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Operator Manual

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-144SO CONTAINER/PALLET LOADER

CHAPTER ONE, SECTION 2: OPERATOR INSTRUCTIONS

A. General Information

WARNING: DO NOT ATTEMPT TO OPERATE THIS LOADER UNTIL YOU HAVE

BEEN TRAINED AND AUTHORIZED TO DO SO.

WARNING: THIS LOADER WAS NOT DESIGNED TO TRANSPORT CARGO.

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TRANSPORTING CARGO WITH IT MAY RESULT IN INJURY TO

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PERSONNEL AND DAMAGE TO THE EQUIPMENT.

A.1 control Locations

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All driving and loading operations are controlled from the

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operator's station, which is located on the right side of
the bridge platform. The station has two control
positions. DRIVE mode operations are controlled from the

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DRIVE Control Panel, where the driver faces the front of
the loader. LOAD mode operations are controlled from the
LOAD Control Panel, where the operator faces the rear of
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the loader.
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A.2 Aircraft Compatibility
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The TLC 818 Loader services the following aircraft:

Loader Aircraft Model Aircraft Model

Model Main Deck Lower Lobe
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TLC 818-144 707' 727' 737 747, 757, 767,

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(144 In. (366 em) DC-8, DC-9 DC-10, L-1011,

Door Sill Height) (Including "500"),
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A-300, A-310, A-320

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TLC 818-218 707' 727' 737 747, 757, 767,

(218 In. (554 em) 747, 757, 767 DC-10, L-1011,
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Door Sill Height) DC-8, DC-9, DC-10, (Including "500"),

L-1011, A-300, A-300, A-310, A-320
A-310, A-320

125" Wide Option 747, 767 With 125 Inch Wide Cargo Door.

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-14480 CONTAINER/PALLET LOADER

The loader may handle the following containers:

LD-1 through LD-11,

88 x 125 pallets
96 x 125 pallets

B. Operator Maintenance Checks

The following maintenance checks should be made daily before

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operating the loader.

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B.1 Hydraulic Reservoir Oil Level Gauge

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The Hydraulic Reservoir Oil Level Gauge is mounted on the
Front of the hydraulic reservoir, which is at the left end

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of the engine compartment. Hydraulic fluid level should be
maintained near the top of the gauge with the elevator and
bridge in the "down" position.

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B.2 Engine Fluid Checks ic
Check that the coolant and engine oil are at the proper
level.
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Check that the battery electrolyte is at the
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proper level.
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 OPERATION AND MAINTENANCE MANUAL
TLC 818-14480 CONTAINER/PALLET LOADER

C. DRIVE Mode

c.1. DRIVE Mode control/Indicator Locations

This section gives the location of the controls and

indicators used in the DRIVE mode. The Driver standing at
the Drive Control Panel is on the right side of the Bridge
facing toward the front of the loader.

DRIVE CONTROL PANEL

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1. Ignition/Starter Switch 9. Bridge Up/Down Switch
2. Emergency Stop Switch 10. Panel Lamps On/Off sw.
3. Engine Temperature Gauge 11. Spot Lamps On/Off Switch

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4. Engine Oil Pressure Gauge 12. Head Lamps On/Off switch
5. Engine/Battery volt meter 13. Back-up Lamps On/Off Sw.

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6. Fuel Gauge 14. Green Lamp, Drive Mode
7. Drive Selector Switch 15. Red Lamp, Load Mode
8. Stabilizers Up/Down switch

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0 0
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0
0

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FIG. 1: DRIVE CONTROL PANEL

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-144SO CONTAINER/PALLET LOADER

c.1.a DRIVE Mode Indicators and Gauges (See Fig. 1)

c.1.a.1 Indicator Lamp Locations

The red LOAD Mode Lamp (Item 15) and the green DRIVE
Mode Lamp (Item 14) are at the lower right of the
DRIVE Control Panel. The LOAD Lamp is illuminated
when the stabilizers are fully extended (DOWN) . The
DRIVE Lamp is illuminated when the stabilizers are

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fully retracted (UP).

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c.1.a.2 Meter and Gauge Locations

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The Engine Oil Pressure Gauge (PRESS) (Item 4) and
the Engine Coolant Temperature Gauge (TEMP) (Item 3)

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are at the upper left of the DRIVE Control Panel.

The Voltmeter (VOLT) (Item 5), which indicates the

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condition of the battery and the charging system, and
the Fuel Quantity Gauge (FUEL) (Item 6) are located
on the upper right side of the DRIVE Control Panel.
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C.1.b DRIVE Mode Control Panel controls (See Fig. 1)
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C.1.b.1 Ignition/Starter Switch (Item 1)
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The Ignition Switch is a four-position switch located

on the left side of the DRIVE Control Panel. An
(Optional) keyed ignition switch may be installed on
specified loaders.
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C.1.b.2 stabilizer Control switch (STAB) (Item 8)

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This three-position switch, on the lower left side of

the DRIVE Control panel, is spring loaded to the OFF
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(center) position.
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C.1.b.3 Drive Selector switch (Item 7)

The Drive Selector Switch is a three-position toggle

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switch on the right side of the DRIVE Control Panel

above the mode lamps. This Switch MUST be lifted
when being toggled. Moving the switch up (F) puts
the loader in FORWARD drive. Moving the switch down
(R) puts the loader in REVERSE drive. The Middle
position (N) puts the loader in NEUTRAL.

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-144SO CONTAINER/PALLET LOADER

C.1.b.4 steering Wheel and Pedals

The steering wheel operates the power steering

system.
The accelerator pedal is the right pedal, beneath the
DRIVE Control Panel. Pressing it increases vehicular
speed. Releasing it results in a Dynamic Braking
action.

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The brake pedal is the left pedal, beneath the DRIVE
Control Panel. Press the brake pedal to apply the
hydraulic disc brake on the loader drive wheel.

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C.1.b.S Lamps and Signal Controls/Indicators (See Fig. 1)

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The Ignition Switch must be in the ON position when
using Lamps and Signal Controls/Indicators.

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The HEAD LAMP switch (Item 12) is a two-position
toggle switch located on the right side of the DRIVE
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Control Panel. Moving the switch UP turns ON the
Headlamps and Taillamps.
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The PANEL LAMP switch (Item 10), is a two-position
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toggle switch located at the center of the DRIVE

Control Panel. Moving the switch UP turns ON all
Instrument and Control Panel Lamps.

The Optional Turn Signal/Hazard Lamps Operating Lever

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is mounted on the steering wheel column. Moving the

lever in the direction the steering wheel is turned,
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flashes the lamps at the front and rear of the loader

on that side. Pull UP on the metal plate at the base
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of the operating lever to flash lights at all four

corners of the loader simultaneously.
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The BACKUP LAMP switch (Item 13) is a two-position

toggle switch located on the right side of the DRIVE
Control Panel. Moving the switch up turns ON the
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Backup Lamps.

The SPOT LAMP switch (Item 11) is a two-position

toggle switch located at the center of the DRIVE
Control Panel. Moving the switch up turns ON the
Spotlamps.

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-144SO CONTAINER/PALLET LOADER

C.2. DRIVE Mode Emergency Control Locations

c.2.a Ignition switch (See Fig. 1, Item 1)

The Ignition switch is the master control switch. If a

fluid leak develops or the loader does not stop when the
throttle is released, turn the Ignition/Starter switch
OFF.

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C.2.b Emergency stop Button (See Fig. 1, Item 2)

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There are two RED Emergency Stop Buttons, one button is
at the top center of the LOAD control Panel. The other

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is located on the electrical box on the left side of the
loader. Pushing either button stops the engine and cuts

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all power.

