This unit is designed for single function operation. Do not attempt to operate more than one function at a time. The resulting action may be unpredictable. Exception: The steering function is designed to be operated simultaneous to the forward and reverse functions. VEHICLE OPERATION: The following control information is presented in sequence as if the user is to: Position the unit; Enable the controls; Enter the platform, change elevation, and operate the oiler or compressor. Concluding this section, is information on controls to be used in emergency situations. Page 2

4 A. ENTER THE VEHICLE & SERVICE AIRCRAFT 1. Position the side view mirror for proper viewing. See engine starting instructions. 2. Depress foot brake and move the parking brake lever completely forward. The brake pads may rub (increasing fuel consumption and/or causing rotor damage) if the parking brake is not completely disengaged. 3. Select gear (forward or reverse), release foot brake, and drive vehicle similarly to an automobile. (See controls on the next few pages.) CAUTION: The parking brake is to be used to hold the unit stationary when not in use. Do not apply the brake when the vehicle is in motion, damage to brake components is certain. If parking brake must be used for emergency purposes, inspect the drive line including drive shaft, rotor, brake pads, calipers, rear end, and transmission for damage or excessive wear. CAUTION: Oil Press. If the battery, engine oil, hydraulic oil heater is plugged into a 110VAC outlet, be sure to unplug before moving the unit Horn Dash Steering Wheel Power Brakes Accelerator Cold Weather 110VAC Input Dash Light CAB Oil Temp. (Water Temp.) Shifter Parking Brake Voltage Glow Plug (Diesel) Fuel Gauge Indicator Light Stabilizers Parking Brake Lowered Engaged Hour Meter Head/ Parking Lights Not Used DASH (LEFT SIDE) Ignition Switch Shift Lever DASH (RIGHT SIDE) Page 3

5 Ignition Switch (Dash Right Side) The Ignition Switch provides power to the engine starter motor and the vehicle accessories (lights, etc.) The transmission shifter must be in neutral and parking brake set to start the engine. To start the engine the Upper Control Station Off On Start switch must be in the "ON" position. (If starting from the Upper Control Station the dash ignition switch must be in the "ON" position.) Turning either ignition switch to the "OFF" position will cause engine to stop. Turn the driver ignition switch to the "ON" position, wait 5 seconds for the glow plug indicator to turn off (Diesel Engine). Cold weather may require a longer wait before glow plug will turn off. Turn ignition switch to the start position, release as engine starts. If engine fails to start or fails to remain started, the complete sequence must be repeated. Temperature Gauge (Dash Left Side) This gauge monitors the cooling system of this vehicle. Determine the normal operating temperatures for your engine 180 to 195 F (82-90 C) If the gauge ever begins to show substantially higher temperatures 266 F (130 C) [210 F for gasoline engine], shut off engine and check engine section of manual for possible causes. Vehicle Lights (Dash Left Side) The vehicle lights are controlled by a three position toggle switch, OFF PARKING HEADLIGHTS. Oil Pressure Gauge (Dash Left Side) This gauge indicates whether lubricating oil is circulating through the engine. At idle the gauge should read 20+ psi. The needle should show 30+ psi when the engine is at 1800 rpm and under load. If the gauge ever continues to read low, have the vehicle checked by qualified personnel. Volt Gauge (Dash Right Side) This device shows the alternator output when the engine is running and the battery condition with the key on and the engine not running. The gauge should read 13 or 14 volts while the engine is running and 12 volts with the engine not running and the key on. Fuel Gauge (Dash Right Side) This gauge indicates the fuel remaining in the 25 gallon fuel tank. Glow Plug (Dash Right Side, Diesel Engine Only) Glow plug light will illuminate when the ignition switch is turned to the ON position. When the engine glow plug has preheated and the engine is ready to start it will turn off. Hour Meter (Dash Right Side) The hour meter indicates the hours of vehicle use. One maintenance person should be assigned to monitor the hour meter and schedule maintenance. (Ref. Maintenance Record in chapter 2 section 1.) Stabilizers Indicators (Dash Right Side) The stabilizer indicator will illuminate when the stabilizers are in the down position. Listen for audible loading indication. Parking Brake Indicator (Dash Right Side) The parking brake light will illuminate when the parking brake is engaged. 4. Drive unit to aircraft and position unit in a convenient location to service aircraft. Position unit carefully taking notice of overhead obstacles. (Opt. Turbine Oil Fill) Drive the unit to turbine oil supply for your facility. Connect the turbine oil supply line (pull back collar-insert hose-release collar) to the quick disconnect fitting (located on top of the oil dispensing tank located directly behind the passenger seat.) Fill the tank (36 gallons when full) keeping close watch on the upper site glass on the rear. DO NOT OVERFILL!! (A shutoff valve will stop filling when the tank is full.) (Opt. Compressor) Before putting compressor into service, break in the new compressor by running for 30 minutes without building pressure to insure proper piston and bearing lubrication. CAUTION: Use caution when positioning and maneuvering the unit around aircraft or other vehicles. 5. Place transmission in neutral and set parking brake, leaving engine running. Lift operations may be accomplished from the lower or the upper control station. Instructions concerning the lower control station will be accompanied by a while the instructions for the upper control station will be accompanied by a. Page 4

