DOUGLAS TUGMASTER Type TBL280 Property of American Airlines · exposed rotating parts. All items are only accessible by lifting covers etc. However, certain items can be reached from

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TBL280 Mk 4 Issue 2 07-02-11

OPERATOR HANDBOOK

FOR

DOUGLAS TUGMASTER

Type TBL280

INDEX

CONTENTS Page No.

Foreword 2

Chassis Conformity Plate 2 Vehicle Data 3 – 4 Safety Precautions 4 Daily or 10 Hour Maintenance Check List 5

Weekly or 50 Hour Maintenance Check List 5

Instrument Panel Layouts 6 - 15 Operating Instructions 16 - 53

Recommended Lubricants 54

Operator Notes 56 - 56

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TBL280 Mk 4 Issue 2 07-02-11

FOREWORD

This operator handbook gives information about the day-to-day operation and maintenance of your Douglas Tugmaster. All available options are covered, therefore some information may not be applicable to your particular vehicle. Douglas Equipment Ltd., (the Company) reserves the right to change the specification, design, material, procedures and dimensions of the vehicle described within this handbook without prior notice at any time in the future, in accordance with the company policy of continuous product improvement. The Company has taken every reasonable effort to supply an accurate and comprehensive guide to the safe and economic running of the vehicle. Following the instructions for basic maintenance will help to minimise down-time and prolong the vehicle life between major overhauls.

ALL RIGHTS RESERVED No part of this publication may be reproduced, stored in any retrieval system or transmitted in any form without prior permission of Douglas Equipment Ltd., (the Company). Compiled and published by: Douglas Equipment Ltd. Tel: +44 (0) 1242 527921

Douglas House Fax: +44 (0) 1242 221198 Village Road

Arle Cheltenham, Glos. GL51 0AB

U.K.

CHASSIS CONFORMITY PLATE When contacting the Service department, to assist you in looking after your vehicle, it is recommended that you have available the data from the Chassis Conformity Plate, (example shown above). This plate is fitted to the chassis frame and will have the unique chassis number for your vehicle.

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TBL280 Mk 4 Issue 2 07-02-11

VEHICLE DATA

MODEL: Douglas-Kalmar TBL280 Tugmaster.

GENERAL: The TBL280 is of a 4 x 2 configuration with one rigid steer/drive axle and two steering support-wheel stub axles, fitted with walking-beam type air suspension. It is powered by a water-cooled diesel engine, driving through an engine-mounted torque converter, and remote Powershift transmission. The Tugmaster has air/hydraulic braking to the drive axle and to the support wheels. The docking cradle is operated by a series of hydraulic rams, controlled by a joystick control lever located in the cab. Aircraft that can be handled include, but is not limited to:

SIZE A: B777, A330/340, DC10, MD11. SIZE B: B767, A300, A310, TRISTAR. SIZE C: B727, B757, A318/319, A320/321. SIZE D: B737, DC9, MD80/90. SIZE E: ERJ170, ERJ190/195. DIMENSIONS

Length: 8430mm. Width: 3400mm. Height: 1935mm. Wheelbase: 4100mm. Turning circle radii (over body): 4 wheel steer (solo): 8050mm. 2 wheel steer: 10900mm. Ground clearance: 180mm. Total Weight: 16,490 kgs. Weight Distribution Drive Axle: 13,850 kgs. Support Wheels: 2,650 kgs.

ENGINE

Make: Deutz. Model: TCD 2013 L6. Power: 190 kW (255 bhp).

TRANSMISSION

Make: ZF. Model: 3WG 211 (3 speed forward, 3 speed reverse).

STEER/DRIVE AXLE

Make: KESSLER. Model: LT81.

COOLING Engine: Radiator, pressurised to 7 psi.

Transmission: Air-blast oil cooler, remote mounted. Braking: Air blast oil cooler, remote mounted.

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TBL280 Mk 4 Issue 2 07-02-11

BRAKING

Footbrake

Steer/Drive wheels: Oil-immersed, air operated actuators. Support Wheels: Independent full air braking.

Parking/Emergency

Spring operated transmission brake.

HYDRAULICS

Cradle

Large capacity variable displacement hydraulic pump, driven from transmission mounted power take-off. Oil from the reservoir passes to the pump, then to the module block and then to the valve module, controlling various cradle functions.

Steering

The above mentioned pump also provides pressure for the steering system.

TYRES

Drive/steer axle: Single pneumatic tyres - 445/65 R 22.5.

