AAT CargoMaster A142 Installation and operating instructions

CargoMaster A 142/310
Translation of the original user's manual

1Table of Contents
2. Introduction
3. Brief Survey
3.1 General Information
3.2 Functional Concept
3.3 Functional Sequence
3.4 Description A 142
3.5 Description A 310
4. Before Using the CargoMaster
4.1 Checking the Safety Brakes
5. Operating the CargoMaster
5.1 Safety Instructions
5.2 Parking without a Load
5.3 Parking with a Load
5.4 Moving on Level Ground
5.5 Adjusting the Handlebars
5.6 Picking up Loads
5.7 Loading with the Adjustable Toe Plate (A 310 only)
5.8 Loading a Vehicle
5.9 Unloading a Vehicle
5.10 Single Step Control
5.11 Continuously Adjustable Speed
5.12 Climbing Upstairs
5.13 Climbing Downstairs
6. Accessories
6.1 Horizontal Platform
6.2 Supporting Frame (only applicable to A 310)
6.3 Portable Stairs
6.4 Spare Batteries
7. Care and Maintenance
7.1 General Information
7.2 Changing the Electrical Fuses
7.3 Changing the Batteries
8. Lead Batteries
8.1 General Information
8.2 Charging the Batteries
9. Problems and Solutions
10. Warranty and Liability
10.1 Warranty
10.2 Liability
11. Appendix
Noise and Vibrations
CE Declaration of Conformity
Note
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2Introduction
Congratulations! You acquired a powerful and versatile machine to
transport loads.
The CargoMaster will shortly be an indispensable help to you.
However, in order to transport heavy loads effortlessly up- and
downstairs, it is necessary to acquire a certain skill in using the
CargoMaster.
For this reason we ask you to read the operator´s manual carefully
and pay particular attention to all warning and safety instructions
before using the CargoMaster for the first time.
We further suggest that, in order to get used to this stair-climbing
device, you practise handling it first without loads.
For safety reasons it is mandatory that you strictly observe the ma-
ximum limit for loads.
The warranty does not cover damage due to exceeding the maxi-
mum load or to inappropriate handling, e.g.:
•warped axles
•warped frames
•warped handlebars or grips
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3Brief Survey
3.1 General Information
Everybody who sees the CargoMaster in action for the first time is
fascinated by its climbing mechanism.
Precisely those people who are technically inclined end up shaking
their heads as they try to understand how it works. If one did not see
the CargoMaster actually climp up- and downstairs, one would re-
ach the conclusion that this couldn´t possibly work, and yet it does.
3.2 The Functional Principle
The major focus lies at the axle (F) at the frame (A) of the Cargo-
Master, around which the lifting levers (E) together with the big
wheels (C) rotate (see 3.3 "Functional Sequence").
The big wheels are not powered; instead they rotate freely on the
motor shaft. The small supporting wheels (B) are also not powered
but rotate freely.
The lifting levers are fixed to the motor shaft by means of teeth. If
the motor rotates, then the lifting levers inevitably also rotate
around the axis (D), which is both the axis of the motor shaft as well
as of the not powered big wheels. The other ends of the lifting le-
vers, as described previously, rotate freely around the axis (F) atta-
ched to the frame of the CargoMaster. This free rotation inevitably
results in the climbing process` intended up or down movement of
either the big wheels or the frame of the CargoMaster on the stairs.
Depending on the constellation of the frame, lifting levers, and big
wheels to each other certain positions follow in which one can eit-
her drive or park the CargoMaster.
How one can use the up and down movement of the big wheels and
the frame of the CargoMaster to climb stairs is shown and descri-
bed in details as follows.
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A
B
C
D
E
F
D
F

3.3 Functional Sequence
For the purpose of describing the functional sequence, please as-
sume that the CargoMaster is in the position "moving on level
ground". More precisely, the moving gear and the frame are in such
a position to each other that one can easily drive on level ground.
This starting position of the CargoMaster is called 0°. The lifting
lever are in an approximately horizontal position as shown on the
picture. The rotating axis of the lifting levers and the axles of the
big wheels are on about the same level.
The First Phase
Drive the CargoMaster to the first step of the stairs in the position
0°. Push the up/down-switch to "UP" and the motor begins to
rotate.
The motor shaft can rotate freely in the big wheels and, since the
lifting levers are connected with the motor shaft, the lifting levers
rotate around the axis of the big wheels, which, in turn, inevitably
lifts the frame.