C.2.c Stabilizer Emergency Hand Pump/Valve (See Fig. 2)

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The emergency hand pump is on the hydraulic plate on the
right side of the loader, behind the right stabilizer
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cylinder. The emergency retraction valve is next to the
pump. The pump may be used to raise the stabilizers in
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the event of a hydraulic system failure.
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STABILIZER HAND PUMP

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EMERGENCY RETRACTION

FIG. 2: STABILIZER HAND PUMP

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-144SO CONTAINER/PALLET LOADER

c. 2 .d Emergency Drive switch (See Fig. 3)

The Emergency Drive Switch is located inside the

Electrical Enclosure Box, which is at the left side of
the loader. The Emergency Drive Switch routs power
directly to the Drive Selector switch, allowing the
loader to be driven Forward or Reverse in the event
of system failure.

EMERGENCY

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DRIVE

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SWITCH

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OPTIONAL
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FIG. 3: EMERGENCY DRIVE SWITCH
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c.2.e Propulsion Bypass Valve (See Fig. 4)

The Propulsion Bypass Valve, which must be opened before

the loader is towed, is located on the upper rear frame
crossmember weldment below the bridge.
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PROPULSION
BYPASS VALVE

FIG. 4: PROPULSION BYPASS VALVE

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-14480 CONTAINER/PALLET LOADER

C.3. DRIVE Mode operator Instructions

C.3.a. General Information

The loader is protected by interlocks in the control

system against improper operation which could result in
injury or damage. The Stabilizers cannot be raised
(shifting the loader into the DRIVE Mode) unless the
Elevator Platform is completely lowered. The
Stabilizers cannot be lowered while the loader is in

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DRIVE. A detailed technical description of the

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interlocks is in Chapter Two.

These instructions are for a typical sequence. They

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describe operations necessary to start the loader and
move it to an aircraft.

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WARNING: DO NOT ATTEMPT TO OPERATE THIS LOADER UNTIL YOU HAVE
BEEN TRAINED AND AUTHORIZED TO DO SO.

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WARNING: BEFORE STARTING THE ENGINE, PUT THE DRIVE CONTROL SWITCH
IN THE NEUTRAL (N) POSITION. ic
WARNING: DO NOT OPERATE THIS LOADER IN AN ENCLOSED AREA WITHOUT
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ADEQUATE VENTILATION. EXHAUST FUMES FROM AN INTERNAL
COMBUSTION ENGINE CONTAIN CARBON MONOXIDE, A COLORLESS,
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ODORLESS, DEADLY GAS.

C.3.b. Power Unit Operation

See the Engine Manual, which is part of the

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Manufacturer's Appendices, for detailed information on

the operation of the specific engine installed in this
loader.
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C.3.b.1. Prestart Instructions

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Lift and move the Drive Selector Switch to the

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neutral (N) position. The starter may operate only

when the engine is not running and this switch is in
the N position.
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TLC 818-144SO CONTAINER/PALLET LOADER

DRIVE SELECTOR SWITCH

MUST BE LIFTED WHEN
BEING TOGGLED.

STAI

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FIG. 5: DRIVE SELECTOR SWITCH

C.3.b.2 Starting Instructions

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CAUTION: DO NOT OPERATE THE STARTER CONTINUOUSLY FOR MORE THAN 30

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SECONDS. AFTER PROLONGED USE, ALLOW THE STARTER TO COOL
BEFORE ENGAGING IT AGAIN.

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Move the Ignition/Starter switch directly from the
OFF position to the START position and hold for
approximately ten (10) seconds or until the engine
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starts. Release the switch when the engine starts.
The lever will automatically return to the IGN
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position. The switch may not be turned to the START
position without first returning to the OFF position.
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If the engine dies or fails to start, the ignition

switch must be moved to the OFF position before it
may be returned to the START position.
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When the switch is released, a timing cycle begins

and prevents immediate re-engagement of the starter.
This assures that the engine comes to a complete stop
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before the starter motor is re-engaged.

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Moving the switch to the ACC position has no function

on the standard TLC 818 Loader.
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Moving the switch to the OFF position shuts off the

engine and all systems.
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The switch returns to the IGN position when it is

released after the starter is operated. It is the
"RUN" position.

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TLC 818-14480 CONTAINER/PALLET LOADER

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FIG. 6: IGNITION SWITCH
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The engine is equipped with an automatic shutdown

system which operates in the event of low fuel supply
{Optional), loss of engine coolant, high engine
coolant temperature or loss of engine oil pressure.
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The cause of the shutdown must be determined and

corrected before the engine is started again.
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NOTE: Complete scheduled operator maintenance checks before

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operating this loader to insure against engine shutdown.

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NOTE: If the ignition switch should be left in the IGN position

prior to being moved to the START position, a shutdown could
occur due to the engine protection system. Before a restart
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is attempted the ignition switch must be turned off for 30

seconds to allow the system to reset.

C.3.b.3 Emergency Battery Charging

Check that the problem is not an open circuit
breaker. Reset the breakers to insure that the
circuit is closed. Discharged batteries should be
removed, recharged, or replaced.

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-14480 CONTAINER/PALLET LOADER

WARNING: WHEN USING JUMPER CABLES, POLARITY MUST BE OBSERVED.

CONNECT NEGATIVE (-) TO NEGATIVE AND POSITIVE (+) TO
POSITIVE, OTHERWISE SERIOUS DAMAGE TO THE ALTERNATOR
SYSTEM MAY OCCUR. TO PREVENT THE IGNITION OF HYDROGEN GAS
WHICH MAY BE PRESENT IN THE VICINITY OF THE BATTERIES,
CONNECT THE JUMPER CABLES IN THE FOLLOWING SEQUENCE:

1. CHECK THAT THE LOADER IS NOT IN ANY WAY IN CONTACT

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WITH THE EXTERNAL POWER SOURCE.

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2. CONNECT THE JUMPER CABLE TO THE POSITIVE (+)
EXTERNAL 12 VOLT SOURCE, THEN CONNECT THE OTHER

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END OF THE CABLE TO THE POSITIVE (+) POLE OF THE
LOADER BATTERY.

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3. CONNECT THE SECOND JUMPER CABLE TO THE NEGATIVE
(-) EXTERNAL 12 VOLT SOURCE, THEN CONNECT THE

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OTHER END OF THIS SECOND CABLE TO AN UNPAINTED
SPOT (AWAY FROM THE BATTERY) ON THE LOADER FRAME
OR BUMPER.
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C.3.b.4. Cold Weather starting option
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Ether Injector Option, (Detroit Diesel Option Only).
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Some engines are equipped with an optional ether

injection system as an aid to cold weather starting.
If the engine temperature is below 60°F, the system
automatically injects a controlled amount of starting
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fluid into the intake manifold as the engine is

started. The reservoir tank contains approximately
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200 measured injections of starting fluid and will

normally last for a full winter season.
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Cold Weather Heater Option (115V)

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CAUTION: DO NOT RUN THE ENGINE WHILE THE ENGINE COOLANT HEATER IS
CONNECTED. DO NOT OPERATE THE COOLANT HEATER UNLESS THE
COOLANT IS AT THE PROPER LEVEL.
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The Cold Weather Engine Heater option is an engine

coolant heater. The heater aids cold weather
starting by heating the engine cooling system. This
helps maintain proper oil viscosity and increases the
cylinder wall temperatures, making engine cranking
and starting easier.

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TLC 818-14480 CONTAINER/PALLET LOADER

The Hydraulic Oil Heater Option provides a heating

element inside the Hydraulic Reservoir. This helps
maintain proper oil viscosity.

