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Aviation Ground Handling & I.T Solutions inc Aviation Ground Handling & I.T Solutions inc Training Division. FMC JC-PL-2 OPERATOR TRAINING 1 Aviation Ground Handling & I.T Solutions inc Aviation Ground Handling & I.T Solutions inc. Operator Training Manual FMC JC/PL-2 Lower Deck Cargo Loader 2 Aviation Ground Handling & I.T Solutions inc FMC JC/PL-2 CARGO LOADER : OPERATOR TRAINING This Operation manual covers the basic requirements for operating the FMC JC/PL-2 loader and should be retained for reference purposes. The practical training, done in conjunction with the theoretical training will enable the Driver/operator to operate this unit efficiently and safely. Contents: Section 1: Description, capabilities & basic specifications. Overview of the FMC JC/PL-2 Section 2: Controls and instruments Overview of the three control panels as fitted to unit. Section 3: Operations. Operating the unit, pre-start checks, starting, driving, positioning at

aircraft, loading and unloading cargo. Section 4: Emergency procedures What to do in case of breakdowns. Section 5: Basic trouble shooting Common faults which occur and can be rectified on the flight line. Section 6: Safety Precautions. Section 7: Figures and drawings of FMC JC/PL-2 3 Aviation Ground Handling & I.T Solutions inc Section 1: Description & Basic Specifications 1.1 Description: The FMC JC/PL-2 Container/Pallet loader is a single operator, self propelled unit, designed to lift, load and unload cargo or baggage, on pallets or in containers, up to a maximum mass of 6804Kg in and out of the following aircraft: a) Lower Decks of: • Boeing 747 and 767 • Airbus A300, A310, A320, A330* & A340 (- forward cargo compartments only) • DC 10 and MD-11 • Lockheed L1011 • Any other wide body aircraft with cargo doorsill heights of up to 3550mm. b) Main Decks of: • Boeing 727, 737 & 707 cargo or Combi • DC-8 and DC-9 • BAC 1-11 • Any other narrow

body aircraft having cargo doorsill heights up to 3550mm. 1.2 Capabilities & Features: 1. Operating heights for the JC/PL-2 are: a) Minimum height of rear platform : 508mm b) Minimum transfer height from rear, to front platform : 1905mm c) Maximum transfer height of front platform: 3556mm 2. The unit is capable of handling the following aircraft ULD’s (Unit load devices) a) Up to two LD-1, LD-2 or LD3 containers b) 1 x LD-4 or LD-11 Container. c) 1 x Pallet up to 125x96” 3. Normal loading is carried out longitudinally, ie on & off the rear of the loader. This unit also has the facility to do side loading on the rear platform. Loading can be done in the fully lowered position and also at “Truck bed height”, 4 Aviation Ground Handling & I.T Solutions inc 1500mm above ground level. 4. For handling containers in & out of aircraft with narrow cargo doors (e.g A300 rear door, A320 etc), the front platform has an extending front section. 5. Container rotation

on rear platform to allow for correct orientation of containers for loading. 6. Manual lateral positioning of containers on front platform to align containers with door. 1.3 Basic Secifications The FMC JC/PL-2 is powered by a Deutz air cooled diesel engine and a hydrostatic transmission. Loading operations are carried out Electro-hydraulically ULD’s are moved across platforms by means of belts and rubber lagged rollers. The unit has three control panels for the various operations, i.e 1. Main control panel, positioned forward of the right front wheel. (See Figure 2) 2. Driver’s compartment (See Figure 3) 3. Operators console, located on the right hand side of the front platform (See Figure 4) The various operations & functions are described fully in the “Operating” section of this manual. Section 2: Controls and Instruments The controls and instruments fitted to the JC/PL-2 control panels, are as follows. 2.1 Main Control Panel (Fig 2) Hour meter Emergency stop button

Ignition switch Low oil pressure bypass switch Circuit breakers 5 Aviation Ground Handling & I.T Solutions inc 2.2 Warning lights Drivers compartment (Fig 3) Emergency stop button Starter switch Low oil pressure bypass switch Driving controls, Steering wheel, foot brake, accelerator etc. Hand throttle Forward/reverse selection lever Drive/operate switch Front platform raise/lower switch Front platform extend/retract switch Light switch Indicator switch Handbrake Warning lights 2.3 Operator console (Fig 4) Emergency stop button Work light switch Main (rear) platform raise/lower switch Front platform raise lower switch Front platform load transfer selector lever Rear platform load transfer selector lever, front and rear sections. Rear platform guide retraction switch Front platform belt retraction switch 2.4 Transmission shift gate. (Fig 5) Low ratio, Neutral (No traction) & High ratio 6 Aviation Ground Handling & I.T Solutions inc Section 3: Operating the