The rotation moves from 0° to
45 ° and at position 90° one
can see that the lifting levers
lifted the frame into its highest
possible postition. The small
supporting wheels climbed
along and touch down on the
next step at approximately
135°. This concludes the first
phase.
The Second Phase
Once the supporting wheels touched down on the step, the big
wheels are moved up to the same step passing the positions 180°
and 225°.
At roughly 270° the big
wheels reach their highest
possible position and at about
315° they take over the load of
the small supporting wheels.
In the meantime one pulls the
CargoMaster back to the edge
of the following step. The final
position 360° coincides with
the starting position 0°, which
concludes the second phase
and the process can be repea-
ted.
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45°
0° 90° 135°
180° 225° 270° 315° 360°

3.4 Description A 142
1 = Handlebars
2 = UP/DOWN-switch
3 = Control Knob for Speed
4 = ON/OFF-switch
5 = Safety Belt
6 = Battery
7 = Toe Plate
8 = Safety Brakes
9 = Big Wheels
10 = Supporting Wheels
11 = Fuse
12= Fastening Lever
Technical Data: A 142
Dimensions
Height: 1120 mm
Width: 580 mm
Depth: 470 mm
Handlebars extractable up to 1770 mm
Weight Frame 26 kg, Batteries 6 kg
Lifting Capacity 140 kg
Sealed Batteries 2 x 12 V / 7,2 Ah (sealed)
DC Motor 24 V
Climbing Rate 8 - 25 steps per minute, continually adjustable
Capacity with one charge of the batteries 30 - 50 floors, depending on the load
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3.5 Description A 310
1 = Handlebars
2 = UP/DOWN-switch
3 = Control knob for continually adjustable
speed
4 = ON/OFF-switch
5 = Safety Belt
6 = Battery
7 = Single step control
8 = Toe Plate
9 = Big Wheels
10 = Safety Brake
11 = Supporting Wheels
12 = Stop bolts for toe plate adjustment
13 = Fuse
14 = Fastening screw knobs
15 = Push handles
Technical Data: A 310
Dimensions
Height: 1130 mm
Width: 590 mm
Depth: 520 mm
Handlebars extractable up to 1800 mm
Weight Frame = 40 kg, Batteries = 6 kg
Lifting Capacity 310 kg
Sealed Batteries 2 x 12 V / 7,2 Ah (sealed)
DC Motor 24 V
Climbing Rate 4 - 10 steps per minute, continually adjustable
Capacity with one charge of the batteries 15 - 30 floors, depending on the load
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4Before Operation
Before you use the CargoMaster for the first time, please make
sure that the batteries are completely charged, as shown in chapter
8.2 "Charging the Lead Batteries".
FPlease check the safety brakes each time before you use the CargoMaster.
4.1 Checking the Safety Brakes
First, put the CargoMaster in parking position by pus-
hing the UP/DOWN-switch.
Then, tilt the machine so far towards you that the
loading surface of the frame is almost in a horizon-
tal position; this movement lifts the big wheels off
the ground, so that only the small, supporting
wheels still touch the ground. At this point the sa-
fety brakes hinge down, engage and block the sup-
porting wheels.
If the machine cannot be pushed forward, but only
rolled backward, then the braking effect for a safe
use of the CargoMaster is achieved.
FIf this braking effect does not set in, the CargoMaster my not be used under any circumstances. Plea-
se contact your local dealer or the manufacturer immediately.
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5Operating the CargoMaster
5.1 Safety Instructions
For the safe operation of the CargoMaster, it is imperative to obser-
ve all requests for caution and all instructions of the operator´s ma-
nual as well as all safety measures and instruction labels on the
machine itself.
FThe CargoMaster may only be used by a trained person.
FDuring operation, never put your hand underneath the loading shovel.
FCheck the safety brakes before each time you use the machine.
FThe maximum load, see label on the machine, may never be exceeded.
FEach load you transport must be secured with the safety belt.
FIf any of the power-driven elements of the CargoMaster lock, turn off the machine
immediately.
FNever transport people with the CargoMaster.
FOnly operate the CargoMaster in conjunction with the safety devices that belong
to the particular machine.
FPlease turn off the CargoMaster, i.e. put the power switch in position "0", when
you stop the machine or take a break in transporting a load.