Support wheel axle: Single pneumatic tyres - 7.50 R15.

FUEL

262 Litres (57.63 Gallons) capacity tank.

ELECTRICAL

24 Volt system - CANBUS controlled.

PRIOR TO OPERATION OF THIS MACHINE,

PLEASE REFER TO THE FOLLOWING:

a) Adhere to the “FOR YOUR SAFETY” document, located at the front of the workshop manual.

b) Ensure that all operators are made aware of requirements for PERSONNEL PROTECTION EQUIPMENT for your own particular site requirements. Hearing protection is not necessary when driving with cab doors and windows closed.

c) If your Tugmaster is fitted with seatbelts, ensure they are used at all times outside workshops. d) Operators (drivers) and maintenance staff must be aware of rotating items (hazards), including

prop shafts, engine parts (alternator and fan belts), steering chain mechanisms and any other exposed rotating parts. All items are only accessible by lifting covers etc. However, certain items can be reached from beneath the Tugmaster, when on ramps, pits and vehicle stands. All employees must keep clear of these items if the engine is running.

WARNING!

With Towbarless tractor operation, if an incorrect wheel size selection is made, in certain circumstances this could result in the imposed load on the aircraft nose landing gear exceeding the airframe manufacturer’s recommendations.

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TBL280 Mk 4 Issue 2 07-02-11

IT IS THE RESPONSIBILITY OF THE TOWBARLESS TRACTOR OPERATOR TO ENSURE THAT THE CORRECT WHEEL SIZE MODE IS SELECTED AT ALL TIMES

DAILY OR 10 HOUR MAINTENANCE CHECK LIST 1. Check coolant levels. 2. Check fuel level. 3. Check engine oil level. 4. Check tyres condition - (visual). 5. Check general condition of vehicle - (visual). Check for the correct function of: a. Instrumentation/warning lights/warning horns. b. Windscreen wipers/windscreen washers. c. Lighting system. d. Brakes. e. Steering operations. f. Alternator charging and no charge warning lights. g. Nose wheel cradle.

WEEKLY OR 50 HOUR MAINTENANCE CHECK LIST Daily checks, plus: 1. Check tyre pressures. 2. Check batteries, top-up with distilled water as required. 3. Check hydraulic oil level, power steering hydraulic system, top-up as required. 4. Check transmission oil, top up as required. 5. Check brake fluid level, top up as required. 6. Check wheel nuts (after first 50 hours. Thereafter every 500 hours):

Drive Axle: 650 Nm. Support Wheels: 650 Nm.

7. Check air induction system for leaks or damage. 8. Check/drain fuel pre-filter (after first 50 hours, thereafter every 1000 hours). 9. Tighten all nuts & bolts to specified torques:

- (after first 50 hours, thereafter every 1000 hours). NOTE: For further maintenance instructions, please consult workshop manuals, supplied.

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TBL280 Mk 4 Issue 2 07-02-11

CL47 - CAB CONTROL LAYOUT


1. G.P.U. control panel (if fitted) 2. Operational functions display unit 3. Footbrake pedal (x 2) 4. Throttle pedal (x 2) 5. Nose wheel cradle functions control joystick 6. Electric external mirrors switch (if fitted) 7. Direction indicators/horn stalk 8. Heater/air conditioner fan control switch 9. Cab heater vent 10. Crew seat 11. Differential lock control button 12. Handbrake control lever 13. Steering column adjustment lever 14. Gear change control lever (Twist grip)

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TBL280 Mk 4 Issue 2 07-02-11

IP68 - OVERHEAD SWITCH PANEL - L.H.

IP68 - OVERHEAD SWITCH PANEL - L.H.

1. (Blank) 2. Emergency steering switch 3. Front windscreen wiper switch 4. Front windscreen intermittent wiper switch 5. Rear windscreen wiper switch 6. Rear windscreen wash/wipe switch (if fitted) 7. Heated front and rear windscreen switch (if fitted) 8. Heated external mirrors switch (if fitted) 9. Roof ventilator switch (if fitted) 10. Intercom switch 11. Warning lights test switch

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TBL280 Mk 4 Issue 2 07-02-11

IP139 - CENTRE ROOF PANEL


1. Emergency stop button 2. Ignition key switch 3. Start button 4. (Blank) 5. Engine protection lamp (red) - engine 6. (Blank) 7. Engine diagnostics switch

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TBL280 Mk 4 Issue 2 07-02-11

IP140 - OVERHEAD SWITCH PANEL - R.H.

