AAT cargomaster C 141 User manual
Operator’s Manual
CargoMaster
C 141
C 141 Vario
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
1 Table of contents
2. Introduction
3. Brief Survey
3.1 General Information
3.2 Functional Concept
3.3 Functional Sequence
3.4 Description C 141, C 141 Vario
4. Before Operation
4.1 Checking the Safety Brakes
5. Operating the CargoMaster C 141, C 141 Vario
5.1 Safety Instructions
5.2 Parking With/Without Loads
5.3 Moving on Level Ground
5.4 Picking up Loads
5.5 Loading a Vehicle
5.6 Unloading a Vehicle
5.7 Climbing Upstairs
5.8 Climbing Downstairs
5.9 Continuously Adjustable Climbing Speed
5.10 Foldable toe plate
5.11 Adjustable handles C 141 Vario
6. Accessories
6.1 Portable Stairs
6.2 Spare Batteries
7. Care and Maintenance
7.1 General Information
7.2 Changing the Electrical Fuses
7.3 Changing the Batteries
7.4 Tightening the Chain
8. Sealed lead acid batteries
8.1 General Information
8.2 Charging the sealed lead acid batteries
9. Warranty and Liability
9.1 Warranty
9.2 Liability
10. Appendix
Noise and Vibrations
Declaration of CE Conformity
Note
2
CargoMaster
c141_gb_12/02
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
2 Introduction
Congratulations, you acquired a powerful and versatile ma-
chine 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
stairclimbing device, you practise handling it first without
loads.Please practice at the lowest speed possible.
For safety reasons it is mandatory to observe strictly the
maximum limit for loads.
For damage done by exceeding the maximum load or im-
proper use such as...
•warped axles
•deformed frame
•deformed handles
...we do not assume any warranty.
3
CargoMaster
c141_gb_12/02
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
3 Brief 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 climb up-
and downstairs, one would reach the conclusion that this
couldn’t possibly work, and yet it does.
3.2 The Functional Principle
The major focus lies at the axle (D3) of the CargoMaster’s
power unit (A) around which the levers (B1 und B2) rotate
(please see also 3.3 “Functional Sequence”).
The big wheels and the braking wheels are not powered, but
rotate freely on their own axles.
A chain and tooth wheel system integrated in motor lever
(B2) and lifting lever (B1) transfer the rotation of the mo-
tor’s axle in such a way that the lever (B2) rotates around
the motor’s axle (D3) and the lever (B1) in an opposite di-
rection around the connecting axle (D2). The axle (D1), con-
nected to the climbers, thus makes the up and down
movement necessary for the CargoMaster’s climbing pro-
cess. The climbers, guided on the rail (E), follow that move-
ment.
Depending on how levers (B1 and B2) climbers (C) and fra-
me are located in relation to each other there are certain
positions in which the CargoMaster should preferably be dri-
ven or parked.
How the up and down movement of the CargoMaster‘s climb-
ers and frame can be used to climb stairs is desribed and
explained as you read on.
4
CargoMaster
c141_gb_12/02
B1
B2
D1
A
D2
D3
Fig. 1
B1
B2
D1
A
D2
D3
E
C
C
Fig. 2
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
3.3 Functional Sequence
For the description of the functional sequence we assume
that the CargoMaster’s climbing mechanism and the climb-
ers are at their highest position as shown in Fig. 3
This is the position in which one drives the CargoMaster on
level ground. It is further the position in which one can rest
the CargoMaster on its toe plate. In the following description
of the functional sequence this neutral or starting position
of the CargoMaster is called position 0°.
The First Phase
Drive the CargoMaster to the first step of the stairs in posi-
tion 0°.Push the UP/DOWN switch “UP” and the motor be-
gins to rotate. Both levers of the climbing system rotate
as well and the climbers move downward.
The climbers touch the ground
and take over the load. The motor
continues to rotate, and because
the rotating movement is
transfered to the climbers, the
frame is pushed upward, i.e.
lifted.
The motor lever’s rotation moves
from 90° to 120° and you notice
that the big wheels pass over the
edge to the next step. At approximately 180° the climbing
mechanism lifts the frame to the next step, and the big
wheels take over the load once more (see Fig. 4). This con-
cludes the first phase.
