OPERATION AND MAINTENANCE MANUAL WASP, Inc. 757 Towbar Model No. A01568D

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1 OPERATION AND MAINTENANCE MANUAL WASP, Inc. 757 Towbar Model No. A01568D

2 WASP RECORD OF REVISIONS REV. ISSUE DATE BY REV. ISSUE DATE BY NO. DATE INSERTED NO. DATE INSERTED Original May 19/ June 10/03

3 LIST OF EFFECTIVE PAGES SECTION PAGE DATE R List of Effective Pages 3 June 10/03 R Table of Contents 4 June 10/03 Warranty 5 R Operations 6 May 19/97 R Operations, Cont. 7 May 19/97 R Operations, Cont. 7A Aug. 08/00 R Illustrated Parts List 8 May 19/97 R Illustration (Main Assembly) 9B May 19/97 R Parts List 9 May 19/97 R Illustration (Towing Pin Head Assembly) 10A May 19/97 R Parts List 10 May 19/97 R Illustration (Swivel Lunette Assembly) 11A May 19/97 R Parts List 11 May 19/97 R Illustration (Wheel Carriage Assembly) 12A Sept. 28/98 R Parts List 12 Sept. 28/98 Notes 13 List of Effective Pages June 10/03 Page 3

4 TABLE OF CONTENTS PAGE Title Page Record of Revisions List of Effective Pages Table of Contents Warranty 5 Operations 6 Operations, Cont. 7 Operations, Cont. 7A Illustrated Parts List 8 Illustration (Main Assembly) 9B Parts List 9 Illustration (Towing Pin Head Assembly) 10A Parts List 10 Illustration (Swivel Lunette Assembly) 11A Parts List 11 Illustration (Wheel Carriage Assembly) 12A Parts List 12 Notes 13 Table of Contents June 10/03 Page 4

5 WARRANTY WASP, Inc. warrants, to the original purchaser only, each of its new products to be free from defects in material and workmanship under normal and recommended use and service, subject to the conditions and qualifications herein set forth. The obligation of WASP, Inc. hereunder is limited to the repair or replacement of those parts which WASP, Inc., at it's sole discretion, determines to have failed as a result of defects in material or workmanship within a period of twelve (12) months after the date of purchase. No warranty of any kind, statutory implied or other wise is made or shall be imposed upon WASP, Inc. with respect to: 1. Second-hand parts or components. 2. New parts or components which, after shipment from the factory of it's origin, have been subject to operation in excess of the recommended capacities, misuse, negligence, or accident, or have been altered or repaired in any manner not authorized by WASP, Inc. 3. Tires, batteries, motors, electrical controls, etc. except that WASP, Inc. agrees to make available to the first user whatever Warranty benefits may be made available to WASP Inc. for these purchased components. This warranty does not apply to failures resulting from the use of attachments not sold or approved by WASP, Inc. WASP, Inc. will repair, or at it's option replace any part of its new products which under normal use and service fail to conform to this Warranty, providing that such part shall be returned to WASP, Inc. or to an Authorized Representative or Dealer of WASP, Inc. transportation charges prepaid. This Warranty is express in lieu of any other Warranties, expressed or implied, including any Warranty of merchantability or fitness for a particular purpose. This Warranty shall immediately become void if any service other than normal maintenance, is performed by anyone other than an authorized WASP Representative or Dealer; or if any alteration or modification is made without the prior consent of WASP, or if, in the sole discretion of WASP, Inc., the failure is due to abuse or neglect in the operation or maintenance of the product due to failure to follow the provisions set forth in the Operator's Manual. For Warranty Help Call Ask For Warranty Department. Warranty Page 5

