Operation and Maintenance manual

Goldhofer V03A-05.08 Goldhofer OverTorque-Indication-System Documentation GOTIS AST-1, AST-2, AST-3 (not AST-3 R) Operation and Maintenance manual

GOTIS Index Page 1 Index Name Chapter - Page Index The GOTIS documentation AST-1, AST-2, AST-3 (not AST-3 R) Introduction A A Use according to purpose A 1.0 Overview of monitoring elements and controls of the GOTIS 1-1 Reset of GOTIS 1-2 1.1 Flashing code table for diagnosis 1-3 1.2 Approvals 1-4 2.0 Description of the GOTIS 2-1 3.0 Maintenance intervals of the GOTIS 3-1 4.0 Maintenance schedule 4-1 4.1 Maintenance records GOTIS 4-2 5.0 Maintenance work 5-1 5.1 Maintenance of the GOTIS 5-2 5.1.1 GOTIS Lamp check 5-2 5.1.2 Electric check of the GOTIS 5-3 Description of the adapter cable 5-4 5.1.2.1 Electric check of the amplifier voltage supply 5-5 5.1.2.1a Electric check of the fuse in the amplifier 5-6 5.1.2.2 Electric check of the load cell voltage supply 5-7 5.1.2.3 Electric check No.1 of the load cell 5-8 5.1.2.4 Electric check No. 2 of the load cell 5-9 5.1.2.5 Electric check of measuring signal 5-10 5.1.2.6 Adjustment and electric check of the amplifier output signal 5-11 5.1.3 Amplifier 5-12 5.1.4 Mechanical check of GOTIS using the GOTIS test tool 5-13 5.1.4.1 Installation of the GOTIS test tool 5-13 5.1.4.2 Mechanical check of GOTIS 5-15 5.1.5 GOTIS - Reference Value Table 5-18

GOTIS Index Page 2 Index Name Chapter - Page 5.1.5.1 Test report 5-19 6.0 Electric setting of the GOTIS 6-1 6.0.1 AST-1 / AST-2 6-1 6.0.2 AST-3 (not AST-3 R) 6-1 7.0 Troubleshoot List AST-1/-2/-3 (CAN-Bus with blue light) 7-1 Amplifier Order Form 8-1 Appendix A 9-1

Primary information Page A The GOTIS documentation AST-1, AST-2, AST-3 (not AST-3 R) The designation GOTIS is explained in this Operating and Maintenance Manual. GOTIS means: Goldhofer OverTorque-Indication-System. Introduction This Operating and Maintenance Manual contains the principal items for a quick and safe putting into operation of the GOTIS. This GOTIS Operating and Maintenance Manual does not replace the general AST Operating and Maintenance Manual. It is an integral part of the AST Operating and Maintenance Manual. The Warning Instructions in the Operating and Maintenance Manual of the GOTIS and in the Operating and Maintenance Manual of the AST, particularly the Safety Instructions and the Important Information contained in the Operating Manual as well as the legal regulations and accident prevention regulations must be met. Use according to purpose The GOTIS is a Goldhofer System which is used to monitor the torques of the nose wheel. The GOTIS is used on all aircraft that require an overtorque system and that are approved for the Goldhofer AST product range (see Approvals). Any other use is to be understood as a use for an unauthorised purpose. The manufacturer cannot accept any liability for damages resulting from it; solely the user shall bear the risk. Moreover, the compliance with the operation, maintenance and repair instructions given by the manufacturer are also part of a use according to purpose. Unauthorized modifications of the GOTIS do not include the manufacturer s liability for damages resulting from it.

Monitoring elements and Chapter 1 controls of the GOTIS Page 1 1.0 Overview of monitoring elements and controls of the GOTIS Fig. 1 Overview of monitoring elements and controls of the GOTIS 1 = Alarm light (red) Alarm threshold: When the maximum allowable torque on the nose wheel is being exceeded, the red alarm light is activated. When the red alarm light (1) lights up, the yellow warning light (2) lights up at the same time. Additionally, a warning is given by means of a buzzer. 2 = Warning light (yellow) Warning threshold: When 70 % of the maximum torque on the nose wheel is reached, the driver is alerted by the warning light that flashes yellow and the additional buzzer (at intervals). When the steering forces are decreased, the warning light goes out. 3 = GOTIS light (green) The lighting up of the green indicator signals that the GOTIS is operative. An aircraft that requires an overtorque system may only be moved when the GOTIS light (green) indicates operation readiness after loading and during operation of the aircraft. For aircraft that do not require an overtorque system, the GOTIS light (green) light also indicates operation readiness. In this case, however, operation readiness does not mean that the aircraft is monitored by the GOTIS. When after a wrong aircraft selection (see also Operating Manual of AST, Part 1) the aircraft selection is confirmed a second time via TDM, solely the operator will be responsible for this process. The manufacturer will not be liable for any damages resulting from it.