Preheat Cold Start (Perkins Diesel Only)

Perkins Engines may be fitted with a preheater which

is operated by pressing a button at the lower right
of the DRIVE Control Panel before operating the
starter.

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NOTE: Cold weather starting instructions are in the engine manual.
C.3.b.S Post start Instructions

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CAUTION: IF THE OIL PRESSURE AND VOLTAGE READINGS DO NOT RISE TO

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THE PROPER LEVEL WHEN THE ENGINE IS RUNNING, SHUT THE
ENGINE OFF IMMEDIATELY AND REPORT THE MALFUNCTION.

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As the engine starts, perform the following checks:

1. Check that the oil pressure (PRESS) rises. The

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oil pressure should be approximately 60-70 PSI at
1000 RPM.
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2. The voltmeter (VOLT) reading should rise to 14-15
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volts and remain in the green area if the battery

is in good condition. At a fast idle, the reading
should be between 13 and 15 volts if the
alternator and regulator are working properly. A
reading of less than 12 volts indicates that the
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alternator or regulator is not operating properly.

If the voltmeter reading is off scale low with the
engine running, a circuit breaker is tripped or
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there is a circuit malfunction.

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3. Allow the engine coolant temperature to reach

normal operating temperature (160F-185F) before
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applying a load to the engine.

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•• ••
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FIG. 7: METERS AND GAUGES
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 OPERATION AND MAINTENANCE MANUAL
TLC 818-144SO CONTAINER/PALLET LOADER

C.3.b.6 Engine Shutdown

WARNING: WHEN PARKING THE LOADER, PLACE THE STABILIZERS IN THE

"DOWN" POSITION BEFORE SHUTTING OFF THE ENGINE. VERIFY
THAT THE RED "LOAD" LAMP IS ILLUMINATED.
Move the ignition switch to the "OFF" position to
stop the engine and the electrical system.
C.3.c Stabilizer operation

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The TLC 818 Loader may be driven only when in the DRIVE
mode, which is indicated by the green "DRIVE" lamp on
the Driving Control Panel.

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C.3.c.1 stabilizer UP Instructions

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STAB

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FIG. 8: STABILIZER CONTROL SWITCH

To place the loader in the "DRIVE" mode, hold the

Stabilizer Control Switch (STAB) in the "UP" position
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until the GREEN "DRIVE" Lamp is illuminated. The

stabilizers will retract until they are fully UP or the
switch is released.
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The Adjustable Level Rear Wheel System may raise and

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lower the rear of the loader. The rear of the loader

raises for clearance whenever the stabilizers are
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raised.

As the stabilizers move "UP" the LOAD mode functions are

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disabled and the RED "LOAD" lamp is turned off. When

the stabilizers reach the full "UP" position, the drive
system is activated.

The controls are interlocked to prevent the loader from

being driven with the Elevator UP or the stabilizers NOT
retracted. The interlock also prevents accidental
extension of the stabilizers while the loader is being
driven.

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TLC 818-144SO CONTAINER/PALLET LOADER

C.3.c.2. Stabilizer DOWN Instructions

When the stabilizer switch is moved to the "DOWN"

position, the stabilizers extend until the control
switch is released or the stabilizers are fully
extended.

When both stabilizers have moved into the full "DOWN"

position, the drive system is disabled, the loading
systems operate, and the red LOAD indicator lamp is

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illuminated.

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C.3.d. Emergency stabilizer Operation

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The position of the stabilizers controls whether the TLC
818 is in the LOAD Mode (Stabilizers DOWN) or the DRIVE

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Mode (Stabilizers UP). If the stabilizers are not fully
UP or fully DOWN, the loader will not be in either mode,
and neither the DRIVE nor the LOAD systems will work.

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These emergency procedures allow the stabilizers to be
operated to complete a loading cycle and to move the
loader off an aircraft in the event of a system failure.
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C.3.d.1 Emergency Stabilizers UP Operation
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If the engine is running but the stabilizers do not
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raise when the Stabilizer Control Switch is held UP:

1. Check that the Elevator is completely DOWN.

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2. Check that the drive selector switch is in

NEUTRAL.
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3. Close the Stabilizer Emergency Retraction Valve by

turning the knob fully clockwise.
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If the stabilizers still do not raise, do the

following three things at the same time:
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1. Hold the steering wheel in a full turn to either

side.
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2. Hold the Stabilizer Control Switch UP.

3. Override the Stabilizers UP Solenoid Valve on the

Valve Plate by pressing and holding the override
button.

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TLC 818-144SO CONTAINER/PALLET LOADER

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STABILIZERS UP
SOLENOID VALVE
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FIG. 9: STABILIZERS UP CONTROL VALVE

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If the engine is not running or if the stabilizers do

not raise when the control valve is overridden:
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1. Open the stabilizer Emergency Retraction Valve,

which is located on the hydraulic plate, by
turning the knob fully counter-clockwise.

2. Operate the Stabilizer Emergency Retraction Hand

Pump until both stabilizers clear the ground.

3. Turn the knob on the Emergency Retraction Valve

fully clockwise to close the valve.

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TLC 818-14480 CONTAINER/PALLET LOADER

NOTE: It may be necessary to loosen the jam nut on the valve

stem before the knob may be turned.

STABILIZER HAND PUMP

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FIG. 10: HAND PUMP AND VALVE

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C.3.d.2 Emergency Stabilizers DOWN Operation

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If the engine is running but the stabilizers do not

lower when the Stabilizer Control Switch is held
DOWN.
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1. Check that the Drive Selector Switch is in

NEUTRAL (N).

2. Close the stabilizer Emergency Retraction Valve by

turning the knob fully clockwise.

If the stabilizers still do not lower, do the

following three things at the same time:

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TLC 818-14480 CONTAINER/PALLET LOADER

1. Hold the steering wheel in a full Left turn.

2. Hold the Stabilizer Control Switch DOWN.

3. Override the Stabilizers DOWN Solenoid Valve on

the Valve Plate by pressing and holding the
override button.

NOTE: Do not assume that the stabilizers are not fully down

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because the LOAD indicator is not illuminated. The bulb

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may be defective.

C.3.e Driving Operations

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WARNING: DO NOT DRIVE THE LOADER WITH THE BRIDGE RAISED UNLESS

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MAKING A FINAL APPROACH TO THE AIRCRAFT. DRIVING THE
LOADER WITH THE BRIDGE RAISED CAN LEAD TO MISJUDGMENT
OF OVERHEAD/SIDE CLEARANCES WHICH CAN RESULT IN INJURY

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OR DEATH.

WARNING: DO NOT TRANSPORT CARGO WITH THE LOADER. SUCH USE MAY
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RESULT IN INJURY TO PERSONNEL AND DAMAGE TO THE LOADER.
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CAUTION: IF THE WINTERIZATION KIT IS INSTALLED, CHECK THAT THE
ENGINE HEATER SERVICE CORD IS DISCONNECTED FROM THE
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ELECTRICAL POWER OUTLET BEFORE DRIVING THE LOADER.

C.3.e.1 Normal Speed Driving Instructions

Check that the loader is in the DRIVE mode. Lift and
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move the drive selector switch to F (forward) or R

(reverse).
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Accelerate the loader to the desired speed by

pressing on the accelerator pedal. Releasing
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pressure on the accelerator while the loader is

under way provides hydraulic dynamic braking to
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stop loader movement.

Remove pressure from the accelerator pedal to stop

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loader movement. The brake pedal operates the

service brake used during final positioning of the
loader at the aircraft.

NOTE: THIS SWITCH MUST BE LIFTED WHEN BEING TOGGLED.