The Second Phase
Once the big wheels take over the load on the next
step at approximately 180°, the climbers are
lifted as well passing 210° and 270°.
At 330° the climbers are “retracted” sufficiently
so that the CargoMaster can be pulled back to the
edge of the following step (see Fig. 5). The final po-
sition, 360°, coincides with the starting position
0°, which concludes the second phase. Now you
can repeat the process.
5
CargoMaster
c141_gb_12/02
Fig. 3
90° 180°120°0°
Fig. 4
270° 330°
210°
Fig. 5
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
3.4 Description C 141
C 141 Vario
1 = Handlebars
2 = UP/DOWN-Switch
3 = Knob for continuos speed control
4 = On/Off Switch
5 = Battery pack
6 = Climber
7 = Big Wheels
8 = Climbing mechanism
9 = Clamp plus locking screw
10 = Helix cable
Technical Data: C 141 C 141 Vario
Dimensions
(toe plate folded in / out)
Height: 1390 mm
Width: 440 mm
Depth: 300 / 550 mm
Height: 1060-1400 mm
Width: 440 mm
Depth: 300 / 550 mm
Weight Frame = 23,5 kg (51,8 lbs)
Batteries = 4,5 kg (9,9 lbs)
Frame = 20,5 kg (45,2 lbs)
Batteries = 4,5 kg (9,9 lbs)
Lifting Capacity 140 kg (308 lbs) 140 kg (308 lbs)
Sealed lead acid batteries 2 x 12V/5Ah(sealed) 2 x 12V/5Ah(sealed)
D.C. Motor 24 V 24 V
Climbing Rate 8 - 30 steps per minute,
continuously adjustable
8 - 30 steps per minute,
continuously adjustable
Capaticity with one
charge of the batteris
15 - 30 stories, depending on
the load
15 - 30 stories, depending on
the load
We reserve the right for technical and/or optical changes as well as for changes in
outfit.
6
CargoMaster
c141_gb_12/02
1
1
2
4
5
6
7
8
3
Fig. 6
1
1
2
4
5
6
7
8
3
10
9
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
4 Before Operation
Before you use the CargoMaster for the first time, please
make sure the batteries are completely charged, as shown
in chapter 8.2 “Charging the Lead batteries”.
+Please check the safety brakes each time
before you use the CargoMaster.
4.1 Checking the Safety Brakes
Retract the climbers entirely by pushing the
UP/DOWN switch.
Unlock the safety brakes with the tip of your foot.
You need to push the stopping levers upward until
the looking mechanism opens. Now the brake levers
move down unencumbered, and the braking wheels
touch the ground as shown in Fig. 7
Then, tilt the machine towards you until the
frame’s loading surface is almost in a horizontal
position. At this point the safety brakes must
engage and lock the running wheels. If the machi-
ne cannot be pushed forward, but only rolled
backward, then the braking effect for a safe use
of the CargoMaster is achieved.
+If this braking effect does not set in, the CargoMaster may not be used under any
circumstances. Please contact your local dealer or the manufacturer immediately.
+To climb up- or downstairs you must always unlock the safety brakes.
7
CargoMaster
c141_gb_12/02
Fig. 7
à
à
Fig. 8
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
5 Operating the CargoMaster
5.1 Safety Instructions
+For the safe operation of the CargoMaster,itis
imperative to observe all requests for caution and all
instructions of the operator’s manual as well as all
safety measures and instruction labels on the
machine itself.
+The CargoMaster may only be used by a trained
person.
+During operation, never put your hand underneath
the toe plate.
+Check the safety brakes each time you use the
machine.
+to climb up- or downstairs always unlock the safety
brakes.
+The maximim load, see label on the machine, may
never be exceeded.
+Each load you transport must be secured with the
safety belt.
+If any of the power-driven elements of the
CargoMaster lock, turn off the machine immediately.
+Never transport people with the CargoMaster.
+Only operate the CargoMaster in conjunction with the
safety devices that belong to the particular machine.
+Please 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.
+Repair work on the CargoMaster may only be done by
the manufacturer or authorized dealers.