Monitoring elements and Chapter 1 controls of the GOTIS Page 2 Fig. 2 4 = Error light (blue) In the case of a system error in the GOTIS, the blue error light flashes (see also flashing code table). On all new tractors (from about October 2001 on ) a message is shown on the TDM in addition to the flashing codes 5 = Key switch This key switch enables the alarm threshold (red alarm light) to be reset to normal operation. ALARM may only be reset by authorised personnel. The definition of authorised personnel must be given by the user (Operating Authority). Reset of GOTIS 1. Switch the GOTIS key switch (5) ON. 2. Switch the ignition OFF 3. Switch the GOTIS key switch (5) OFF. 4. Switch the ignition ON. Overview of monitoring elements and controls of the GOTIS In situations of a lighting up of the red alarm light, the user must determine and document the consequential actions to be taken in accordance with the regulations in force. We recommend to make these actions available to the operator/driver in the cabin as a job instruction.

Monitoring elements and Chapter 1 controls of the GOTIS Page 3 1.1 Flashing code table for diagnosis Type of error Flashing code (Blue error light) Action / System check START ERROR 2x Switch the ignition off/on CAN_RX_ERROR 3x Switch the ignition off/on CAN_TX_ERROR 4x Switch the ignition off/on KEY SWITCH 5x Key switch A/C-CLASSIFIC.FAILED 6x Unload the A/C ZERO LEVEL ERROR 7x Unload the A/C HW-ERROR (EEPROM_RD) 9x Replace PLC AP07 HW-ERROR (EEPROM_WR) 10x Replace PLC AP07 SYSTEM ERROR 11x Switch the ignition off/on CABLE RUPT. BS01 (LL li) 12x Switch the ignition off/on BS01 DEFECT. (LL le) 13x Switch the ignition off/on CABLE RUPT. BS02 (LL ri) 14x Switch the ignition off/on BS02 DEFECT. (LL ri) 15x Switch the ignition off/on If the errors mentioned above are not eliminated by suitable actions/system check, the AST must go to the workshop.

Monitoring elements and Chapter 1 controls of the GOTIS Page 4 1.2 Approvals Fig. 3 Approvals For current approvals, see Primary Information in the Operating Manual Part 1.

Description of the Chapter 2 GOTIS Page 1 2.0 Description of the GOTIS Fig. 1 Description of the GOTIS The GOTIS monitors the torques (5) of the nose wheel. Basically, this gives more security to the customer. The steering forces are permanently measured and transmitted to a microcontroller by two load cells (7) which are incorporated in the longitudinal links (4) of the pick-up system. This microcontroller compares the current with the stored limit of the aircraft manufacturer. The system starts when the ignition of the AST is switched on. A lamp check and a check of all relevant signals is now carried out. When one or more lamps are defective, they must be replaced before starting to work with the tractor. When further errors occur during this system check, they are indicated by means of the BLUE error light which flashes accordingly and also by means of a message which appears on the TDM (See Flashing Code Table 1.1) When an aircraft is loaded, the system checks all relevant signals for correctness. In the case of no errors, the system activates the GOTIS light (green) and thus indicates operation readiness. Only from that moment, the monitoring of the torque starts working on aircraft which require an overtorque system. As long as the steering forces are not in a critical range, the lighting up of the GOTIS light (green) indicates to the driver that the system works properly. When the aircraft is unloaded again, the monitoring of the airplane stops and the GOTIS light (green) goes out.

Description of the Chapter 2 GOTIS Page 2 When 70% of the current limit value is reached, the driver is alerted by the flashing of a warning light (yellow) and an additional buzzer. When the steering forces are decreased, this warning will stop. An exceedence of the torque Overtorque is indicated by an additional activation of the red light and the sound of a buzzer. This alarm is maintained after unloading the airplane. This alarm can only be reset using the key switch for reset. This alarm is not stopped by switching the ignition off and on. In situations of an Overtorque (red alarm light), the user must determine and document suitable actions to be taken in accordance with SAE ARP 5285. We recommend to make these actions available to the operator/driver in the cabin as a job instruction. The measurement is interrupted when an error occurs in the system, the GOTIS light (green) goes out and the error is indicated by the error light (blue) as a flashing code (see Flashing Code Table 1.1) and also appears as a message on the TDM.