IP140 - OVERHEAD SWITCH PANEL - R.H.

1. Hazard warning lights switch 2. Glo-plug ON warning light (if fitted) 3. No charge warning light 4. Direction indicators warning light 5. Low fluid level warning light 6. Low air pressure (Brake system problem?) warning light 7. Hydraulic filter obstruction warning light 8. Water in fuel warning light 9. (Blank) 10. Side/head/tail lights switch 11. Cab floodlights switch - rear of roof 12. Cradle floodlights switch 13. Strobe lights switch (if fitted) 14. Cab floodlights switch - front of roof (if fitted) 15. Fuel heater switch (if fitted)

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IP141 - SWIVEL CONSOLE INSTRUMENT PANEL

IP141 - SWIVEL CONSOLE INSTRUMENT PANEL

1. (Aircraft) Wheel size “A” selector button/indicator light 2. (Aircraft) Wheel size “B” selector button/indicator light 3. (Aircraft) Wheel size “C” selector button/indicator light 4. (Aircraft) Wheel size “D” selector button/indicator light 5. (Aircraft) Wheel size “E” selector button/indicator light 6. Operational functions display unit 7. Seat release button 8. “Insert (Aircraft) nose wheel pin” reminder light/acknowledge button 9. Nose wheel cradle functions control joystick

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TBL280 Mk 4 Issue 2 07-02-11

IP77 - NOSEWHEEL FUNCTIONS CONTROL JOYSTICK

IP77 - NOSEWHEEL FUNCTIONS CONTROL JOYSTICK

1. Nosewheel cradle control joystick 2. "Cradle down" warning light 3. "Gate closed" indicator light 4. "Cradle raised" indicator light

5. "Gate open" warning light

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TBL280 Mk 4 Issue 2 07-02-11

IP79 - OPERATIONAL FUNCTIONS DISPLAY PANEL

IP79 - OPERATIONAL FUNCTIONS DISPLAY PANEL

1. Front wheel steer selection button 2. Four wheel steer selection button 3. Rear wheel steer selection button 4. Crab wheel steer selection button 5. “Jog dial” (toggles between date and time display) 6. Function button - to display engine, pneumatic and transmission

- information 7. Video camera system selection button 8. Cab air suspension dump button 9. Differential lock override button 10. Display screen

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TBL280 Mk 4 Issue 2 07-02-11

IP37 - CAB HEATER / AIR CONDITIONER CONTROLS (IF FITTED)

IP37 - CAB HEATER / AIR CONDITIONER CONTROLS (IF FITTED)

1. Fan speed selection knob 2. Water valve (temperature) control knob 3. Fresh / re-circulated air selection knob 4. Air conditioner ON / OFF switch (if fitted)

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TBL280 Mk 4 Issue 2 07-02-11

IP38 - CAB HEATER TIMER CONTROLS (IF FITTED)

IP38 - CAB HEATER TIMER CONTROLS 1. Actual time

2. Pre-set 3. Heat 4. Setting backwards 5. Setting forwards 6. Memory display 7. Symbol for radio remote control (if fitted) 8. Weekday or pre-set day 9. Current time or pre-set time 10. Temperature display 11. Operating display 12. Temperature pre-selection (not applicable)

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TBL280 Mk 4 Issue 2 07-02-11

CL48 - EMERGENCY HYDRAULIC CONTROL LEVERS


1. Nose wheel cradle raise/lower lever 2. Cradle gate open/close lever 3. Hook open/close ever 4. Nose wheel size selector lever 5. Offside front safety bar open/close lever 6. Nearside front safety bar open/close lever

7. Rear safety bars open/close lever

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TBL280 Mk 4 Issue 2 07-02-11

OPERATING INSTRUCTIONS

Page

Rotating The Seat / Console 17

Gear Selection 18

Differential Lock 19

Adjusting The Driver’s & Crew Seat 20

Cab Heater Timer Controls 21

Cab Heater / Air Conditioner Controls 23

Starting Procedure 24

Cold Starting 25

Driving The Vehicle 26 Computer Steering Control 27

Docking With The Aircraft Nose Wheel 29 Cab Suspension Dump System 32 Emergency Park Brake Release System 32

“Aircraft Nose Wheel Pin Inserted” Warning System 33

TBL Automatic Cradle Lift - Method Of Operation 34

Maintenance Towing 35 Aircraft Nose Wheel Over steer 36 TBL280 Cradle Transducers 36 Mechanical Gate Lock 37 Nose Wheel Coupling Video Cameras 37