6 Consult airline maintenance manual for specific details concerning the aircraft being serviced. 6. Before using lift, transmission must be in neutral, parking brake must be set, both ignition switches must be in the ON position, all "EMERGENCY STOP" buttons must be in the out position, and engine must be running. If lifting above 8 feet (2.44 meters) or (Opt.) traversing the platform the stabilizers must also be lowered. 7. After positioning the unit, the lower control station may be used to lower the stabilizers. Press and hold the "ENABLE" button while pressing the "STABILIZERS RAISE LOWER" toggle toward "LOWER". Lower until fully extended (an audible loading sound will indicate full extension.) (This step may be omitted if lift is to be raised less than 8 feet (2.44 meters) and platform is not going to be (Opt.) traversed.) Do not lift or (Opt.) traverse the platform unless the personnel on the platform are aware of your intentions. Damage to aircraft, serious personal injury, or death could result. CAUTION: In cab stabilizers light is not an indication of full extension. CAUTION: Stabilizers must be deployed onto a solid surface that is free of debris to be effective. If Warning Lights option was selected, warning lights will flash and an audible warning will sound as unit is lowered. 8. From lower control station the "ENABLE" button must be pushed and held while toggling the "LIFT RAISE LOWER" switch to position the platform at the desired work height. 9. (Optional) To traverse the platform the "ENABLE" button must pressed and held while toggling the "TRAVERSE OUT IN" switch Optional until the desired extension is achieved. Traversing is not available unless the platform is raised above 8 feet (2.44 meters). 10. Any "EMERGENCY STOP" switch will stop all functions in progress. Lower Control Station B. PLATFORM ENTRY & UPPER CONTROLS: The platform must be completely lowered before attempting to enter the platform. 110VAC may be provided to the upper control station by plugging in the isolated circuit to the upper platform. Lower 110VAC input is in the lower enclosure. 1. Enter the platform from the front or rear of the unit. Entry requires personnel to ascend step(s), unlatch bars, and step onto platform. 2. After entering the platform, insure that the entrance bars are securely latched. If you can not negotiate a climb of this height without undue strain, do not operate the unit. 3. To raise or lower the stabilizers, the Enable button (Upper Control Station) must be held in the "ENABLE" position while simultaneously holding the Stabilizers Raise/Lower switch in the "RAISE" or "LOWER" position. Releasing either switch will stop raise or lower function. The Platform Raise Lower functions and the (Opt.) Traverse In Out functions are controlled at the Upper Pendant Controller; while the Stabilizer Raise Lower, the Oil system, the Compressor system are all controlled at the Upper Control Station. 4. To raise the platform, the Enable switch (Upper Pendant Controller) must be held in the "ENABLE" position while simultaneously holding the Lift Raise/Lower switch in the "RAISE" position. Releasing either switch will stop raise or lower function. Page 5

7 Stabilizers Raised Light Upper Control Station Stabilizers Raise Lower (Opt.) Oil System ON Light Toggle Enable Stabilizers Panel Light Lowered Light Upper Pendant Controller (Opt.) Compressor - Oiler ON - OFF Toggle (Opt.) Compressor ON Light Engine OFF ON START Switch (Opt.) A utility light is located within an access panel at the right rear of the platform, in the floor panel. Lift the floor panel and remove the light. The light is attached to a cord reel which will allow the light to be used anywhere within the platform. Pull the cord reel out to allow the light to be installed on the guard rail by means of a U-hook. Position the light and turn light "ON" by means of the pushbutton switch on the back of the light assembly. Replace light when finished using light. 5. (Opt.) When the platform is raised above the 8 ' level, the platform may be traversed by pressing and holding "ENABLE" switch while pressing the Traverse switch to the "OUT" position. Retracting is done by pressing and holding the "ENABLE" switch while pressing the retract switch to the "IN" position. Releasing either switch will stop the extend or retract feature. (Opt. Oiler System) The controls for the oil system are located on the Upper Control Station. Turn the Oil System Compressor switch to the "OIL SYSTEM" position. An Oil System "ON" light will illuminate. The optional Oiler System and the optional Compressor will not operate simultaneously. Emergency Stop Lift Raise Lower Enable (Opt.) Traverse Out In If the optional Oil System or optional Compressor is "ON" and the Mast Raise is activated, the Oil System will shut down until Mast Raise is released. Both systems will not operate simultaneously. (Opt. Oiler System) Rotate the dial on the dispenser to the "0" position before starting to pump turbine oil. Follow aircraft instructions for connecting nozzle to aircraft. Connect overflow container quick disconnect to the aircraft turbine oil overflow fitting. (Opt. Oiler System) Press dispenser safety switch and pull trigger until desired amount of turbine oil has been pumped into aircraft turbine oil tank (dispenser dial indicates amount pumped in pints.) Release trigger and disconnect oil dispenser and overflow container from aircraft. Turn Oil System switch to the center position (see Upper Control Station). Do not pump the turbine oil supply tank completely empty. Running the pump without turbine oil will cause the pump to fail! An internal switch will turn off oiler system until reservoir is refilled. If the Compressor is "ON" and the Mast Raise is activated, the Compressor will shut down until Mast Raise is released. Both systems will not operate simultaneously. (Opt. Compressor) The controls for the compressor are located on the Upper Control Station. Turn the Oil System Compressor switch to the "COMPRESSOR" position. A Compressor "ON" light will illuminate. Page 6