6 OPERATIONS This towbar is designed to push or pull Boeing 757 aircraft equipped with an 1.50 inch diameter nose gear cross pin. The following operational instructions are only intended to familiarize the operator with the basic functions of the towbar. They are not intended to teach actual pushback procedures or techniques. RAISING AND LOWERING The towbar is equipped with a hand operated hydraulic pump/tank which supplies a flow of hydraulic oil to a single acting hydraulic cylinder. This cylinder raises or lowers the wheel carriage assembly to which the tires are attached. To raise the towbar, first make sure the fill cap on the tank is in the vent position and the small control valve located on the side of the pump is in the complete closed (clockwise) position. Actuate the pump handle until the desired elevation is achieved. To lower the unit, turn the control valve handle counter-clockwise until hydraulic oil flows back into the tank and allows the cylinder to retract. Close the valve when the towbar has reached the desired elevation. ATTACHING TO THE AIRCRAFT The towbar is equipped with a jaw type attachment head. When attached properly it will allow the aircraft to be pushed or pulled safely. To attach the towbar to the aircraft, raise or lower the towbar so that it is level to the ground and at the same height as the nose gear attachment point. Open the jaws by first removing the safety pin from the side of the head assembly. This pin is located next to the round black knob. Once the safety pin is removed, pull the black knob outward and turn the large handle 90 degrees to release the center jaw. Position the lower jaws under the nose gear cross shaft and clamp the middle jaw around the shaft by pushing back down on the large handle until it is secured around the shaft. Turn the large handle 90 degrees until the black knob moves inward indicating the "locked" position. Insert the safety pin into the side of the head, making sure that it is secure. SHEAR BOLTS The towbar is also equipped with shear bolts that are designed to shear when the design limits of the aircraft nose gear are exceeded. One set of spare shear bolts has been provided with the towbar. Operations May 19/97 Page 6

7 IMPORTANT!! NEVER use other bolts in place of factory supplied shear bolts - aircraft damage may result!! In the event that the shear bolts should fail during operation, carefully inspect all parts of the towbar for damage before replacing the shear bolts and returning the towbar to service. ATTACHING TO TRACTOR The towbar is equipped with a towing eye that swivels to eliminate any possible binding due to irregular terrain or camber changes in the aircraft nose gear during pushback or towing operations. To attach the towbar to the tractor, raise or lower the towbar so that it is level with the ground and at the same height as the tractor hitch point. Position the lunette eye into the hitch opening and secure the hitch pin according to the tractor manufacturer s instructions. The towbar can be safely towed on typical ramp surfaces up to 15 MPH. Exceeding this speed may result in damage to the towbar. MAINTENANCE Towbar maintenance should be done at least once every three months or sooner depending on usage. 1. Check shear bolts for wear or a partial shear and replace if necessary. Check bolts by rotating them and looking movement of the shear plates at the same time. 2. Check tires pressure and inspect for wear or damage. 3. Check the hydraulic fluid in the reservoir and maintain at the correct level. 4. Check for hydraulic leaks. 5. Check all nuts, bolts, and screws for tightness. 6. Check the unit overall for wear or damage. 7. Grease hubs through zerk provided in hub. Operations, Cont. May 19/97 Page 7

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9 ILLUSTRATED PARTS LIST The following illustration and parts list should be used to order parts for repairs. When ordering parts, match the item number in the illustration with the item number on the parts list, and then order using the part number following the item number in the parts list. Illustrated Parts List May 19/97 Page 8

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11 MAIN ASSEMBLY PARTS LIST ITEM QTY. PART # DESCRIPTION R 1 1 W003974B Towbar Tube Weldment R 2 1 A002642A Towing Pin Head Assembly, See Page 9 R 3 1 A003227A Swivel Lunette Assembly, See Page 10 R 4 1 W003973A Handle Weldment R 5 1 A003163A Wheel Carriage Assembly, See Page 11 R 6 1 A001812A Hyd. Hose Assembly R 7 2 H Spring R 8 1 H Hydraulic Cylinder R 9 1 P057417A Mod. Hand Pump R 10 1 H /4 x 90 deg. Hydraulic Street Swivel R H /8 NC Serrated Flange Nut R H /8 NC x 1-1/4 Lg. Capscrew R 13 4 H /8 NC x 1 Lg. Capscrew R 14 2 H /8 x 1-1/2 Lg. Cotter Pin R 15 1 P054191A 1 Cylinder Mounting Pin R 16 4 H /8 Lock Washer R H /8 SAE Washer R 18 1 H /4 Hydraulic Straight Swivel R 19 1 H /4 x 1.00 Lg. AB Sheet Metal Screw R 20 1 H /2 Vinyl Coated Clamp R 21 1 H Open Valve Before Towing Decal R 22 3 H Shearbolt Decal R 23 1 H Decal R 24 2 H /16 NF x 2-1/2 Lg. Shearbolt R 25 2 H /16 NF Nut R 26 1 P057615A Flag R 27 1 H /16 x 2 Lg. Detent Pin R 28 2 H /32 Aluminum Hourglass Sleeve R 29 1 H /8 x 1/4 x 36 Lg. Plastic Pigtail R 30 1 H /16 x 1-1/2 Lg. Cotter Pin R 31 2 H /16 x 1 Lg. Cotter Pin R 32 1 W003995A Head Mount Weldment R 33 4 H /8 NC x 1-1/2 Lg. Capscrew R 34 1 W004914A Wear Shoe Weldment R 35 4 H /2 NC Nylok Nut R 36 4 H /2 NC x 1-1/2 Lg. Capscrew Main Assembly Parts List May 19/97 Page 9