JC/PL-2 3.1 Pre-start checks: Before starting or operating the machine, the following checks must be carried out: a) Walk around the machine, checking tyres for damage and inflation and for signs of oil leaks. b) Check engine oil level. c) Check Hydraulic oil level d) Check fuel level (physically check fuel, do not rely on fuel gauge) e) Check that the emergency cut-off switches are not depressed. f) Check that the “Drive/operate” switch is in the “operate” position. g) Check that the transmission selector lever is in neutral position (i.e in drivers cab) h) Place transmission shift lever into “High” position. i) Ensure Handbrake is on. (Also refer to Daily task Form) 3.2 Starting the machine Hold the “Bypass” switch next to the ignition switch in the up position & turn on the ignition switch. Once the engine starts, continue to hold the switch in the up position, until the red warning lights are extinguished. NB The “Bypass” switch is a safety feature which

automatically cuts the engine if oil pressure is lost. The engine can be started from either the Main control panel or driver’s compartment. Ensure though that the ignition switch on the main control panel is selected to “On” 3.3 Operational checks Prior to starting positioning and loading aircraft, a full operational check must be carried out, i.e 7 Aviation Ground Handling & I.T Solutions inc With the machine in “Operate” mode, check the following: 1. Drivers Compartment: a) Front platform raise and lower b) Bridge extend and retract c) Lights and indicators 2. Operators console: a) Front platform raise and lower b) Rear platform raise and lower c) Side and rear guide retraction d) ULD belt drives, both front and rear platforms e) Side loading and container rotation f) Front platform belt retraction. 3.4 Driving the JC/PL-2. a. With the engine running and both platforms fully lowered, Select, “Drive/operate switch to “Drive” mode, for safety reasons, also

depress footbrake. b. Select forward or reverse as required and release the handbrake. c. The unit may now be driven, by depressing the accelerator. d. When approaching the aircraft, check the brakes by bringing the loader to a full stop at least 3 metres away from aircraft. VERY Important! (See also Emergency procedures. 3.5 Approaching and positioning at aircraft. a. where loading aircraft with narrow door, (eg A320 etc), extend the front platform before approaching aircraft b. Lower the front platform safety rail (Left side of front platform) c. When approaching the aircraft, ensure that the machine is well clear of aircraft wings and engines & other Ground support equipment. d. Approach the aircraft, lining the loader up square with the cargo door and stop loader in a position where aircraft door controls can be reached, ensuring that door will not connect with the loader during opening cycle. e. Apply handbrake and set gearshift to neutral position 8 Aviation Ground

Handling & I.T Solutions inc f. Open cargo door, ensuring that it clears the loader g. Raise the front platform to a height slightly lower than doorsill height. Select forward and inch loader to a distance of 60 to 80mm from doorsill. h. Apply handbrake, set transmission lever to neutral and select “operate” i. Ensure stabilizers are fully extended and raise the front platform safety rail, checking that it is clear of all obstructions and cargo door j. Adjust front platform height to doorsill height k. Position walkway over driver’s cab and swing control pedestal into a position where you can safely work the loading functions. The loader is now ready for loading/unloading. CAUTION: During the loading/unloading process, monitor the difference in height between he loader front platform and doorsill height and adjust as required to ensure an even transfer of ULD’s at all times. 3.6 Loading/Unloading Please note that this section covers the operation of the FMC JC/PL-2 loader

only. The various Aircraft loading/unloading systems are not covered in this section. Refer to relevant aircraft ULD operations manual for operation of aircraft systems. a) Loading: This can be accomplished at either 508mm (minimum reap platform height) or at 1500mm (Trick bed height) 1. 2. Adjust the rear platform to the required height and lower the applicable side guide/stop. Move the ULD onto the platform and activate the rear platform belt or roller switch to move the ULD across the bed. 9 Aviation Ground Handling & I.T Solutions inc 3. 4. 5. 6. When the ULD is in position on the rear platform, raise the relevant side guide/stop and raise the rear platform to interface with the front platform. Activate the ULD transfer switches and move the ULD from the rear platform to the front platform and into the aircraft. Once the ULD is clear of the rear platform, lower the platform to load the next ULD. Repeat this process, until all ULD’s are loaded. Note: the ULD’s can