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TLC 818-144SO CONTAINER/PALLET LOADER

Drive Selector switch

Note:
switch must be lifted
when toggled

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FIG. 11: DRIVE SELECTOR SWITCH

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C.3.e.2. Inching Instructions

Apply very light pressure on the accelerator pedal

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for extremely slow ground speed when operating close
to aircraft, or in confined areas.
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C.3.e.3. Positioning the Loader at the Aircraft
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These are general instructions. Observe company

procedures and safety regulations when operating this
equipment.
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WARNING: ALWAYS APPROACH AIRCRAFT AT A SLOW SPEED. BE AWARE OF

CLEARANCES BETWEEN THE LOADER AND ALL AIRCRAFT SURFACES.
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Approach the aircraft with the loader so that the

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leading edge of the Bridge is centered below and

parallel to the aircraft cargo door.
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Stop the loader so that the leading edge of the bridge

will be no closer than two (2) inches, or (5)
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centimeters, from the aircraft when the bridge is

raised.

Raise the bridge as required, by moving the BRIDGE

Lift Switch on the DRIVE Control Panel to the "UP"
position, to reach the aircraft door controls.

Open the aircraft door and raise the bridge to sill

height. Inch the loader into final position and lower
the stabilizers, placing the loader in the LOAD Mode.

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If installed, connect the Bridge Auto Leveling System

per instructions in this chapter.

C.3.e.4 Backing the Loader Off the Aircraft

The loader must be clear of cargo.

Close the aircraft door and lower both platforms
completely.

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Raise the stabilizers by holding the Stabilizer

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Control Switch "UP" until the green DRIVE Lamp is
illuminated.

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Lift and move the Drive Selector Switch to the
reverse position and carefully back the loader clear

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of the aircraft.

C.4. Emergency DRIVE Mode Operations

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These emergency procedures are for moving the loader
clear of the aircraft and towing it. Continued use of
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any of these procedures is not recommended.
Troubleshooting is covered in Chapter Two.
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C.4.a Emergency Driving Operations
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C.4.a.1 Emergency systems Shutdown

If a system does not stop when its control is moved

to the OFF position or a brake is applied, press the
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Emergency Stop Button or move the ignition switch to

the "OFF" position.
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Note: The Emergency stop Button must be pulled back out before
the engine may be started again.
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C.4.a.2 Emergency Short Distance Movement Without DRIVE Lamp

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(Engine Operating)

WARNING: LOWER THE BRIDGE TO THE "FULL DOWN" POSITION BEFORE

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MOVING THE LOADER. DO NOT DRIVE THE LOADER WITH THE

BRIDGE RAISED.

1. Hold the ELEVATOR LIFT Switch (LOAD Control Panel)

in the DOWN position until the elevator bottoms on
the frame.

2. Use the emergency procedures to raise the

stabilizers clear of the ground.

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-144SO CONTAINER/PALLET LOADER

3. one ramp attendant must open the Electrical

Enclosure door at the left front of the loader and
hold the Emergency Drive Switch in the UP position
while the operator backs the loader clear of the
aircraft.

EMERGENCY
DRIVE

s
SWITCH

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Ai
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FIG. 12: EMERGENCY DRIVE SWITCH

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4. When the loader is clear of the aircraft, lower

the stabilizers using the emergency procedures and
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place the loader out of service.

C.4.b Emergency Towing Procedures

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C.4.b.1 Short Distance Towing

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CAUTION: DO NOT USE THIS PROCEDURE IF THE LOADER IS TO BE TOWED A

DISTANCE IN EXCESS OF 1/4-MILE.

1. Retract the stabilizers, using the emergency

procedure if necessary, and apply the brake.

2. Place the Drive Selector Switch in the NEUTRAL (N)

position.

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-144SO CONTAINER/PALLET LOADER

3. Open the Propulsion Bypass Valve, located on the

upper rear frame crossmember weldment below the
bridge (See Fig. 13).

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~RoruLSION
BX~ASS VALVE

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FIG. 13: PROPULSION BYPASS VALVE

an
4. Attach the tow line to the loader at the tow points
which are located on either side of the loader at
the rear. Use specified points at the front end
ic
behind the engine compartment (See Figure 13A) .
If your loader does not have these holes or the
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tow-ring shown in figure 13A, Do NOT tow from the
front end. Release the brake, and tow no faster
Am

than 10 MPH.

CAUTION: TOWING AT SPEEDS IN EXCESS OF 10 MPH MAY RESULT

IN REAR WHEEL DAMAGE.
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TOW BAR HOLES

BOTH SIDES

FIG. 13A: TOWING POINTS, FRONT END

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-14480 CONTAINER/PALLET LOADER

C.4.b.2 Long Distance Towing

1. Remove the cover plate from the center of the

planetary drive, which is at the center of the
front wheel, and is reached from the right side
of the loader. Remove the thrust washer and the
sun gear from the planetary. Reverse the gear
(turn it over) and replace it. Replace the thrust
washer and the cover. This will disconnect the
gearbox (See Fig. 14).

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WASHER

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COVER PLATE
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FIG. 14: PLANETARY DRIVE COVER PLATE

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WARNING: DISCONNECTING THE PLANETARY ELIMINATES THE LOADER'S

DYNAMIC BRAKING. ELIMINATION OF DYNAMIC BRAKING WILL
INCREASE THE STOPPING DISTANCE. TOW AT 5 MPH MAXIMUM.
op
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2. Raise the stabilizers, using the emergency

procedure if necessary, and apply the brake.

3. Place the Drive Selector Switch in the NEUTRAL (N)

position.

4. Complete preparations using short distance towing

procedures.

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-14480 CONTAINER/PALLET LOADER

D. LOAD Mode

After the loader has been correctly positioned at the

aircraft, and the bridge has been raised so that the aircraft
cargo doors may be opened, move the Stabilizer (STAB) switch
to the "DOWN" position and hold until the red LOAD indicator
lamp on the Driving Control Panel is illuminated. This places
the loader in the "LOAD" mode.

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D.l. Load Mode Control/Indicator Locations (See Fig. 15)

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LOAD mode operations are controlled from the LOAD Panel
which is on the front side of the operator's console

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opposite the DRIVE Control panel. The cargo handler faces
the rear of the loader.

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D.l.a. Lift Switches

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There are two Bridge Lift Control Switches. The switch
which is at the left center of the Driving Control Panel
raises or lowers the bridge at a fast speed. The BRIDGE
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LIFT Switch (Item 4) located at the upper left side of
the LOAD control Panel raises or lowers the bridge
er
slowly.
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The ELEVATOR LIFT switch (Item 5), located at the upper

center of LOAD Control Panel, controls the raising and
lowering of the elevator.

D.l.b Bridge Controls

of

The BRIDGE REAR GUIDES and BRIDGE FORWARD GUIDES

Switches (Item 7) are at the left center of the LOAD
ty

Control Panel. They control the lateral alignment of

the bridge guide rails.
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The BRIDGE TILT Switch (Item 6) is at the center of the

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LOAD Control Panel. It controls the height adjustment

of the left corner of the bridge platform. If the
Optional dual tilt system is installed, both sides of
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the bridge will tilt.

some Loaders may be equiped with the Optional Automatic

Bridge Leveler System (See Paragraph D.3.a.2).