FRepair work on the CargoMaster may only be done by the manufacturer or authori-
zed dealers.
FOnly use original spare parts by AAT Alber Antriebstechnik GmbH.
FPeople under age are not allowed to operate the CargoMaster (except those over
16 who are trained under supervision).
FMake sure that the fastening screw knobs or fastening levers of the handlebars are
always securely tightened, particularly after adjusting the handlebars.
FMake sure that the lead batteries are recharged after each operation.
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5.2 Parking without a Load
Put the wheels in such a position as shown on the picture; then
park the CargoMaster by resting it on the loading shovel like a re-
gular sack trolley.
5.3 Parking with a Load
To park the CargoMaster with a load safely, all four
wheels, that is the big wheels and the small supporting
wheels, must touch the ground.
Ideally the load´s center of gravity is between the big
wheels and the smaller supporting wheels.
If this is not the case, one can shift the load accordingly,
provided that your type of CargoMaster is equipped with
an adjustable loading shovel as shown in chapter 5.7. If
your machine has a fixed loading shovel, you can insert a
wooden block or something similarly suitable under the
load.
The position of the load´s center of gravity determines
the angle of inclination in which the CargoMaster plus
load are balanced in the park position, in other words, the equilibri-
um is retained and the CargoMaster rests securely on the floor.
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5.4 Moving on Level Ground
Push the UP/DOWN-switch and bring the moving gear
in such a position as shown on the picture.
The lifting levers are in a roughly horizontal position
and point backward in reference to their axis of rotati-
on on the frame.
5.5 Adjusting the Handlebars
In order to drive, take up loads, and climb stairs with as little effort
as possible, the handlebars of the CargoMaster should be adjusted
to the operator´s height.
For the most comfortable and safe way to use the CargoMaster,ad-
just the height of the handlebars to the height of the operator´s
shoulders.
Depending on your type of CargoMaster,adjust the handlebars by
loosening either the fastening levers or the fastening screw knobs
on the frame and push the handlebars into the desired direction.
Make sure that the handlebars are always sufficiently inserted into
the frame, that is, do not pull them out too far. With models featu-
ring round pipe handlebars this is guaranteed, if the slits in the
clamping pipes of the frame are always filled out by the handle-
bars. With models featuring rectangular pipe handlebars, such as
model A 281, stop bolts keep you from pulling out the handlebars
too far. With these models stop bolts also lock the handlebars, even
if they are completely pushed in.
FAfter adjusting the handlebars, always make sure that they are secu-
rely fastened.
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5.6 Picking up Loads
Put the wheels in the position shown on the picture and move the
shovel of the CargoMaster under the load you want to transport.
FSecure the load with the safety belt.
You pick up the load by pushing your foot against the plastic plate
of the driving unit - the other foot rests firmly on the ground - while
pulling at the handlebars tilting the CargoMaster with its load to-
ward you.
FIt is easier to pull at the bow than at the top of the handles.
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5.7 Picking up Loads with the Height-Adjustable Toe Plate (A 310 only)
If your CargoMaster is equipped with the optional, height-adjus-
table shovel, you need to put the shovel in the position at which the
load´s center of gravity is positioned between the big wheels and
the smaller supporting wheels as described in chapter 5.3 "Parking
with a Load".
To adjust the height-adjustable toe plate, unlock the particularly
provided spring-urged stop bolts.
Pul out the stop bolt as shown on the picture ...
... turn in by 90°, at which point the stop bolt snaps into a small in-
dentation securing it against turning at ist own.
Adjust the shovel to the appropriate position and turn the stop bolts
again by 90°, at which point they snap back into their grooves.
You might have to slide the shovel back and forth in its guiding de-
vice to make sure that the stop bolts snap into their grooves
securely.
FThe nose must be fully inserted into the groove, see picture.
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5.8 Loading a Vehicle
Drive straight to the edge of the loading
platform and bring the CargoMaster with
its load into the parking position as shown
on the picture.
Bring the CargoMaster in its highest possible
position.
Drive the CargoMaster to the edge of the vehicle´s
loading platform as shown on the picture and tilt
the load onto it.
FFor your safety and convenience we recommend to use the AAT Alber portable stairs (see 6.3 "Portable
Stairs") when loading platforms.
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5.9 Unloading of a Vehicle
Push the load as fas as possible over the
edge of the loading platform.