Undocking From The Aircraft Nose Wheel 38

Emergency Undocking - Engine Failure - and Vehicle Recovery 40

Emergency Undocking - Electrical System Failure - and Vehicle Recovery 42

PBTO1 - Recommended Practice - Towing 44

PBOT2 - Recommended Practice - Push Back 46 Emergency Engine Shutdown Buttons, Isolation Switch 47-48

Warning Lights, Circuit Breakers 48

Alternator Warning 48 Drive Inhibit Override 49

Integral Jacking System 50

Jacking Points 51

Flat Tyre Conditions, Fitting Road Wheels 51 Pro

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TBL280 Mk 4 Issue 2 07-02-11

ROTATING THE SEAT / CONSOLE (Refer to illustration IP141)

1. Apply the handbrake and select neutral.

2. Rotate the seat to the required position, i.e. facing aircraft, by pressing the seat release button (7) and then pushing the console assembly in the desired direction, until it locks onto its stops.

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TBL280 Mk 4 Issue 2 07-02-11

GEAR SELECTION The vehicle is fitted with a Powershift transmission with a full automatic mode when travelling solo and when loaded in wheel size A or B. However, it is important to select the appropriate gear for the required operation, before moving the vehicle, for example: When travelling solo: The vehicle will operate in automatic mode. If 2nd gear is selected, the vehicle will stay in 2nd gear. If 3rd gear is selected, the vehicle will change from 2nd to 3rd at the appropriate speed. (There is an option for 1st gear to be activated when travelling solo). SIZE A aircraft pushback: The vehicle will operate in automatic mode. Power reduction is active in 1st gear only. If 1st gear is selected, the vehicle will stay in first gear. If 2nd gear is selected, the vehicle will stay in 2nd gear. If 3rd gear is selected, the vehicle will change from 2nd to 3rd or 3rd to 2nd at the appropriate speed. SIZE B aircraft pushback: The vehicle will operate in automatic mode. Power reduction is active in 1st gear only. If 1st gear is selected, the vehicle will stay in 1st gear. If 2nd gear is selected, the vehicle will stay in 2nd gear. If 3rd gear is selected, the vehicle will change from 2nd to 3rd or 3rd to 2nd at the appropriate speed. SIZE C aircraft pushback: Power reduction is active in 2nd gear only. 1st gear is not available. If 2nd gear is selected, the vehicle will stay in 2nd gear. If 3rd gear is selected, the vehicle will stay in 3rd gear. SIZE D aircraft pushback: Power reduction is active in 2nd gear only. 1st gear is not available. If 2nd gear is selected, the vehicle will stay in 2nd gear. If 3rd gear is selected, the vehicle will stay in 3rd gear. SIZE E aircraft pushback: Power reduction is active in 3rd gear forward only. 1st and 2nd gears are not available. If 3rd gear is selected, the vehicle will stay in 3rd gear.

Maintenance towing: 2nd or 3rd gear (Depending on weight of aircraft being towed). NOTES: 1. When stationary ALWAYS select NEUTRAL. 2. Due to the hydraulic system of the transmission, the Tug should NOT be towed over longer distances with the drive wheels turning. These should be raised clear of the ground and the propeller shaft disconnected at the axle flange. 3. The Tug CANNOT be started by towing.

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TBL280 Mk 4 Issue 2 07-02-11


DIFFERENTIAL LOCK

(Reference cab control layout CL47).

To operate the differential lock:

1. Depress the button (11) mounted to the left of the driver's seat.

2. The button MUST be held down whilst the Tugmaster is being driven/manoeuvred.

3. A YELLOW warning light will be illuminated on the driver’s display panel whilst the button is depressed.

NOTE: When the button is released, the differential lock will immediately become disengaged. Pro

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TBL280 Mk 4 Issue 2 07-02-11

ADJUSTING THE DRIVER’S SEAT (Type KAB 856) A Height adjustment

B Ride indicator

C Backrest angle adjustment

D Swivel adjustment (If fitted)

E UP: Horizontal adjustment (If fitted)

MIDDLE: Horizontal suspension (If fitted)

DOWN: Locked (If fitted)

F Thigh support adjustment (If fitted)

G Lumbar support adjustment (If fitted) H Armrest angle adjustment (If fitted)

COMBINED HEIGHT AND WEIGHT ADJUSTER DO NOT ADJUST THE SEAT WHEN THE VEHICLE

IS IN MOTION

1. Always sit on the seat whilst making adjustments.

2. Use lever A to adjust seat height. Pull up to raise seat. Push down to lower seat.

3. Check ride indicator B shows green.

If red, readjust seat height (see 2).