Maintenance of the GOTIS Chapter 3 Maintenance intervals Page 1 3.0 Maintenance intervals of the GOTIS The following maintenance schedule contains an overview of the maintenance work and the intervals. Due to the special operating conditions of the AST, the maintenance work is broken down into one-off or several periodical maintenance services, dependent on the number of operating hours, as well as into periodical special services. The specified intervals refer to the number of operating hours displayed on the instrument panel of the engine. Before all maintenance procedures, the vehicle must be cleaned! The maintenance schedule does not include maintenance-free bearings and joints, i.e. lubricating points which are fitted with life-time lubrication, which are self-lubricating or automatically lubricated (e.g. encapsulated or supplied by the central lubrication system) or lubricating points which are lubrication-free. Basically, the user undertakes to adhere to the specified maintenance periods and the corresponding maintenance services and to enter these records in the Maintenance Chart. (Maintenance Records see WA Part 1, Chapter 4.1)

Maintenance of the GOTIS Chapter 4 Maintenance schedule Page 1 4.0 Maintenance schedule It is absolutely necessary to adhere to the maintenance instructions (see Maintenance Manual Part 1, General). General Functioning, fixing and tightness of total system GOTIS lamp check Electric System 5.1 every 12 months Electric check of wiring every 12 months Electric check No.1 of load cell every 12 months Electric check No.2 of load cell every 12 months Electric check of measuring signal every 12 months Electric check of output signal on amplifier every 12 months Electric check of voltage supply on amplifier every 12 months Electric check of voltage supply of load cell every 12 months Electric check of fuse in amplifier Mechanical check of the GOTIS 5.1.3 every 24 months or every 4000 operating hours Mechanical check of the GOTIS by means of GOTIS test tool

Maintenance of the GOTIS Chapter 4 Maintenance schedule Page 2 4.1 Maintenance records GOTIS The user undertakes to always adhere to the maintenance intervals and the corresponding maintenance services and to enter these records in the following maintenance chart. Maintenance service Maintenance record 500 1.500 2.500 3.500 4.500 5.500 6.500 8.500 1.000 3.000 5.000 7.000 9.000 2.000 4.000 6.000 8.000 carried out at...(h) Date Signature

Maintenance of the GOTIS Chapter 4 Maintenance schedule Page 3 Maintenance service Maintenance record carried out at...(h) Date Signature 9.500 10.000 10.500 11.500 12.500 13.500 14.500 15.500 16.500 17.550 18.500 11.000 13.000 15.000 17.000 19.000 12.000 14.000 16.000 18.000

Maintenance of the GOTIS Chapter 4 Maintenance schedule Page 4 Maintenance service Maintenance record carried out at...(h) Date Signature 19.500 20.000 20.500 21.500 22.500 23.500 24.500 25.500 26.500 27.500 28.500 21.000 23.000 25.000 27.000 22.000 24.000 26.000 28.000

Maintenance of the GOTIS Chapter 5 Maintenance work Page 1 5.0 Maintenance work Basically, the safety regulations applicable to the control and the operation of the AST also apply to the maintenance (see Operating Manual, Primary Information Safety Instructions ). During all maintenance work on the AST, the local accident prevention regulations and other official regulations and directives must be met. Any deviation from regulations and approvals carried out by the user must in each individual case be clarified with the manufacturer. For all maintenance work to be carried out, switch off the engines, ensure non-energized state, main vehicle switch OFF, battery isolating switch OFF. The only exceptions to this ruling are formed by individual maintenance steps for adjustment and trial runs or test driving. In these cases, maintenance staff must take suitable precautions. During load tests of the hydraulic system (high pressure up to 420 bar), there is danger to life if any leakages occur within the high-pressure system. After all maintenance works and before re-starting operation of the vehicle, a functional check of all parts and a test drive must be carried out.

Maintenance of the GOTIS Chapter 5 Maintenance work Page 2 5.1 Maintenance of the GOTIS 5.1.1 GOTIS Lamp check Fig. 1 When the ignition of the AST is switched on, the system carries out a lamp check. When no lamps are defective, all four indicators (1-4) light up 1time simultaneously. All defective lamps must be replaced before every ride. GOTIS Lamp check

Maintenance of the GOTIS Chapter 5 Maintenance work Page 3 5.1.2 Electric check of the GOTIS The electric check must be carried out every 2000 operating hours or yearly - whatever comes first - according to the following checklist. This ensures that the components used in the GOTIS work properly. The check of the ma-signals may only be carried out using a multimeter connected in series. A measurement between vehicle mass and ma-output causes damage to the amplifier. The checks/tests as described on the following pages are also checklists used for the maintenance. It is advisable to copy these pages before every maintenance to be carried out. During the electric check of the GOTIS, the ignition of the AST must be ON. To be able to carry out the following electric checks of the GOTIS correctly and error-free, the corresponding Electric Systems must be considered. For older versions, it may be necessary to request the suitable adapter cables from Goldhofer. If the check proves that there is a defect in the load cells, it is always necessary to replace both the load cells and the amplifiers. Load cells and amplifiers are always co-ordinated. Recommendation: The functioning must be tested with a testtool after replacement of the components. The functional test applies to replaced sets consisting of load cell and amplifier as well as to separately replaced amplifiers. To order the load cells and the amplifiers, please use the enclosed order form. Complete the form and mention the relevant nominal / actual.