8 (Opt. Compressor) The pressure for the compressor system must be set at the compressor assembly at ground level (the compressor will have to be turned on at the Control Station before setting pressure.) The gauge and the regulator for the compressor system is located on the right side and inboard of the compressor. If for any reason, the platform will not lower after following the normal lowering procedure, raise the platform slightly and STOP ALL OPERATION! Visually check for obstructions around the mechanism or under the platform and re-position unit as required. If no obstructions are apparent, remove personnel from platform! This situation indicates a bind in the scissors, or loose or broken parts with-in the mechanism. This condition should not be corrected while personnel are on the platform! Before changing the elevation of a platform, be sure that the platform travel pathway is clear and free of obstacles before proceeding. The units raise and lower speeds are preset, but may vary slightly in relation to the temperature and the platform load. Attempts to drive the vehicle with the lift raised or stabilizers lowered will cause the engine to shut off. The lift must be lowered to retract stabilizers. The lift may not be lowered below 8 feet if the (Opt.) platform is traversed. LOWER CONTROL STATION: The Lower Controls (at ground level) may be used in emergency situations, such as assisting the platform operator in the event that he or she becomes incapacitated. The controls can also be used by authorized persons to access components during maintenance and testing. The lower controls will always override the upper controls in any situation. Clearance must be maintained between operator and scissors or platform. Failure to maintain clearance could result in injury or death. Unauthorized tampering with or use of the controls at the Lower Control Station, especially when personnel are in the platform, may be dangerous and could result in death or serious personal injury. A 110VAC duplex outlet is located below the upper control station on the side of the pedestal. The 110VAC input must be plugged in at the lower enclosure (left side behind rear tire.) C. EMERGENCY : 1. Depressing any "EMERGENCY STOP" button will stop function and shut off engine. 2. Emergency platform lowering, platform traverse, (Opt.) platform retract, stabilizers raise, and stabilizers lower is available at the lower enclosure rear of unit on the drivers side.) 3. Press and hold the spool shifter (blue button) into the end of the solenoid to shift the valve in the direction to activate the desired function. (See Lower Enclosure) Press any "EMERGENCY STOP" button to eliminate the possibility of accidental activation of the unit. 4. With the spool shifter firmly held in place, pump the hand pump to build pressure. Retract the platform if the platform is extended. Failure to retract the platform before lowering the platform assembly will result in damage to the unit or personal injury if some one is in the vehicle. 5. The platform extension solenoid and the stabilizers solenoid will pump the desired function slowly with each stroke of the pump, however the platform lower will build pressure in the main lift cylinder holding valves and allow complete lowering of the platform after pressure has built. Page 7

9 Hand Pump All personnel who use this unit as well as their supervisors should be fully familiar with the emergency operations. Do NOT wait until an actual emergency exists before learning the operation of the Emergency System. D. BEFORE LEAVING THE VEHICLE AT END OF SHIFT OR DURING PERIODS OF INACTIVITY 1. Place the vehicle in neutral and shut off the engine. 2. Return parking brake to the straight up (engaged) position. 3. Insure that Ignition Switch is in off position. 4. Plug in cold weather engine oil, hydraulic oil, and battery heater if needed. Receptacle for heater is located on engine tunnel near parking brake. (See Cab Illustration) Stabilizers Platform Lift Traverse Lower Enclosure Insert Spool Shifter into Center of Coil Page 8

Property of American Airlines

Property of American Airlines 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