Within the green band of the ride indicator, there is 75mm of height adjustment for any driver. NOTE: The seat is designed so that is unnecessary to make any adjustment for the driver weight.

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TBL280 Mk 4 Issue 2 07-02-11

CAB HEATER TIMER CONTROLS (If fitted)

All signals will start to flash on the display when the heater clock is connected to the power supply. The clock must be properly set. The heater cannot be switched on until the clock is set.

Setting the time and weekday for the first time.

Briefly press 1. (The time display flashes 12:00). Set the current time with either 4 or 5. The time is stored as soon as it stops flashing. The weekday will then flash. Set the current weekday with either 4 or 5. The weekday is stored as soon as it stops flashing. The display is retained with ignition ON; the display is turned off after 10 seconds ignition OFF.

Changing the time and weekday.

Keep 1 depressed until the time flashes. Then proceed as described above. If only the time is to be reset, press 1 twice after the time has been reset - to skip flashing and weekday setting. After the weekday has been reset, press 1 to shorten the duration of weekday flashing.

Heater operation without pre-selection in ignition OFF state. (Heating symbol 11 = observe operating display).

Switching ON the heater. Briefly press 3. (Operating display 11 and display of heating duration): The heating duration is factory set to 120 minutes. It can be changed for a single heating period or permanently changed.

Changing the heating period for a single heating period. After switch-on: To shorten heating duration (down to minimum 1 minute): Press 4. To lengthen heating duration (up to maximum 120 minutes): Press 5.

Changing the heating duration permanently. Do not switch on 3. Press 4 and hold down (approx. 3 seconds), until the display appears and flashes. Release. Now set the heating duration (from 10 to 120 minutes), with 4 or 5. The new heating duration has been stored when the display disappears.

Turning OFF the heater. Briefly press 3. (The operating symbol 11 disappears). The fan continues to run, to cool down the heater. Heater operation without pre-selection in ignition ON state. (Heating symbol 11 = observe operating display).

Switching ON the heater.

Briefly press 3. (Operating display 11, as well as time and weekday). The heater will continue to operate for as long as the ignition remains switched on. A residual heating time of 15 minutes continues after the ignition has been switched off. (This can be lengthened up to a maximum of 120 minutes, by pressing 5, or shortened down to a minimum of 1 minute, by pressing 4).

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TBL280 Mk 4 Issue 2 07-02-11

Switching OFF the heater. Briefly press 3. (The operating display 11 disappears). The fan automatically continues to run, to cool the heater down.

External switch: “Heater ON/OFF” If an additional switch has been fitted, then the heater can be turned off from a remote point in the manner described above.

Pre-select heating start. Three switch-on times within the next 24 hours can be selected, or one switch-on time within up to 7 days. Only one switch-on time can be activated at any given time!

1. Select memory and activate. (Proceeding from a neutral setting, whilst the display is visible): First memory: Press 2 once. Memory display: 1 (basic setting 12 00). Second memory: Press 2 twice. Memory display: 2 (basic setting 12 00). Third memory: Press 2 three times. Memory display: 3 (basic setting 12 00).

Neutral setting - No memory is activated. Continue pressing 2, until the memory display disappears.

2. Start heating within 24 hours. Setting pre-selected day: The pre-selected day is automatically obtained and doesn’t have to be set.

Setting a pre-selected time: Continue pressing 2, until the required memory (1, 2, 3) flashes on the display. Briefly press 4 or 5 and release. (The pre-set time flashes on the display). Use 4 or 5 to set the pre-selected time for heating. Setting is only possible as long as the pre-selected time flashes on the display. Renewed selection: Press 2.

3. Start heating later than 24 hours (max. 7 days).

Setting a pre-selected time: Continue pressing 2, until the required memory display

(1, 2, 3) flashes on the display. Briefly press 4 or 5 and release. (The pre-set time flashes on the display). Use 4 or 5 to set the pre-selected time for heating.

Setting a pre-selected day:

The pre-selected day starts to flash approximately 5 seconds after the pre-selected time has been set. Use 4 or 5 to set the pre-selected day for heating.

The pre-selected time and pre-selected day are stored as soon as the time display disappears or when the display is changed over to indicate the time. The memory display indicates the activated memory. A flashing heating symbol (11) additionally indicates an activated memory.