be adjusted laterally on the rear platform by using the side rollers, and on the front platform by lowering the drive belts and manually moving the ULD to line up with aircraft door guides c) Unloading aircraft is the reverse of the loading procedure. Exercise caution by ensuring that the rear stop is up whilst the rear platform is in the raised position. Prior to lowering the rear platform, ensure that the ULD is clear of the forward stop on the rear platform. Also check that there are no personnel under the rear platform. 3.7 Removing the JC/PL-2 from aircraft On completion of the loading/unloading cycle, the following procedure must be followed. a) Lower both platforms completely b) Lower the front platform safety rail (on the left side of platform) c) Stow the Operators console. d) Close aircraft door, ensuring that there are no obstructions, which could damage the door. e) Set the Drive/operate switch to “Drive” mode and gear selector to reverse, depressing footbrake for

safety reasons. f) Check area behind loader is clear and when stabilizers have retracted, release handbrake and slowly reverse away from aircraft, again, ensuring that loader is well clear of aircraft wings, engines etc. as well as other Ground Support Equipment. 10 Aviation Ground Handling & I.T Solutions inc g) Return loader to parking bay, set gear selector to neutral, set park brake and select “Operate”. h) When stabilizers are fully extended, engine may be switched off. i) Ensure engine has stopped running before leaving loader. j) Report any defects noted and stand by to assist with removal of loader, if so required. Section 4: Emergency procedures In the event that the Loader has an engine failure whilst positioned at aircraft, the following procedure must be followed to safely remove the loader from the aircraft. a) Set Gearshift to neutral b) Set Transmission shift lever (Below main control panel) to “Neutral” c) Push manual pump valve knob in (Manual pump

and valve are located in engine compartment, near battery) d) Ensure that any ULD’s still on loader are not bridging the two platforms. e) Activate pump, while selecting relevant platform switches to “lower” position. NB Activating the manual pump, will also retract stabilizer jacks. f) Remove any ULD’s manually from the loader. g) Carefully tow loader away from aircraft. N.B After loader has been removed from aircraft, ensure that manual pump valve is pulled back out to the “power” position. N.B 2 If loader has flat battery and requires a “Jump Start”, check all operations before positioning unit as certain operations will not function if battery is flat. 11 Aviation Ground Handling & I.T Solutions inc Section 5: Basic Trouble shooting The problems and possible solutions listed under this heading are basic checks for Drivers/operators. If remedies listed to not rectify the problem, the loader should be taken out of service and sent to the maintenance workshop

for rectification by Technicians. Problem Possible cause Remedy No power when Unit is switched on Ignition circuit breaker Tripped Reset Breaker Battery flat Check battery One or more Emergency cut out Buttons engaged Check all three buttons. Battery disconnected Connect Battery Unit out of fuel Refuel unit Low oil pressure Bypass switch hasn’t Been used when Trying to start engine Hold low oil pressure bypass switch in override Position and try again Transmission in Neutral Select low or high gear Gearshift in neutral Select fwd or Reverse Handbrake engaged Release Handbrake Engine cranks but Won’t start Unit will not drive 12 Aviation Ground Handling & I.T Solutions inc Traction speed is Slow Drive/operate switch in Operate mode set switch to “Drive” Low hydraulic oil Top up oil Engine not at full RPM Set throttle To full RPM Set Transmission Lever to “High” Transmission lever is Set to “Low” Loader has little or No power

steering Low hydraulic oil Top up oil Stabilizers will not Extend Park brake is off Set park brake Mode switch is in drive Mode Set switch to operate mode Rear Platform won’t raise after stabilizers Have extended Gearshift not in neutral Set gearshift to neutral position Stabilizers will not Retract Mode switch in operate mode Set switch to “Drive” Rear platform not fully Retracted/down lower rear platform fully 13 Aviation Ground Handling & I.T Solutions inc Section 6: Safety precautions • • • • • • • • Personnel must never move under or stand under raised platforms unless safety stands are in position. Do not leave the loader unattended with the engine running. Do not tow, or drive the loader with a load on either platform. Do not operate loader in winds exceeding 160 KPH. Do now tow loader with stabilizers extended. Always check foot brake when approaching aircraft. Stop Loader approximately 3 metres from aircraft, to check brakes. In

case of emergency, use Emergency cut off button to kill loader engine. As an alternate, in extreme emergency, of brake failure, select neutral and select “drive/operate” switch to operate. This will extend stabilizers and bring loader to a halt. NB this may cause damage to loader, but is preferable to damaging aircraft. Compiled by: Aviation Ground Handling & I.T Solutions 2004 14