Maintenance of the GOTIS Chapter 5 Maintenance work Page 4 Description of the adapter cable The adapter cable is required for the electric check on older tractors. This cable enables to place the occupancy of the terminal strips outwards. So, the plug connections must not be opened to carry out the check. Fig. 2 In case of a fault in the system, this adapter cable is no replacement for looking in and checking the plastic plugs (for example cable rupture within the plug). Also consider the corresponding electric systems. During that check, additionally check the plastic plugs for any damage. Adapter cable

Maintenance of the GOTIS Chapter 5 Maintenance work Page 5 5.1.2.1 Electric check of the amplifier voltage supply In doing so, it can determined if the operating voltage is existing on the amplifier. Description of checks Value left vehicle side Value right vehicle side Check operating voltage of the amplifier between terminal 1 and terminal 2 NOMINAL ACTUAL NOMINAL ACTUAL Observe polarity: Red point to terminal 1 = + or red Black point to terminal 2 = - or black For the nominal of the electric check, see chapter 6. Fig. 3 Electric check of the amplifier voltage supply Fig. 4 Electric check of the amplifier voltage supply

Maintenance of the GOTIS Chapter 5 Maintenance work Page 6 5.1.2.1a Electric check of the fuse in the amplifier This check is only necessary in the case of no signal existing during the electric check in 5.1.2.2 and 5.1.2.6. Description of checks Functional test of fuse Value left vehicle side NOMINAL ACTUAL Value right vehicle side NOMINAL ACTUAL Fig. 5 Electric check of the fuse in the amplifier

Maintenance of the GOTIS Chapter 5 Maintenance work Page 7 5.1.2.2 Electric check of the load cell voltage supply In doing so it can be determined if the amplifier exchanged (output) the operating voltage as needed by the load cell. Description of checks Value left vehicle side Value right vehicle side Check the operating voltage of the load cell between terminal 6 and terminal 7. Observe polarity: Red point to terminal 6 = - or black Black point to terminal 7 = + or red NOMINAL For the nominal of the electric check, see chapter 6. Fig. 6 Electric check of the load cell voltage supply ACTUAL NOMINAL ACTUAL Fig. 7 Electric check of the load cell voltage supply

Maintenance of the GOTIS Chapter 5 Maintenance work Page 8 5.1.2.3 Electric check No.1 of the load cell In doing so, the internal resistance of the load cell is checked. Description of check Value left vehicle side Value right vehicle side Remove plug panel from amplifier. Measurement of resistance between + and - signal. Red wire and black wire; Terminal 6 und terminal 7 in amplifier. Observe polarity: Black point to 6 = - or black Red point to 7 = + or red NOMINAL For nominal of electric check, see chapter 6. If the are exceeded, replace the load cell and amplifiers. Fig. 8 Electric check No.1 of the load cell ACTUAL NOMINAL ACTUAL Fig. 9 Electric check No.1 of the load cell

Maintenance of the GOTIS Chapter 5 Maintenance work Page 9 5.1.2.4 Electric check No. 2 of the load cell In doing so, the external resistance of the load cell is measured. Description of check Value left vehicle side Value right vehicle side Remove plug panel from amplifier. Measurement of resistance between + and - signal. White wire and green wire; Terminal 9 and 10 in amplifier. Observe polarity: Black point to 9 = - or black Red point to 10 = + or red NOMINAL For the nominal of the electric check, see section 6. If the are exceeded, replace the load cell and amplifiers. Fig. 10 Electric check No. 2 of load cell ACTUAL NOMINAL ACTUAL Fig. 11 Electric check No. 2 of load cell

Maintenance of the GOTIS Chapter 5 Maintenance work Page 10 5.1.2.5 Electric check of measuring signal In doing so, the signal voltage of the load cell is measured. The pick-up device is raised empty. Description of check Value left vehicle side Value right vehicle side Check the mv-signals of the load cell on terminal 9 and 10 in the amplifier. NOMINAL ACTUAL NOMINAL ACTUAL Observe the polarity: Black point to 9 = - or black Red point to 10 = + or red For the nominal of the electric check, see chapter 6. If the are exceeded, replace the load cell and amplifiers. Fig. 12 Electric check of measuring signal Fig. 13 Electric check of measuring signal

Maintenance of the GOTIS Chapter 5 Maintenance work Page 11 5.1.2.6 Adjustment and electric check of the amplifier output signal In doing so, the output signal of the amplifier in ma is checked. Description of check Value left vehicle side Value right vehicle side Green wire disconnected from terminal 3. Check ma-signals of amplifier on terminal 3 in amplifier. Observe polarity: Red point to terminal 3 Black point to green wire = + or red = - or black NOMINAL For the nominal of the electric check, see chapter 6. Instructions to adjust the amplifier see Index 5.1.3 ACTUAL NOMINAL ACTUAL Fig. 14 Electric check of the amplifier output signal