+Only use original spare parts by AAT Alber
Antriebstechnik GmbH.
+People under age are not allowed to operate the
CargoMaster (except those over 16 who are trained
under supervision).
+Make sure that the batteries are recharged after
each operation.
8
CargoMaster
c141_gb_12/02
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
5.2 Parking With/Without Loads
Handle the CargoMaster C 141 like a regular sack trolley.
9
CargoMaster
c141_gb_12/02
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
5.3 Moving on Level Ground
Retract the climbers as much as possible using the
UP/DOWN switch (see Fig. 9), and lock the brakes.
+Driving with unlocked brakes can lead to more
wear and tear as well as to damage of the braking
mechanism.
Handle the CargoMaster C 141 like a regular sack trolley.
You can also use it without the power unit on level ground.
10
CargoMaster
c141_gb_12/02
Fig. 9
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
5.4 Picking up Loads
To pick up loads retract the CargoMaster’s climbers as
much as possible as shown in Fig.10
+Drive the CargoMaster’s toe plate under the load you
want to pick up, and secure it with the safety belt
Then pick up the load by pressing your foot against the mo-
tor housing (on the back side in the middle of the climbing
mechanism).
+Your other foot must rest firmly on the ground
Finally pull at the handlebars and tilt the CargoMaster plus
load toward you, as you would with a regular sack trolley.
11
CargoMaster
c141_gb_12/02
Fig. 10
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
5.5 Loading a Vehicle
Tilt the CargoMaster backwards as low as possible
and drive straight forward to the loading plat-
form. Remove the safety belt.
Push the UP/DOWN switch “UP” lifting the load
to its highest possible position.
+Using “UP” instead of “DOWN” makes it
easier to keep the CargoMaster balanced.
+By letting your arms climb with the
CargoMaster you keep the device plus its
load balanced, regarding a potential shift
of the center of gravity.
While the CargoMaster lifts the load, tilt it forward
towards the loading platform so that the load tou-
ches the loading platform.
Then push it entirely onto the loading platform.
+For your safety and convenience we recommend using the AAT Alber portable stairs
(see chapter 6.1 “Portable Stairs”).
12
CargoMaster
c141_gb_12/02
Fig. 11
à
Fig. 12
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
5.6 Unloading a Vehicle
Push the load as far as possible over the edge of
the loading platform.
Put the CargoMaster into its highest position as
shown in Fig. 13, and drive with the toe plate as
closely as possible under the load to the edge of
the loading platform.
Tilt the load onto the CargoMaster and secure it
with the safety belt, see Fig.14.
+For your safety and convenience we recommend using the AAT Alber portable stairs
(see chapter 6.1 “Portable Stairs”).
13
CargoMaster
c141_gb_12/02
à
Fig. 13
à
Fig. 14
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
5.7 Climbing Upstairs
You will manage the climbing process without problems and
in next to no time, if you follow instructions 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 to-
ward the stairs and then you climb 2 to 3 steps. Please
make sure that the CargoMaster’s big wheels are touching
the edge of the lowest step and the climbers are in their
utmost position (see Fig. 15).
+Always make sure that the safety brakes are
unlocked when you climb stairs.
+During 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 “UP” to initiate the climbing
process. The motor rotates while the climbers lift the fra-
me plus load.
+Imitate the frame’s climbing process with your arms
and hold the handlebars in such an angle that the
wheels can grip the next step.
3. The climbing process takes place in two phases per step.
The first phase is finished when the running wheels touch
down on the next step and take over the load from the clim-
bers.
+Do not hold the handlebars too low because in such
case the running wheels do not reach the next higher
step.
14
CargoMaster
c141_gb_12/02
Fig. 15
Fig. 16
Fig. 17
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
4. The second phase starts with “retracting” the climbers
before the lifting process begins.
It ends when the climbing mechanism has reached the next
step and is in its neutral position.
Because the CargoMaster is always pulled slightly backward,
it rolls automatically to the next step (see Fig. 20). The
climbing process repeats itself as described in 5.2.