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 LOADER

LOAD/UNLOAD CONTROL PANEL

1. Elevator Inner Guides 8. Main Deck Wide Body

Up/Down Switch switch (Optional)
(Optional) 9. Elevator Conveyors Joysticks
2. Elevator Outer Guides 10. Bridge Conveyor Joystick
Up/Down switch (Optional) 11. Elevator Rear Stop
3. Rear Adjust Up/Down Retract Button
Switch 12. LD-3 Container Rotate Switch

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4. Bridge Platform 13. Lower All Conveyors Switch

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Up/Down Switch 14. Container Rotate Switch
5. Elevator Platform 125 11 wide Guides Up/Down
Up/Down Switch (Optional)

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6. Bridge Tilt Switch 15. Side Load Switch
7. Bridge Guides 125" wide Guides Up/Down

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Left/Right Switches (Optional)
(Optional)
1 2 4 9

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11
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Fig. lS: Load/Unload control Panel 1-2

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-14480 CONTAINER/PALLET LOADER

D.1.c Elevator Guides controls

The Elevator Platform has a maximum of six guides which

may be raised so that cargo may be driven against them
and aligned. The Elevator Guides switches are at the
left of the LOAD Control Panel. The upper two switches
(Item 1) control the INNER GUIDES, and the lower two
(Item 2) control the OUTER GUIDES. The Optional switches
located in a seperate box (Item 14 and 15) at the bottom

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of the control panel, control the outer guides on the

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125" Wide extensions. The outer guide rails can be
controlled independently for side loading. In the
rotate mode, both outer guide rails lower, along with

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the rear pallet stop to clear cargo.

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D.1.d Rear Adjust switch

The REAR ADJUST switch (Item 3), located on the lower

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left of the LOAD Control Panel, controls the Adjustable
Level Rear Wheel System. This system allows the
operator to raise and lower the rear of the loader so
ic
that it is at a height equal to the cargo transport
equipment.
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D.1.e cargo Movement Controls
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There are three systems for moving cargo on the Elevator

Platform:

1. The two sets of conveyor chains and the rear roller

of

move cargo lengthwise.

2. The two sets of lateral drive tires and the frame-

ty

mounted side rollers move cargo laterally.

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3. The rear set of lateral drive tires may be operated

by the LD-3 Rotate Switch (Optional) to rotate cargo.
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D.1.e.1 Conveyor Controls

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The three CONVEYOR switches (joy sticks) are located

at the right center of the LOAD Control Panel. The
top lever (Item 9) controls the Elevator Rear
conveyors, Elevator Rear Lateral Drive, and the Side
Rollers. The middle lever (Item 9) controls the
Elevator Forward Conveyors, the Forward Lateral
Drive, and the Side Rollers. The lower lever (Item
10) controls the Bridge Conveyors.

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-14480 CONTAINER/PALLET LOADER

D.1.e.2 LD-3 Rotate switch

The LD-3 Rotate Switch (Item 12) is at the right
center of the LOAD Control Panel. It controls the 2
sets of lateral drive tires located at the rear of
the Elevator Platform. Activating the LD-3 Rotate
Switch will operate the tires in opposite directions
to rotate containers only.

WARNING: THE REAR ROLLER WILL OPERATE WHENEVER THE LD-3 ROTATE

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SWITCH IS ACTIVATED.

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D.l.e.3 Pallet Rotation

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Large Pallets are rotated by locating the pallet over
the two sets of drive tires located at the center of

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the elevator platform. Hold the conveyor joysticks
in opposite directions left and right to rotate the
pallet.

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D.l.e.4 Rear stop Retract Button
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The REAR STOP RETRACT Button (item 11) at the upper
right of the LOAD Control Panel controls the rear
er
stop. Pressing the button lowers the stop, which is
normally raised.
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 OPERATION AND MAINTENANCE MANUAL
TLC 818-144SO CONTAINER/PALLET LOADER

D.2 LOAD Mode Emergency Controls

WARNING: IN THE EVENT OF A LIFT CYLINDER HYDRAULIC LINE FAILURE,

IMMEDIATELY STOP ANY ASCENT OR DESCENT OF THE PLATFORM.
DO NOT OPERATE ANY ASCENT OR DESCENT OF THE PLATFORM.
IMMEDIATELY CONTACT A QUALIFIED SERVICE PERSON FOR
REPLACEMENT OF THE FAILED LINE.

D.2.a Emergency systems Shutdown

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If a fluid leak develops, or a system does not stop when
a control is moved to the "OFF" position, push the

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Emergency Stop Button or move the ignition switch (DRIVE
Control Panel) to the "OFF" position.

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D.2.b Emergency Main Bypass Valve

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The main bypass valve must be closed before any of the
LOAD systems will operate, except for the Elevator Lift
System. Turning the steering wheel to a full Left and

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holding it in that position will cause the steering
circuit to act as an emergency Main Bypass Valve.
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D.2.c Lift Cylinder Lock Valves
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LOCK
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ELEVATOR LIFT CYLINDER

LOCK VALVE

FIG. 16: LIFT CYLINDER LOCK VALVE LOCATIONS

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-144SO CONTAINER/PALLET LOADER

The lift cylinders are held in position by lock valves

which may be opened in an emergency to lower the
Elevator and Bridge platforms. The lock valves are
mounted on the lift cylinders. Use extreme caution when
opening lock valves.

D.2.d Emergency cargo Movement controls

D.2.d.1 Bridge conveyor Bypass Valve

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The Bridge Conveyor Bypass Valve is a needle valve

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located under the left front corner of the Bridge.
Opening the valve allows cargo to be pushed off the
Bridge Conveyor.

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D.2.d.2 Emergency conveyor Operation Using switches

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The three Conveyor Switches (Joysticks) on the LOAD
Control Panel, may be used when cargo is to be

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manually pushed off a platform due to a power unit
failure if the loader still has electrical power. If
the Loader still has electrical power, it is not
ic
necessary to open the Conveyor Drive Motor By-pass
er
Valve.

D.2.d.3 Lower conveyors switch

Am

This switch is at the lower right of the LOAD Control

Panel. It lowers all conveyor systems on the
Elevator Platform so that cargo is supported by the
of

casters and may be moved manually.

D.2.e Manual override of Solenoid Valves

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All of the hydraulic systems of the LOAD Mode are

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governed by valves which are operated by solenoids. If

a valve fails to operate it can be manually overridden
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by pressing the override button on the valve solenoid.

D.3 Load Mode Operator Instructions: Aircraft Loading

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WARNING: DO NOT OPERATE THIS LOADER UNTIL YOU HAVE BEEN

TRAINED AND AUTHORIZED TO DO SO.

WARNING: THE CAPACITY OF THIS LOADER IS 15,000 LBS ON

EACH PLATFORM.
These instructions follow a typical loading operation
sequence. Controls which are located on the LOAD Control
Control Panel work only when the loader is in the LOAD mode.

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-144SO CONTAINER/PALLET LOADER

D.J.a. Bridge Lift and Alignment Operation

D.3.a.1 Initial Bridge Alignment

WARNING: DO NOT DRIVE THE LOADER WITH THE BRIDGE RAISED EXCEPT
DURING FINAL APPROACH. APPROACH THE AIRCRAFT AT A SLOW
SPEED.
CAUTION: BE SURE THE OPERATOR'S PLATFORM GUARD RAILS CLEAR THE
AIRCRAFT AS THE BRIDGE IS RAISED. REPOSITION THE LOADER

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AS REQUIRED FOR PROPER ALIGNMENT.

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D.3.a.2 Bridge Auto Leveling System (Optional)

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Some loaders may be equiped with the Optional Bridge
Auto Leveling System, located at the front of the

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bridge platform (See Fig 16 A). If your loader is
not equiped with this feature, move onward to
"Raising The Bridge". If your loader is equiped

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with this feature proceed with the following.
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FIGURE 16A: BRIDGE AUTO LEVELING SYSTEM INTERFACE

CAUTION: REVIEW THE INSTRUCTIONS IN THIS CHAPTER FOR

"RAISING THE BRIDGE" BEFORE APPROACHING AIRCRAFT.