Bring your CargoMaster into its highest
position, and drive with the shovel as clo-
sely as possible under the load to the edge
of the loading platform. Then tilt the load
onto the CargoMaster.
Put the CargoMaster in park
position and secure the load
with the safety belt as shown on
the picture.
FFor your safety and convenience we recommend to use the AAT Alber portable stairs (see 6.3 "Portable
Stairs") when loading platforms.
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5.10 Single Step Control
If your CargoMaster A310 is equipped with a single step control,
and it is turned on, you must press down the UP/DOWN-switch un-
til the device stops by itself.
FKeep the stair climber always under pressure while you press the UP/DOWN-switch.
Please also observe the instructions on stairs climbing described in chapters 5.12 and 5.13.
At the end of the single step control´s climbing cycle the device´s
braking wheels are on the step so that it is impossible to roll over
the step´s edge. If you want to continue the climbing process you
need to let go of the UP/DOWN-switch and press it again until the
next climbing cycle ends automatically.
The single step control is particularly useful when you first get used
to the CargoMaster or when the stairs are difficult to climb e.g.
narrow or winding stair cases.
The single step control is activated by a rocker switch located on
the right side of the power unit. If the rocker switch is in position "I"
it is activated. Position "0" indicates that it is not activated.
FThe green LED lamp next to the rocker switch does not indicate whether the single step control works
or not. This green light is always on when the CargoMaster is turned on, whether the single step con-
trol is activated or not.
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5.11 Continuously Adjustable Climbing Speed
Select the climbing speed you are comfortable with by turning the
knob located underneath the UP/DOWN-switch. If you are not used
to the CargoMaster or whenever the loads are difficult to transport
you should select the lowest speed possible.
FNote that the CargoMaster is equipped with an automatic turn off function. Once the device has tur-
ned itself off (e.g. during a break) you need to turn the CargoMaster first off and then on again with the
ON/OFF-switch.
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5.12 Climbing Upstairs
You will manage the climbing process without pro-
blems and in next to not time, if you follow instruc-
tions closely. At first you should practice climbing
stairs up and down with the CargoMaster without
loads to get familiar with the device and how it
works.
1. To climb stairs, drive with the CargoMaster
backwards toward the stairs and climb 2 to 3 steps.
Please make sure that the CargoMaster´s big wheels
are touching the edge of the lowest step as shown on
the picture.
FDuring the entire climbing process, always pull the CargoMaster slightly backwards towards you, i.e.
keep the device always under tensible force.
2. Push the UP/DOWN-switch to "UP" initiating
the climbing process. The motor and the lifting le-
vers begin to rotate and uplift the frame plus load.
FImitate this powered climbing process of the frame with your arms and consequently with the handle-
bars. Hereby you keep the CargoMaster in a sufficiently steep angle so that the supporting wheels can
touch down on the next higher step.
3. The climbing process takes place in two sec-
tions per step. The first section is finished when the
small supporting wheels touch down on the next
step and take over the load from the big wheels.
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4. At this point a load alternation takes place.
You can clearly feel a pull forward at the handle-
bars. Compensate this movement of the Cargo-
Master by pushing the handlebars downward,
thus decreasing its angle of inclination as shown
on the picture.
FMake sure the handlebars are not held too
low because in such case the supporting
wheels do not reach the next higher step.
5. The second section begins with the
lifting or pulling up of the big wheels as
shown on the picture; it is finished when
the big wheels touch down, next to the
small supporting wheels, on the following
step.
At this point there is another load alterna-
tion, which is compensated, in turn, by lif-
ting the handlebars holding the
CargoMaster at a steeper angle.
By keeping the CargoMaster always
slightly under tensible force, it rolls automati-
cally to the next step. The climbing process re-
peats itself as described above.
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5.13 Climbing - Downstairs
FNotice that only the small supporting wheels are equipped with brakes; the big wheels don´t have
brakes.
1. Bring the big wheels in
the position as shown on the
picture and rest the Cargo-
Master on its small supporting
wheels by pushing the handle-
bars down. Hold the device
precisely at such a position
that the big wheels do not
touch the ground anymore.
2. Push the CargoMaster all the way up to
the edge of the step until the braking wheels
just reach over said edge; however, the safety
brakes should not be activated.
FDo not use the safety brakes as a kind of
"stopper". The safety brakes are intended, if the case arises, to keep the small supporting wheels from
rolling over the edge of the step.
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