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TBL280 Mk 4 Issue 2 07-02-11

4. Checking the activated memory.

The pre-selected time of the displayed memory is shown for approximately 15 seconds. This is then either turned off or the time is displayed (with ignition ON). The display of the pre-selected time and pre-selected data (for approx. 5 seconds), can be called up by pressing 2 once.

Please Note: Brief power interruptions will be bridged by the heating clock. All symbols will flash on the display after an extended power failure. The heating clock will have to be totally reset.

The time and weekday are permanently displayed when the ignition is switched ON. Their display is switched off after 15 seconds if the ignition is switched OFF.

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TBL280 Mk 4 Issue 2 07-02-11

CAB HEATER / AIR CONDITIONER CONTROLS

1. Fan speed selection knob. 2. Water valve (temperature) control knob.

3. Fresh / re-circulated air selection knob. 4. Air conditioner ON / OFF switch (If fitted).

AIR COOLING (If fitted) 1. Ensure all cab outlet louvres are open. 2. With engine running; a) Switch air conditioner ON / OFF switch (4) to ON. b) Using knob 1, select required fan speed - Low, Medium or High. c) Ensure water valve control knob (2) is turned to cold (blue). d) Using knob 3, select re-circulated air for best results.

Note: Do not run the air conditioning system with condenser fans disconnected, or condenser in raised position.

HEATING (If fitted) 1. Ensure all cab outlet louvres are open. 2. With engine running; a) Ensure water valve control knob (2) is turned to hot (red). b) Using knob 1, select required fan speed - Low, Medium or High.

c) Switch air conditioner ON / OFF switch (4) to OFF.

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TBL280 Mk 4 Issue 2 07-02-11

IP139 - OVERHEAD WARNING LIGHTS PANEL

STARTING PROCEDURE (Refer to illustration IP139)

1. Carry out daily checks.

2. Check the parking brake is ON.

3. Ensure that the direction selector is in the NEUTRAL position on the gear change control.

NOTE: Unless direction selector is in NEUTRAL - the starter is not energised.

4. Switch ON the ignition key switch (2).

5. Depress throttle pedal.

6. Press start button (3) - when engine fires, release immediately.

7. Adjust the throttle to run at a fast idle speed.

NOTE: If engine fails to start, do not re-engage starter until all movement has stopped. Pro

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COLD STARTING (Refer to illustration IP139)

Carry out start procedure, cold starting is automatic.

POST START CHECKS

Having started the engine in accordance with the previous instructions, check the following instruments for correct function:

1. No charge warning lights (OFF). 2. Engine oil pressure readout (OFF).

- Press the function button on the driver’s display to show engine data.

3. Air pressure readout (5 bar minimum). - Press the function button on the driver’s display to show pneumatic data.

4. Transmission temperature readout. - Press the function button on the driver’s display to show transmission data.

5. Transmission pressure readout. - Press the function button on the driver’s display to show transmission data.

6. Engine temperature readout. - Press the function button on the driver’s display to show engine data. 7. Warning lights test button.

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TBL280 Mk 4 Issue 2 07-02-11

IP77 - NOSEWHEEL CRADLE CONTROL JOYSTICK

DRIVING THE VEHICLE (Refer to illustration IP77)

Providing all instruments and systems are functioning correctly:

1. Push the cradle control joystick (1) to the right, to the Gate Closed position, until indicator light (3) is illuminated and cradle locking bars close or contact the aircraft nose wheels.

2. Raise the cradle by pulling the cradle operating joystick (1) back, until indicator light (4) is

illuminated.

3. Apply the foot brake.

4. Select forward or reverse drive.

5. Select the appropriate speed range.

6. Release the parking brake.

7. Release foot brake gradually.

8. Depress the throttle pedal - drive away.

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STOPPING THE VEHICLE

1. Apply Footbrake and bring vehicle to rest

2. Select Neutral

3. Apply Parking Brake

4. Turn Ignition Key to ‘OFF’ position Wait 30 seconds after ignition is switched off before isolating the vehicle

SWITCHING OFF THE IGNITION

When the ignition key switch is turned off, the red Engine Protection warning light (on the overhead ignition panel) will remain illuminated for a few seconds.