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13 TOWING PIN HEAD ASSEMBLY PARTS LIST ITEM QTY. PART # DESCRIPTION R 1 REF. W003975A Head Mount Weldment R 2 1 W004955A Pin Pivot Weldment R 3 1 P054531A Cam Handle R 4 1 P054532A Cam R 5 1 H /4 x 2 Lg. Roll Pin R 6 1 P054533A Lock Pin R 7 1 H Lock Pin Spring R 8 1 H Lock Pin Knob R 9 1 H /8 NC x 6-1/2 Lg. Capscrew R 10 1 H /8 NC Nylok Nut R 11 2 H /16 NF x 2-1/2 Lg. Shearbolt R 12 2 H /16 NF Jam Nut R 13 4 H /16 x 3/4 x 1/2 Headless Press Bushing R 14 2 H /4 NC Nylok Nut R 15 1 H /4 NC x 3-1/2 Lg. Capscrew R 16 2 P054534A Pivot Head Spacer R 17 REF. W003995A Head Mount Weldment R 18 REF. W003974B Chassis Tube Weldment R 19 2 H /16 x 1 Lg. Cotter Pin R 20 1 H /4 x 2-1/2 Lg. Detent Pin R 21 1 P058787A Coated Cable R 22 2 H /8 Cable Clip R 23 1 H /4 x 1/2 Lg. Dowel Pin R 24 1 P058572A Caution... Decal NOTE: Complete assembly can be ordered by part number A002642A. Towing Pin Head Assembly Parts List May 19/97 Page 10

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15 SWIVEL LUNETTE ASSEMBLY PARTS LIST ITEM QTY. PART # DESCRIPTION R 1 1 W003887A Hitch Pin Weldment R 2 1 W003888A Pin Block Weldment R 3 2 P054190A Pivot Washer R 4 1 H /4 NF Slotted Nut R 5 1 H /16 x 2 Lg. Cotter Pin R 6 1 H /4 SAE Washer R 7 1 A002574A Lunette Assembly R 8 1 W004666A Adapter Assembly R 9 4 H /2 NC Nylok Nut R 10 4 H /2 NC x 5 Lg. Capscrew NOTE: Complete assembly can be ordered by part number A003227A. Swivel Lunette Assembly Parts List May 19/97 Page 11

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17 WHEEL CARRIAGE ASSEMBLY PARTS LIST ITEM QTY. PART # DESCRIPTION 1 1 W003889A LH Wheel Plate Weldment 2 1 W003890A RH Wheel Plate Weldment 3 2 P054192A Hydraulic Cylinder Mounting Plate 4 1 P054193A Spindle Tube Connector 5 1 P054194A Cylinder Mounting Pin 6 2 P054195A Spacer Mounting Rod 7 4 H /2 NC Nylok Nut 8 2 P054196A Spacer Tube 9 4 P054197A Spacer Tube 10 2 P054198A Wheel Assembly Washer 11 2 P054199A Sleeve Bushing 12 1 P054200A Wheel Assembly Mounting Rod 13 2 H /8 NC x 1-1/4 Lg. Capscrew R 14 2 H Wheel, 4.80/8 Pneumatic R 15 6 H /4 NC x 1-3/4 Lg. Capscrew 16 6 H /4 NC Nylok Nut R 17 2 W004605A Offset Axle Weldment R 18 2 H /4 NF Slotted Nut R 19 2 H /16 x 1-1/2 Lg. Cotter Pin 20 2 H Plug, 1 Plastic R 21 2 H /4 18 GA NR Machinery Bushing R 22 2 H /8 x 2 Lg. Cotter Pin R 23 2 H /8 Lock Washer NOTE: Complete assembly can be ordered by part number A003163A. Wheel Carriage Assembly Parts List Sept. 28/98 Page 12

18 WASP, INC STATE HWY P.O. BOX 249 GLENWOOD, MN NOTES