Maintenance of the GOTIS Chapter 5 Maintenance work Page 12 5.1.3 Amplifier Readjustment potentiometer in the amplifier. If the value in test step 5.1.2.6 is out of the nominal value, it can be readjusted by means of the potentiometer (see arrow). Turn the potentiometer slowly and with caution. After adjustment /turning the potentiometer, wait for 5 to 10 seconds to get the stabilised value. (Control mode of the amplifier) Fig. 15 Amplifier

Maintenance of the GOTIS Chapter 5 Maintenance work Page 13 5.1.4 Mechanical check of GOTIS using the GOTIS test tool 5.1.4.1 Installation of the GOTIS test tool Working steps to install the GOTIS test tool (1-7): 1. Remove roller supports from pull arms. Fig. 16 2. Install crossbeam (1) of test tool between the vehicle frame and fix it with bolts (2). Fig. 17 Working steps Installation of GOTIS test tool Working steps Installation of GOTIS test tool 3. Assemble thrust rod (3) and carrier of pull arms (4) on the ground and fix it with bolt (5) and safety pin. Fig. 18 Working steps Installation of GOTIS test tool

Maintenance of the GOTIS Chapter 5 Maintenance work Page 14 4. Install thrust rod (3) and carrier of pull arms (4) in the pick-up device using a suitable auxiliary tool. (Weight approx. 150 kg) - Observe the correct mounting position. Fig. 19 Fig. 20 Working steps Installation of GOTIS test tool Working steps Installation of GOTIS test tool 5. Install the hydraulic cylinder (6) in the test tool. Bolt (8) must not yet be fixed. 6. Connect pressure gauge (400 bar) to measuring point on the piston side (MP-K) of the hydraulic cylinder (6). 7. Ensure the hydraulic supply of the hydraulic cylinder (6). (External supply). Fig. 21 Working steps Installation of GOTIS test tool

Maintenance of the GOTIS Chapter 5 Maintenance work Page 15 5.1.4.2 Mechanical check of GOTIS Working steps - Check GOTIS (1-5): All aircraft types must be tested which the built-in Gotis-system is activated for. Exact information about the activated aircraft models can be obtained from the user/operating authority. The mechanical check must be carried out on the basis of the GOTIS- reference. (see Reference Values Table 5.1.5). Example: If the GOTIS check is carried out for an aircraft type B767, a 120 mm thrust part must be installed in the pull arms. In the example given, the yellow lamp must light up and the buzzer be activated when a pressure of 76 ± 3 bar is reached (70% of the maximum permissible torque is reached). When achieving a pressure of 106 ± 3 bar, the red lamp must light up and a buzzer be activated (100% of the maximum permissible torque is reached). 1. Fit the thrust parts (7) which correspond to the AST and the aircraft in the pull arms and retract the pull arms slowly. 2. Fix bolt (8) of the hydraulic cylinder. (See Fig. 21) 3. Simulate the switching point of the sensor BA26 / BA27 using a suitable auxiliary tool. 4. Lift the pick-up device using the control lever on the seat console Working step 5 is only applicable to AST-1 / AST-2 (for AST-3, see working steps 6-9) 5. Switch over calibration switch SS09 in control box X39.

Maintenance of the GOTIS Chapter 5 Maintenance work Page 16 Working steps 6-9 are only for AST-3 (Depressurise hydraulic cylinders (6), set workshop switch SP02- X 35 to ON position) 6. Select the menu point SERVICE in the main menu of the TDM and confirm with ENTER. 7. Select the menu point GOTIS and confirm with ENTER. 8. Select the menu point SYSTEM-CHECK and confirm with ENTER. 9. Select the menu point OVTCHECK and change from OFF to ON by means of button 5 and confirm with ENTER. Fig. 22 Working step 6 Fig. 23 Working step 7 Fig. 24 Working step 8 Fig. 25 Working step 9 Fig. 26 Working step 9