15
CargoMaster
c141_gb_12/02
Fig. 18
Fig. 19
Fig. 20
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
5.8 Climbing Downstairs
+Please make sure that the safety brakes are always
unlocked when you are climbing stairs.
1. Push the CargoMaster, climbers in utmost position, all
the way to the edge of the stairs. The unlocked safety bra-
kes make it impossible that the CargoMaster goes over the
edge of the stairs.
2. Push the UP/DOWN switch “DOWN” and the CargoMas-
ter begins its decent. The downward movement starts with
the lowering of the climbers to the next step.
3. As soon as the climbers touch the surface of the next
step, the frame begins to move downward until the big
wheels also touch the step. Now push the device again to
the curb of the following step and repeat the process des-
cribed in point 2.
+As soon as the climbers take over the load, you feel a
definite pull forward in the handlebars. Counteract
this movement by briefly lowering the CargoMaster’s
handlebars.
16
CargoMaster
c141_gb_12/02
Fig. 22
Fig. 21
Fig. 23
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
5.9 Continuously Adjustable Climbing Speed
Select a climbing speed that suits you by the knob
underneath the UP/DOWN switch. When transporting
loads that are difficult to handle or when you use the Cargo-
Master the first couple of times, choose the lowest speed
possible.
+Note that the CargoMaster is equipped with an automatic turn off function. Once the
device has turned itself off (e.g. during a break) you need to turn the CargoMaster
first off and then on again with the ON/OFF switch.
17
CargoMaster
c141_gb_12/02
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
5.10 Foldable toe plate
The CargoMaster model C 141 is equipped with a foldable toe
plate thus storage and transportation of the device is com-
fortable and easy because it does not take up much space.
In a regular position the toe plate is
locked by a bolt (1).
If you flip the lever (2a) from a verti-
cal to a horizontal position (2b), the
bolt (2c) moves upward, unlocking
the toe plate (2d).
The thus unlocked toe plate can
be moved up by 90° (3a).
In this position you can fix the
toe plate by flipping the lever
(4a) in a horizontal position so
that the bolt (4b) lowers itself
into the aparture at the toe pla-
te and locks it (4c).
c141_gb_12/02
18
CargoMaster
1
2a
2b
2c
2d
3a 4a
4b
4c
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
5.11 Adjustable Handles
C 141 Vario
Due to the handles adjustable in height and angle
the device can be adapted ideally to any situation
of transportation. The storage dimensions of the
device itself are considerably smaller than those of
the standard model.
The handles can be adjusted in height by loosening
the locking screws of the clamps.
+After adjusting the handles retighten the
locking screws.
If you unscrew the locking screws approximately 6
mm the plates of the clamps can be pulled apart so
that a locking bolt clears. At that point the handle
that is in a vertical position can be moved forward or
backward.
Adjust the handles in such a way that the locking
bolt is inserted in one of the three drilled holes in the
clamp.
+After adjusting the handles retighten the
locking screws
19
CargoMaster
c141_gb_12/02
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
6 Accessories
6.1 Portable Stairs
The portable stairs are especially deve-
loped for the CargoMaster to overcome
obstacles higher than 50 cm (~20”)
such as e.g. ramps, platforms or loa-
ding areas of trucks (see Fig. 24)
Technical Data
Portable stairs O 42 Portable stairs O 43
number of steps 3 4
height of loading area (C) 30 cm to max. 52 cm 52 cm to max. 66 cm
maximum dynamic load (D) 350 kg (771 lbs) 350 kg (771 lbs)
protrusion (A) 80 cm 100 cm
minimum support (B) 15 cm 15 cm
weight ~12,5 kg ( 27,5 lbs) ~16,5 kg ( 36,3 lbs)
+The portable stairs must be put up securely, i.e. you need to make sure they cannot
tilt or slide. If necessary, you need to secure the stairs on the loading area by
screws.
+Make sure that the minimum support (see Fig. 28, B) of the portable stairs is at
least 15 cm (~6”) on the loading area and rests there securely.
20
CargoMaster
c141_gb_12/02
A
B
C
D
Fig. 24
Manual Handling Solutions 58, Paige Close, Watlington, Kings Lynn, Norfolk PE33 0TQ UK
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