DO NOT TURN THE IGNITION KEYSWITCH ON AGAIN WHIST THE WARNING LIGHT IS ON

Wait until the warning light is extinguished before turning the ignition switch on again Failure to comply with this instruction could result in serious damage being caused to

the engine

COMPUTER STEERING CONTROL

The TBL280 is fitted with a computer controlled power-steering system. This system is pre-programmed.

NO ADJUSTMENT IS NECESSARY.

The system should be used in conjunction with the steering control keypad (IP79).

With the nose wheel cradle UNLOADED, four steering modes are available:

a) 2 wheel steering. b) 4 wheel steering (large steering angles at rear). c) Rear wheel steering. d) Crab steering. With the nose wheel cradle LOADED, one steering mode is available: a) 2 wheel steering (front wheels only). WARNING! Do not work in the vicinity of any of the wheels, whilst ignition switch is ON. (Steering re-alignment can occur).

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TBL280 Mk 4 Issue 2 07-02-11

COMPUTER STEERING CONTROL

Additional features

NOTES: 1. If at any time (when loaded) the steering angle is too tight for the speed of travel, an

audible voice alarm will sound: “Warning! - Reduce Steering Angle, Safe Steering Envelope Exceeded”.

2. If a high priority fault occurs within the steering system, causing the steering to shut down, an audible voice alarm will sound:

“Warning! - Steering System Failure”.

3. Additional warnings will also be shown on the graphic indicator screen.

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DOCKING WITH THE AIRCRAFT NOSE WHEEL

(Refer to illustration IP77)

PROCEDURE (Ensure all personnel adhere to warning notices in respect to cradle operation).

1. Position the Tugmaster in front of and in line with the aircraft nose wheel.

2. Rotate the seat/console to the required position (i.e. facing the aircraft), using the seat release button on the swivel console panel.

3. Lower the cradle, by pushing forward on the cradle control joystick (1). When the cradle is fully lowered, the indicator light (2) will illuminate.

4. Select correct aircraft wheel size, using the four buttons (A, B, C, D & E), on the swivel console panel

until the relevant (integral) indicator light is illuminated:

SIZE A: (Button 1): B777, A330/340, DC10, MD11. SIZE B: (Button 2): B767, A300, A310, TRISTAR. SIZE C: (Button 3): B727, B757, A318/319, A320/321. SIZE D: (Button 4): B737,DC9, MD80/90. SIZE E: (Button 5): ERJ170, ERJ190/195.

NOTE: If the incorrect wheel size has been selected, a warning light will illuminate and buzzer will sound.

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TBL280 Mk 4 Issue 2 07-02-11


DOCKING WITH THE AIRCRAFT NOSE WHEEL Continued...


5. Select required steering mode, using the steering keypad (positioned on the swivel console). 6. Open the gate, by pushing the joystick (1) to the left. When the gate is fully open, the warning light

(5) will illuminate. (When the gate is open and the cradle fully lowered, the warning light (2) will also illuminate).

7. Ensure the nose wheel lock out pin has been inserted.

8. Drive forward to engage and dock with the nose wheel of the aircraft. When the nose wheel is fully

engaged, a message will flash up on the display. Severe misalignment could prevent the cradle engaging the tyre assembly correctly. The message will only come up when the nose wheel and cradle are correctly positioned. Do not apply the parking brake.

9. Close the gate, by pushing the cradle control joystick (1) to the right, until indicator light (3), is

illuminated and cradle locking bars contact the aircraft nose wheels.

NOTE 1 Apply the foot brake, to keep the vehicle stationary until the gate has closed approximately 45o, then release the foot brake. This will allow the vehicle to move, to compensate for any misalignment. NOTE 2 The CCTV image will automatically appear on the display when the cradle is in operation.

The image will also switch cameras automatically to the required camera.

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TBL280 Mk 4 Issue 2 07-02-11


DOCKING WITH THE AIRCRAFT NOSE WHEEL Continued...


10. Once the gate and cradle locking bars are closed, apply the handbrake.

11. Press the nose wheel pin button (7) on the console, before raising the cradle.

NOTE 3 This vehicle is fitted with automatic wheel size fine adjustment. Once the cradle is loaded and the gate closed and locked, the scoop will automatically move to reduce any gap to the aircraft’s tyres. This takes into account varying tyre diameters. This system is only active in wheel size “B”.

NOTE 4 It is recommended that the cradle is raised once the aircraft’s brakes have been released and the passenger footbridge or stairs have been removed.

12. Raise the cradle by pulling the cradle operating joystick (1) back, until indicator light (4) is

illuminated. 13. Select the appropriate forward or reverse gear as required, (refer to the "Gear selection" page).