Maintenance of the GOTIS Chapter 5 Maintenance work Page 17 10. Pressurise hydraulic cylinder with respective pressure and carry out check. For reference, see GOTIS Reference Value Table, Index 5.1.5. The pressure build-up of the hydraulic supply has to be 3 to 10 bars. The flashing-up of the lamp and the sound of the buzzer are temporally delayed due to the control mode. If the signal is not released after reaching the reference value, the mechanical check must be repeated 3 times more. In doing so, the test pressure must be gradually increased by 2 bar. The required end-test pressure must be put down in the test report, index. 5.1.5.1 and sent to Goldhofer. Working step 11 is only for AST-1 / AST-2 (for AST-3, see working steps 6-9. Working step 9 is now not from OFF to ON, but from ON to OFF ). 11. Reset calibration switch SS09 to initial position. (See also working step 5) 12. Remove bolt (8) of the hydraulic cylinder (6). - Before removal of the pin, decrease the hydraulic pressure in the cylinder Fig. 27 Working steps Installation of GOTIS test tool 13. Reset GOTIS with key switch (5) in driver s cabin (see chapter 1.0) 14. Decrease pressure in the pull arms (Extend pull arms by approx. 5-10 cm). Fig. 28 Overview of monitoring and control elements GOTIS Open the pull arms only so far that the swivel arms cannot swing out! 15. Remove the auxiliary tool simulating the switching BA26 / BA27 16. Check next aircraft (Repeat working steps 1-15).

Maintenance of the GOTIS Chapter 5 Maintenance work Page 18 5.1.5 GOTIS - Reference Value Table AST - 1 Aircraft type Length of thrust part Hydraulic pressure for 70% of the maximum permissible torque (yellow lamp + buzzer) Hydraulic pressure for 100% of the maximum permissible torque (red lamp + buzzer) B767 120 mm 76 ± 2 bar 106 ± 2 bar A330/340-200/-300 250 mm 94 ± 2 bar 132 ± 3 bar B777 300 mm 110 ± 3 bar 160 ± 4 bar A340-500/-600 330 mm 126 ± 3 bar 178 ± 5 bar AST - 2 Aircraft type Length of thrust part Hydraulic pressure for 70% of the maximum permissible torque (yellow lamp + buzzer) Hydraulic pressure for 100% of the maximum permissible torque (red lamp + buzzer) B737 120 mm 26 ± 2 bar 40 ± 2 bar B757 200 mm 68 ± 2 bar 96 ± 3 bar B767 330 mm 86 ± 3 bar 124 ± 4 bar A340-200/-300 440 mm 118 ± 3 bar 168 ± 4 bar B777 500 mm 136 ± 4 bar 196 ± 5 bar AST - 3 Aircraft type Length of thrust part Hydraulic pressure for 70% of the maximum permissible torque (yellow lamp + buzzer) Hydraulic pressure for 100% of the maximum permissible torque (red lamp + buzzer) B737 75 mm 28 ± 2 bar 42 ± 2 bar B757 175 mm 75 ± 3 bar 108 ± 3 bar B767 275 mm 100 ± 3 bar 138 ± 4 bar If the signal is not released after reaching the reference value, the mechanical check must be repeated 3 times more. In doing so, the test pressure must be gradually increased by 2 bar. The required end-test pressure must be put down in the test report, index 5.1.5.1 and sent to Goldhofer.

Maintenance of the GOTIS Chapter 5 Maintenance work Page 19 5.1.5.1 Test report Reached pressure 70% torque Reached pressure 100% torque NOMINAL ACTUAL NOMINAL ACTUAL AST 1 B 767 A330/340-200/-300 B 777 A340-500/-600 NOMINAL ACTUAL NOMINAL ACTUAL AST 2 B 737 B 757 B 767 A330/340-200/-300 B 777 NOMINAL ACTUAL NOMINAL ACTUAL AST 3 B 737 B 757 B 762

Maintenance of the GOTIS Chapter 6 Electric setting of the GOTIS Page 1 6.0 Electric setting of the GOTIS 6.0.1 AST-1 / AST-2 Electric check left vehicle side NOMINAL right vehicle side NOMINAL 5.1.2.1 Electric check of the amplifier voltage supply 23 + 8 V 23 + 8 V 5.1.2.2 Electric check of the load cell voltage supply 10 ± 0,2 V 10 ± 0,2 V 5.1.2.3 Electric check No. 1 of the load cell 750±30Ohm 750±30Ohm 5.1.2.4 Electric check No. 2 of the load cell Serial-No. > LL 12000 see appendix A 5.1.2.4 Electric check No. 2 of the load cell Serial-No. > LL 13000 800±20Ohm Serial-No. > LL 13000 800±20Ohm 5.1.2.5 Electric check of measuring signal 0,0 ± 1,5 mv 0,0 ± 1,5 mv 5.1.2.6 Electric check of the amplifier output signal 15 ± 1,5 ma 15 ± 1,5 ma 6.0.2 AST-3 (not AST-3 R) Electric check left vehicle side NOMINAL right vehicle side NOMINAL 5.1.2.1 Electric check of the amplifier voltage supply 23 + 8 V 23 + 8 V 5.1.2.2 Electric check of the load cell voltage supply 10 ± 0,2 V 10 ± 0,2 V 5.1.2.3 Electric check No. 1 of the load cell 750±30Ohm 750±30Ohm 5.1.2.4 Electric check No. 2 of the load cell Serial-No. > LL 12000 see appendix A 5.1.2.4 Electric check No. 2 of the load cell Serial-No. > LL 13000 800±20Ohm Serial-No. > LL 13000 800±20Ohm 5.1.2.5 Electric check of measuring signal 0,0 ± 1,5 mv 0,0 ± 1,5 mv 5.1.2.6 Electric check of the amplifier output signal 12 ± 1,5 ma 12 ± 1,5 ma If the ACTUAL deviate from the NOMINAL, you must observe the Troubleshout-List in Chapter 7.0.