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-144SO CONTAINER/PALLET LOADER

The Auto Leveling System allows the loader platform to

maintain a constant deck height between the aircraft
door sill and the loader bridge platform.

Connecting The Auto Leveling System To The Aircraft

The bridge auto leveling system allows the operator to

choose the desired deck height for operation. With the

s
auto level system switched to "OFF", interface the loader
with the aircraft per the instructions in this chapter.

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Stop the bridge about 18 inches below the aircraft door
sill. Secure the sensing clamp to the aircraft door stud.
The clamp may be attached to whatever is convenient on the

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aircraft as long as the clamp is below the aircraft
cargo transfer surface and the cable is not at an angle

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left or right. Raise the bridge platform to the desired
height.

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Activating The Auto Leveling system

To activate the system, lift the RED switch guard

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over the "ON/OFF" switch and move the switch to "ON".
er
The GREEN L.E.D. will illuminate indicating the System is
Operating (See figure 16B). When the auto leveling system
is activated, the bridge controls for UP and Down are
Am

disabled to prevent interference.

To readjust the height of the bridge relative to the

aircraft, turn "OFF" the auto leveling system, manually
of

readjust the bridge height with respect to the aircraft

sill, then switch the auto leveling system to "ON".
ty

GREEN L.E.D.
er

BRIDGE AUTO LEVELER

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~ ...., i)
I
I
'
--"'
/ I
I SYSTEM
~--- ---:I ON OPERATING
Pr

I
I
I
I
I
SAFETY
I
I
0 OFF SHUT DOWN RED L.E.D.

FIGURE 16B: BRIDGE AUTO LEVELING SYSTEM CONTROLS

(Auto Leveler)

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AUG/90
 The auto leveler allows the bridge to move 1/4 inch
UP or 1/4 inch DOWN from normal level before the command
to0 move the platform is given.

Motion Of Platforms

With the auto leveling system "ON" and a GREEN Light

(L.E.D.) illuminated, if the sensing cable is pulled in
the UP direction greater than 1/4 inch, the auto leveling

s
system will respond giving the command to move UP. After

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the qualification time has passed and the UP comand is
still present, the system will move the platform in the
UP direction until the UP command is canceled. The system

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responds the same for platform DOWN if the cable is allowed
to retract 1/4 inch from the normal level centered

Ai
position.

The auto leveling system has a STAND-BY feature which

an
incorporates the sensing of the bridge CONVEYOR JOYSTICK
positions. If the bridge conveyors are in use, forward or
reverse, the auto leveling system is put on STAND-BY until
ic
the chains have stopped moving. This feature allows
transfer from the bridge platform to the elevator platform
er
or aircraft door without the auto leveling causing problems
due to loads being straddled.
Am

The ELEVATOR platform is under normal control by the

operator until interfaced with the BRIDGE platform. When
interfaced, if the DOWN command is given to the bridge
platform, the elevator platform will be given the same
of

command until the interface between platforms is broken.

With the auto leveling system back to its neutraljlevel
state, the elevator platform is not allowed to align
ty

itself to the bridge platform. Alignment of the elevator

platform to the bridge platform is left to the operator
er

for safety.
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Safety Shut Downs

In the event of operator error, the auto leveling system

Pr

has two on board safety systems. The first safety system

senses the amount of cable pulled or retracted from the
normal centered operating position. If the cable is
allowed to extend 1 inch beyond or retracted 1 inch form
the normal center position, the auto leveling system will
go into a SHUT-DOWN mode. A shut-down mode consists of
all automated leveling functions and bridge platform
conveyor forward (to aircraft), becomming non-operational.
In the shut-down mode, the RED FLASHING LIGHT (L.E.D.)

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-144SO CONTAINER/PALLET LOADER

will illuminate at the placard "SAFETY SHUT DOWN"

(See figure 16B). In this mode the GREEN "SYSTEM
OPERATING" light (L.E.D.) is no longer illuminated.

The second safety shut-down consists of a "catch all"

timer. This timer allows the automated movement of the
auto leveling system to be in motion for 1.5 seconds.
If the auto leveling system is unable to align itself to
the normal center position after 1.5 seconds of platform

s
movement, the safety catch all timer will then activate
and provide the same system shut-down.

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Reactivation After A Safety Shut-Down

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To reactivate the auto leveling system from a safety
shut-down, perform the following procedures:

Ai
1. Turn the auto leveling system to "OFF".
2. Make sure the sensing clip is secured.

an
3. Realign bridge platform to door sill height.
4. Turn the auto leveling system to "ON".
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D.3.a.3 Raising The Bridge
er
After the loader has been correctly positioned at the
aircraft, lower the stabilizers.
Am

Raise the bridge by lifting either the BRIDGE switch on

the DRIVE Control Panel or the BRIDGE LIFT switch on
the LOAD Control Panel. The bridge will lift until the
of

switch is released or the bridge reaches the limit of

it's travel.
ty

CAUTION: BEFORE OPENING THE AIRCRAFT DOOR, BE SURE THAT THE BRIDGE
IS LOW ENOUGH AND PROPERLY CENTERED SO THAT THE DOOR WILL
er

NOT STRIKE THE LOADER STRUCTURE.

Continue to raise the bridge until the aircraft cargo

op

door may be opened. Release the switch. The bridge

will stop and be held in position.
Pr

The BRIDGE switch on the DRIVE Control Panel raises and

lowers the bridge at a fast rate. The BRIDGE LIFT
switch on the LOAD Control Panel raises and lowers it
at a slow rate. These controls work in either the LOAD
or DRIVE mode.

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-144SO CONTAINER/PALLET LOADER

D.3.a.4 Final Bridge Alignment

Extension

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sr'i dge
Oecl:: Panel

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(Right)

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Bridge Guard Rail
Oecl: Panel Extension
(Lett) ic
FIG. 17: BRIDGE DECK PANELS AND GUARD RAIL EXTENSIONS
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WARNING: SOME LOADERS MAY BE EQUIPPED WITH A POST AND CHAIN
Am

SAFETY RAIL.

WARNING: FULLY EXTEND THE LEFT AND RIGHT EXTENDABLE BRIDGE

DECK PANELS AND KICK INTO POSITION TO COVER THE OPEN
AREA BETWEEN THE FUSELAGE AND THE BRIDGE. IF REQUIRED,
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INSTALL POST AND CHAIN SAFETY RAIL ON THE FORWARD BRIDGE

AREA.
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FIG. 18:

POST AND CHAIN

SAFETY RAIL 1-2
Page 34
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 OPERATION AND MAINTENANCE MANUAL
TLC 818-14480 CONTAINER/PALLET LOADER

Operate the BRIDGE LIFT Switch, either up or down,

until the leading edge of the bridge is level with the
aircraft floor.

WARNING: INSTALL ALL SAFETY POSTS AND CHAINS BEFORE LOADING CARGO.

The Bridge Tilt System raises and lowers the left front
corner of the bridge to compensate for aircraft pitch
changes.

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D.3.b Rear Adjust Operation

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Use the Rear Adjust Switch to raise or lower the rear
wheels of the loader so that the lowered Elevator Platform

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is just below the level of the ground transport vehicle.

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D.3.c Elevator Platform Loading Operations
D.3.c.1 End Load Operation

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Lower the Rear Stop and move the top Conveyor Switch
(joystick) down to operate the rear roller in the
ic
forward direction. This also raises the rear conveyor
chains and operates them in the forward direction. The
er
lateral drive tires will lower below the caster level
so that they do not contact the cargo.
Am

WARNING: THE REAR ROLLER WILL OPERATE WHENEVER THE REAR ELEVATOR
CONVEYOR OPERATES.

As the cargo approaches the forward Elevator Platform

of

conveyor chains, move the middle Conveyor Switch

(joystick) down so that the forward conveyor is raised
ty

and moving forward when cargo reaches it.

er

If space allows, move the cargo to the forward end of

the Elevator Platform and continue loading.
op

An automatic pallet stop at the forward end of the

Elevator Platform prevents cargo from being driven
under the bridge.
Pr

WARNING: NEVER SIDE LOAD WITH THE ELEVATOR ABOVE THE FRAME.
TRANSFER CARGO AT AN INTERMEDIATE LEVEL ONLY AT THE REAR
END OF THE LOADER.

Cargo may be end loaded onto the Elevator Platform at

an intermediate height (platform raised above the frame
but lower than the Bridge Platform).

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-14480 CONTAINER/PALLET LOADER

Hold the Rear Stop Retract button down when transfering

cargo onto the Elevator Platform at an intermediate
height.

D.3.c.2 Container Rotate Operation

WARNING: THE REAR ROLLER WILL OPERATE WHENEVER THE CONTAINER

ROTATE SYSTEM OPERATES.

The LD-3 ROTATE Switch lowers the Rear Conveyor, raises

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the Rear Lateral Drive tires so that they support the

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container, and turns the tires in opposite directions
to rotate the container.

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Use the top CONVEYOR Switch (joystick) to center the
container over the lateral drive tires before using

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the LD-3 ROTATE system.

After the container is rotated, it may be aligned by

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driving it laterally against the inner or outer guide
rails.

D.3.c.3 Pallet Rotate Operation

ic
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WARNING: THE SIDE ROLLERS WILL TURN WHENEVER THE LATERAL DRIVE
SYSTEM OPERATES.
Am

Large containers and pallets are rotated by using both

sets of lateral drive tires. Center the cargo
between the forward and rear pairs of lateral drive
tires. Hold the Joysticks to opposite sides to rotate
of

the cargo. Drive the cargo against the guide rails

to align it after rotation.
ty

D.3.c.4 Side Load Operation

er

To side load cargo onto the Elevator Platform, lower

the outer Guide Rail on that side and raise the rail
op

on the opposite side. These rails are controlled by

the OUTER GUIDES Switches and can be lowered only
when the elevator is resting on the frame, full down
Pr

position. If installed, activate the optional 125"

wide extension guides by using the side load switch
No 15 located in a seperate box at the lower left
corner of the load control panel. The guides will
automatically raise when the ELEVATOR LIFT operates,
but if a switch is left in the DOWN position, the
outer guide will lower whenever the Elevator Platform
is fully down.

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-144SO CONTAINER/PALLET LOADER

Use the CONVEYOR switch to drive the cargo onto the

Elevator Platform. If necessary, use the inner or
outer guide rail to align the cargo. Raise the
conveyor chains and move the cargo by use of the
conveyor joysticks.

D.J.d Elevator Lift Operation

WARNING: NEVER ENTER THE AREA BELOW THE ELEVATOR DURING LOADING
OR UNLOADING OPERATIONS.

s
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Hold the ELEVATOR LIFT Switch in the UP position. The
warning horn will sound while the lift operates. The
elevator will stop at the bridge level.

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When the Elevator reaches the Bridge, the rear Bridge

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Forward Elevator Pallet Stop lower

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REAR LATERAL
DRIVE TIRES REAR ROLLER
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SIDE ROLLERS

~'-L.__..:;-- CL-,._,..-STABILIZERS DOWN

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FIG. 19: LOAD MODE SYSTEMS

NOTE: If necessary, re-adjust the bridge height and bridge trim

to match the aircraft.

WARNING: IF THE AUTOMATIC SLOWING AND STOPPING SYSTEMS ARE

INCORRECTLY ADJUSTED OR MALFUNCTION, THE ELEVATOR WILL
CONTINUE RISING UNTIL IT REACHES FULL HEIGHT, LIFTING
THE BRIDGE WITH IT.

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 OPERATION AND MAINTENANCE MANUAL
TLC 818-14480 CONTAINER/PALLET LOADER

In an emergency, stop the Elevator Lift by pushing the

Emergency Stop Button on the LOAD Control Panel or by
turning the Ignition Switch on the DRIVE Control Panel
to "OFF".
D.3.e Bridge Platform Loading Operations

D.3.e.1 Guide Alignment

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The Bridge Guides switches control the lateral

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movement of the forward and rear ends of the bridge
guide rails. These rails may also be manually
repositioned to accept wide cargo. Align the guides

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with the in-plane system so that cargo can move
directly across the Bridge and into the aircraft.

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The front of the bridge guide rails move laterally
six inches full travel. The rear ends of the rails

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may move four inches (Standard). If equipped the
rear ends of the rails may move six inches
(Optional). ic
Move the switch in the direction of the desired rail
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movement. Releasing the switch stops the rail and
holds it in position.
Am

D.3.e.2 Bridge conveyor operation

Move cargo off the Elevator Platform and onto the

Bridge by using the middle CONVEYOR switch
of

(joystick), which controls the forward Elevator

Platform Conveyor, and the lower CONVEYOR switch
(joystick), which controls the Bridge Conveyor. Use
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the two controls together so that the Bridge Conveyor

is moving when cargo contacts it.
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As soon as the Bridge Platform is clear, move the

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remaining cargo from the Elevator Platform to the

Bridge.
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WARNING: NEVER LOWER THE ELEVATOR PLATFORM WITHOUT CHECKING THAT

CARGO HAS BEEN MOVED COMPLETELY ONTO THE BRIDGE
PLATFORM.

Lower the Elevator Platform when it is clear of cargo.

D.4 LOAD Mode Operator Instructions: Aircraft Unloading

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TLC 818-14480 CONTAINER/PALLET LOADER

WARNING: DO NOT OPERATE THIS LOADER UNTIL YOU HAVE BEEN

TRAINED AND AUTHORIZED TO DO SO.

These instructions follow a typical unloading operation

sequence. Controls which are located on the Cargo
Handling Control Panel work only when the loader
is in the LOAD mode.

D.4.a Bridge Platform Unloading Operations

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D.4.a.l Elevator Platform Lift

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After the Bridge is aligned and level with the
aircraft cargo door, raise the Elevator Platform to

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Bridge level. As the Elevator Platform reaches
Bridge level the forward pallet stop on the Elevator

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Platform and the rear pallet stop on the Bridge
Platform will lower automatically.

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D.4.a.2 Bridge Guide Alignment
The Bridge Guides Switches control the lateral
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movement of the forward and rear ends of the bridge
guide rails. These rails can also be manually
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repositioned to accept wide cargo. Align the guides
with the in-plane system so that cargo may move
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directly across the Bridge and onto the Elevator

Platform.

The front of the bridge guide rails move laterally

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six inches full travel. The rear ends of the rails

may move four inches. Move the switch in the
direction of the desired rail movement. Releasing the
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switch stops the rail and holds it in position.

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D.4.a.3 Bridge Conveyor Operation

Move cargo off the Bridge and onto the Elevator
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Platform by using the lower CONVEYOR switch

(joystick), which controls the Bridge Conveyor, and
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the middle CONVEYOR switch (joystick), which controls

forward Elevator Conveyor. Use the two controls
together so that the Elevator Conveyor is moving when
cargo contacts it.

Use the middle and top CONVEYOR Switches (joysticks)

to move the cargo to the rear of the Elevator
Platform, and continue unloading the aircraft until
the Elevator platform loading is complete.