Maintenance of the GOTIS Chapter 7 Troubleshoot List Page 1 7.0 Troubleshoot List AST-1/-2/-3 (CAN-Bus with blue light) Flashing code of blue light Type of error Cause Trouble-shooting 2x START ERROR Short break in current during vehicle operation to PLC AP07 1. Ignition off/on 2. Check current supply of AP07 3x CAN_RX_ERROR Trouble in data transmission to AP07 1. Ignition off/on 2. Check wiring of CAN-bus 4x CAN_TX_ERROR Trouble in data transmission to AP07 1. Ignition off/on 2. Check wiring of CAN-bus 5x KEY SWITCH_ERROR Key switch in wrong position Set key switch to 0 position 6x A/C-CLASSIFIC. FAILED 1. Wrong selection of tractive power stage 2. Nosewheel diameter too small / too large for selected tractive power stage 3. Nosewheel diameter deviations from determined range 7x ZERO LEVEL_ERROR Tractor-aircraft combination was moving during loading procedure 1. Select correct tractive power stage 2. Check sensor BA49 / BA50 3. Recalibrate sensor BA49 / BA50 9x HW-ERROR (EEPROM_RD) Eeprom read error Replace PLC AP07 10x HW-ERROR (EEPROM_WR) Eeprom write error Replace PLC AP07 Activate parking brake, press ESC-button on TDM and reconfirm tractive power stage

Maintenance of the GOTIS Chapter 7 Troubleshoot List Page 2 12x CABLE RUPT. BS01 (LL le) ma-signal on X35:xxx or X40.7:xxx < 0,2 ma xxx stands for the corresponding terminal as per the Electric System 13x BS01 DEFECT. (LL le) ma-signal on X35:xxx or X40.7:xxx > 25mA xxx stands for the corresponding terminal as per the Electric System 14x CABLE RUPT. BS02 (LL ri) ma-signal on X35:xxx or X40.7:xxx <0,2 ma xxx stands for the corresponding terminal as per the Electric System 1. Check voltage supply on left amplifier (AS03) (see 5.1.2.6); between AS03:1 and AS03:2 Þ 24V 2. Check ma-signal on amplifier (see 5.1.2.5); AS03:3 Þ AST-1/-2 = 15 ± 1,5 ma; AST-3F = 12 ±2mA 3. Check supply voltage of strain gauge (see 5.1.2.7); between AS03:6 and AS03:7 Þ 10 ± 0,1V 4. Check fuse in amplifier (see 5.1.2.8) 5. Ohmic check of cable harness W310 6. Defective amplifier - Replace 1. Check wiring BS01 (left load cell) to AS03 (left amplifier) 2. Check supply voltage of strain gauge (see 5.1.2.7); between AS03:6 and AS03:7 Þ 10 ± 0,1V 3. Check signal voltage of strain gauge (see 5.1.2.4); between AS03:9 and AS03:10 Þ 0 ± 1,5 mv 4. Measure resistance of strain gauge: Draw plug out of amplifier, between AS03:6 and AS03:7 Þ 750 ± 30 Ohm (see 5.1.2.2); between AS03:9 and AS03:10 Þ 700 ± 20 Ohm (see 5.1.2.3) 5. Replace load cell and amplifier 1. Check voltage supply on right amplifier (AS04) (see 5.1.2.6); between AS04:1 and AS04:2 Þ 24V 2. Check ma-signal on amplifier (see 5.1.2.5); AS04:3 Þ AST-1/-2 = 15 ± 1,5 ma; AST-3F = 12 ±2mA 3. Check supply voltage of strain gauge (see 5.1.2.7); between AS04:6 and AS04:7 Þ 10 ± 0,1V 4. Check fuse in amplifier (see 5.1.2.8) 5. Ohmic check of cable harness W311 6. Defective amplifier - Replace

Maintenance of the GOTIS Chapter 7 Troubleshoot List Page 3 15x BS02 DEFECT (LL ri) ma-signal on X35 or X40.7 > 25 ma 1. Check wiring BS02 (right load cell) to AS04 (right amplifier) 2. Check supply voltage of strain gauge (see 5.1.2.7); between AS04:6 and AS04:7 Þ 10 ± 0,1V 3. Check signal voltage of strain gauge (see 5.1.2.4); between AS04:9 and AS04:10 Þ 0 ± 1,5 mv 4. Measure resistance of strain gauge: Draw plug out of amplifier, between AS04:6 and AS04:7 Þ 750 ± 30 Ohm (siehe 5.1.2.2); between AS04:9 and AS04:10 Þ 700 ± 20 Ohm (see 5.1.2.3) 5. Replace load cell and amplifier

Order form Page 1 Amplifier Order Form Vehicle type Vehicle number Vehicle side / Serial No. of the load cells Measuring 5.1.2.3 Nominal / Actual Measuring 5.1.2.4 Nominal / Actual Measuring 5.1.2.5 Nominal / Actual Adress of delivery Please fax this order form to our Service Department Airport Equipment. Fax no. (+49) 0833115180 Fax no. (+49) 083311570288 Fax no. (+49) 083311570254 Fax no. (+49) 083311570181 Fax no. (+49) 083311570182 / / /

Appendix Page 1 Appendix A Depending on the batch, load cells with a serial number > LL 12000" have different external resistances. In the case of replacement of a load cell, you have to compare the serial number with the table below. All serial numbers > LL 15000" are provided with an additional character N ( standardised"). All these load cells have an external resistance of 800 +/- 20 Ohm. Replacement (AT) - Load cells after repair: If the strain gauge is replaced in a load cell, the character N will be added to the serial number after repair. These load cells will then also have an external resistance of 800 +/-20 Ohm. 700 ± 30 Ohm 800 ± 20 Ohm LL 12010-12019 LL 12180-12189 LL 12102-12111 LL 12389-12398 LL 12160-12161 LL 12409-12418 LL 12170-12179 LL 12419-12428 LL 12681-12714 rsi / 14.05.08 Goldhofer Aktiengesellschaft Donaustraße 95 87700 Memmingen BA Part 1/3

GOTIS Index pictures Page 1 Index Name Chapter - Page Index pictures The GOTIS documentation AST-1, AST-2, AST-3 (not AST-3 R) Use according to purpose 1.0 Overview of monitoring elements and controls of the GOTIS 1-1 Fig. 1 Overview of monitoring elements and controls of the GOTIS 1-1 Fig. 2 Overview of monitoring elements and controls of the GOTIS 1-2 1.1 Flashing code table for diagnosis 1-3 1.2 Approvals 1-4 Fig. 3 Approvals 1-4 2.0 Description of the GOTIS 2-1 Fig. 1 Description of the GOTIS 2-1 3.0 Maintenance intervals of the GOTIS 3-1 4.0 Maintenance schedule 4-1 4.1 Maintenance records GOTIS 4-2 5.0 Maintenance work 5-1 5.1 Maintenance of the GOTIS 5-2 Fig. 1 GOTIS Lamp check 5-2 Fig. 2 Adapter cable 5-4 Fig. 3 Electric check of the amplifier voltage supply 5-5 Fig. 4 Electric check of the amplifier voltage supply 5-5 Fig. 5 Electric check of the fuse in the amplifier 5-6 Fig. 6 Electric check of the load cell voltage supply 5-7 Fig. 7 Electric check of the load cell voltage supply 5-7 Fig. 8 Electric check No.1 of the load cell 5-8 Fig. 9 Electric check No.1 of the load cell 5-8 Fig. 10 Electric check No. 2 of load cell 5-9 Fig. 11 Electric check No. 2 of load cell 5-9 Fig. 12 Electric check of measuring signal 5-10 Fig. 13 Electric check of measuring signal 5-10 Fig. 14 Electric check of the amplifier output signal 5-11 A A

GOTIS Index pictures Page 2 Index Name Chapter - Page Fig. 15 Amplifier 5-12 Fig. 16 Working steps Installation of GOTIS test tool 5-13 Fig. 17 Working steps Installation of GOTIS test tool 5-13 Fig. 18 Working steps Installation of GOTIS test tool 5-13 Fig. 19 Working steps Installation of GOTIS test tool 5-14 Fig. 20 Working steps Installation of GOTIS test tool 5-14 Fig. 21 Working steps Installation of GOTIS test tool 5-14 Fig. 22 Working step 6 5-16 Fig. 23 Working step 7 5-16 Fig. 24 Working step 8 5-16 Fig. 25 Working step 9 5-16 Fig. 26 Working step 9 5-16 Fig. 27 Fig. 28 Working steps Installation of GOTIS test tool 5-17 Overview of monitoring and control elements GOTIS 5-17 6.0 Electric setting of the GOTIS 6-1 7.0 Troubleshoot List AST-1/-2/-3 (CAN-Bus with blue light) 7-1 Amplifier Order Form 8-1 Appendix A 9-1