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TLC 818-14480 CONTAINER/PALLET LOADER

WARNING: NEVER LOWER THE ELEVATOR PLATFORM WITHOUT CHECKING THAT

CARGO HAS BEEN MOVED COMPLETELY OFF THE BRIDGE PLATFORM.

D.4.a.4 Emergency cargo Transfer Operations

If the Bridge Conveyor System fails to operate when
the control switch is used:

Use the steering circuit as an emergency main bypass.

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If the system still fails to operate:

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Override the control valve which is under the forward
part of the Bridge.

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If the system still fails to operate, or if the

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loader's engine does not operate, push the cargo off
the bridge, either back into the aircraft or onto the
elevator platform.

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If the electrical system is operating, hold the
control switch (joystick) in the desired direction
while the cargo is pushed.
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If the Bridge Conveyor still will not turn with the
cargo on it, open the Bridge Conveyor Bypass Valve
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below the left front corner of the Bridge Platform

and then push the cargo off the Bridge. Valve
location is shown on the Hydraulic Service Diagram
which is attached to the inside upper right hand
stanchion.
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D.4.b Elevator Lowering Operations

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D.4.b.1 Normal Elevator Lowering

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WARNING: NEVER ENTER THE AREA BELOW THE ELEVATOR DURING LOADING
OR UNLOADING OPERATIONS.
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TLC 818-144SO CONTAINER/PALLET LOADER

ORIVE MOTOR

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ne
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FIG. 20: BRIDGE CONVEYOR BYPASS VALVE

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Hold the ELEVATOR LIFT Switch DOWN until the elevator
bottoms on the frame.

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D.4.b.2 Emergency Elevator Lowering

WARNING: IF THE LINE TO THE BASE OF EITHER ELEVATOR LIFT CYLINDER

ic
HAS BROKEN OR BURST, DO NOT USE THESE PROCEDURES. DO
NOT ATTEMPT TO CHANGE THE ELEVATOR HEIGHT. MOVE ANOTHER
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LOADER INTO POSITION BEHIND THE DISABLED LOADER, MATCH
THE ELEVATOR HEIGHTS, AND TRANSFER THE CARGO. AFTER THE
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CARGO HAS BEEN REMOVED, RAISE THE STABILIZERS AND TOW

THE DISABLED LOADER SLOWLY, FROM THE AFT END.

If electrical system is operating, even if engine is

not operating, move the ELEVATOR LIFT Switch to the
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DOWN direction. The elevator will lower by gravity.

If electrical system is not operating override the

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Elevator Lift Cylinder Lock Valves.

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FIG. 21: ELEVATOR LIFT CYLINDER LOCK VALVE

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TLC 818-144SO CONTAINER/PALLET LOADER

WARNING: CHECK THAT THE IGNITION SWITCH IS IN THE

"OFF" POSITION BEFORE OPENING THE LIFT CYLINDER LOCK
VALVES.

WARNING: ALL PERSONNEL, EXCEPT MAINTENANCE PERSONNEL PERFORMING

THESE PROCEDURES, SHOULD REMAIN CLEAR OF THE LOADER
UNTIL THE ELEVATOR IS LOWERED.

WARNING: DO NOT ENTER THE AREA BELOW THE ELEVATOR DURING THIS
PROCESS.

s
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Open the overrides on the two lock valves by turning
and lifting the cap on the top of the valves. One
lock valve is attached to each lift cylinder. When

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the lock valves are open, the elevator will be held
in position by the Elevator Down Slow valve.

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er
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ELEVATOR DOWN SLOW

OVERRIDE BUTTON
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FIG 22: ELEVATOR DOWN SLOW SOLENOID VALVE

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WARNING: DO NOT REACH BEHIND THE VERTICAL FRAME MEMBER FOR THE
ELEVATOR DOWN SLOW VALVE. THIS WILL PLACE YOU IN THE
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PATH OF THE DESCENDING ELEVATOR. REACH THROUGH THE

VALVE PLATE AREA FORWARD OF THE FRAME. WATCH THE
DESCENDING ELEVATOR.

Press the manual override button on top of the

Elevator Down Slow solenoid valve, located near the
aft end of the hydraulic panel. Hold the button
until the elevator bottoms on the frame.

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D.4.c Rear Adjust Operation

Use the Rear Adjust switch to raise or lower the rear

wheels of the loader so that the lowered Elevator
Platform is just above the level of the ground transport
vehicle.

D.4.d Elevator Platform Unloading Operations

D.4.d.1 End Load Unloading operations

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ne
WARNING: THE REAR ROLLER WILL OPERATE WHENEVER THE REAR ELEVATOR
CONVEYOR OPERATES.

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Lower the Rear Stop then drive the cargo off the
Elevator Platform onto the ground transport

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equipment. Cargo may be unloaded from the Elevator
Platform at an intermediate height of 60" MAXIMUM for
truck height. Move the Elevator Platform level with

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the ground transport equipment and release the
ELEVATOR LIFT switch. The platform will remain at
that level.
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Hold the Rear Stop Retract button down while
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transfering cargo onto the Elevator Platform at an
intermediate height.
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WARNING: NEVER SIDE LOAD WITH THE ELEVATOR ABOVE THE FRAME.
TRANSFER CARGO AT AN INTERMEDIATE LEVEL ONLY AT THE REAR
END OF THE LOADER.
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D.4.d.2 Side Load Unloading Operation

To unload from the side of the Elevator Platform,

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lower the outer Guide Rail on that side and raise the
rail on the opposite side. These rails are
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controlled by the OUTER GUIDES Switches and can be

lowered only when the elevator is resting on the
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frame.

The guides will automatically raise when the ELEVATOR

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LIFT operates, but if a switch is left in the DOWN

position, the outer guide will lower whenever the
Elevator Platform returns to fully down.

Use the ELEVATOR CONVEYOR Joystick to operate the

lateral drive tires and the side rollers, to drive
the cargo off the Elevator Platform. If the Optional
125" wide system is installed, use the side load
switch (SW-15) to lower the guides.

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D.4.e Bridge Lowering Operation

D.4.e.1 Normal Bridge Lowering

Use the BRIDGE LIFT Switch on the LOAD Control Panel

to lower the Bridge at a slow rate, and the BRIDGE
Switch on the DRIVE Control panel to lower the Bridge
at a fast rate. Hold the switch DOWN until the
Bridge bottoms on the frame.

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D.4.e.2 Emergency Bridge Lowering

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WARNING: IF THE LINE TO THE BASE OF EITHER BRIDGE LIFT CYLINDER
HAS BROKEN OR BURST, DO NOT USE THESE PROCEDURES. DO

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NOT ATTEMPT TO CHANGE THE BRIDGE HEIGHT. MOVE ANOTHER
LOADER INTO POSITION BEHIND THE DISABLED LOADER, MATCH

Ai
THE PLATFORM HEIGHTS, AND TRANSFER THE CARGO. AFTER THE
CARGO HAS BEEN REMOVED, RAISE THE STABILIZERS AND TOW
THE DISABLED LOADER SLOWLY FROM THE AFT END.

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If electrical system is operating, even if engine is
not operating, move the BRIDGE LIFT Switch to the
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"DOWN" position. The BRIDGE will lower by gravity.
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If electrical system is not operating override the
Bridge Lift Cylinder Lock Valves. Press in and turn
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knobs to lock both valves in the open position.

Two people are needed to lower the bridge using the

manual override system. Slowly open both lock valves
at the same time. The bridge will lower by gravity.
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BRIDGE LIFT CYLINDER

. LOCK VALVE

FIG. 23: BRIDGE LIFT CYLINDER LOCK VALVE LOCATION

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