To change gear, the Tugmaster MUST be stationary.

NOTE 5 At all other times, the handbrake must be applied whenever the tractor is in neutral or stationary.

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TBL280 Mk 4 Issue 2 07-02-11

CAB SUSPENSION DUMP SYSTEM

ATTENTION:

This vehicle is fitted with a cab suspension dump system that operates automatically to provide additional clearance to the aircraft’s fuselage when coupling up. The cab will lower onto its bump stops when the cradle is down and the gate fully open. NOTE: The cab will also lower when a loaded cradle is lowered - in wheel size "C", "D" or "E". The cab will rise up to its normal ride height when the gate is closed and locked and the cradle is fully raised. NOTE: The cab will lower onto its bump stops after the ignition is switched off. The cab will rise to its normal ride height when the ignition is switched on.

EMERGENCY PARK BRAKE RELEASE SYSTEM ATTENTION: This vehicle is fitted with an emergency park brake release system in case of loss of air in the normal operating system. The emergency system operates via an isolated air supply that can be fed directly to the park brake actuator via an override switch, which is located next to the cradle emergency controls. In case of loss of air to the park brake actuator, operate the override system as follows: 1. Access the override switch either via the access panel on the bonnet, or by opening the

transmission bonnet. 2. Rotate the switch on the emergency park brake release valve to the “RELEASE BRAKE”

position. The park brake is now released and the vehicle can be recovered to a safe location. WARNING! This system is for vehicle recovery in an emergency situation only. The park brake will not operate if the override switch is left in the “RELEASE BRAKE” position. Always turn the switch back to the “NORMAL RELEASE” position before using the vehicle in normal operations.

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TBL280 Mk 4 Issue 2 07-02-11

“AIRCRAFT NOSE WHEEL PIN INSERTED” WARNING SYSTEM


When the Tugmaster is coupled to the aircraft, a warning light (8) will flash on the swivel console panel. This is to remind the driver that the aircraft nose wheel pin MUST be inserted before raising the loaded cradle. Press switch (8) to cancel the warning light. NOTE: The cradle cannot be raised until this procedure has been carried out.

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TBL280 Mk 4 Issue 2 07-02-11

TBL AUTOMATIC CRADLE LIFT

METHOD OF OPERATION

The automatic cradle lift system has been introduced on the TBL Tugmaster, to prevent the damage of runway and taxiway lights during operation of the Tugmaster. The system works as follows:

Undocking

1. When facing the aircraft with the cradle in the lowered position with the gate open, reverse must

be selected to release the Tugmaster from the aircraft. Once the nose wheel engaged light is extinguished, the cradle will automatically close and lift approximately 30 to 40mm off the ground after 10 seconds.

2. If the undocking procedure continues and the Tugmaster is still reversing, the gate will continue to

close. Once the gate is closed and locked, the cradle will automatically rise to it’s fully raised position and the wheel size will default to the smallest position.

3. If at any time during this operation the Tugmaster is stopped (e.g., to disconnect the

communications cord from the aircraft) the automatic lift sequence will also stop and all the timers set within the program to control the sequence will reset. At this time, if neutral is selected, the cradle will automatically drop to its fully lowered position.

NOTE: With the initial 30 to 40mm lift, the cradle down light will be off.

NOTE: Reverse gear is enabled to allow you to come away from the aircraft, but forward gear is inhibited. This is to prevent the Tugmaster being driven towards the aircraft.

Once the cradle down light comes on, the driver then has 2 options to continue and complete the undocking procedure:

a. Carry on reversing (if facing the aircraft), or driving forward (if facing away from the

aircraft). The automatic lift system will again restart after 10 seconds. The sequence will complete by the time the vehicle returns from the taxiway.

b. Using the joystick control, close the gate and raise the cradle in the normal way.

4. During the automatic cradle lift sequence, only 1st gear is available and no changes can be made.

Docking Procedure

When facing the aircraft and moving forward (i.e., cradle towards the NLG) the automatic lift system is inactive. However, in certain circumstances it may be necessary to reverse off the NLG and reposition the Tugmaster to complete the docking procedure. If, when reversing off the NLG, after 10 seconds has elapsed, the automatic lift system will operate. If this occurs, neutral must be selected and the cradle will automatically drop to it’s fully lowered position. Once the cradle down light comes on, the driver can continue with the docking procedure.

NOTE: depending on elapsed time of automatic lift sequence, it may be necessary to open gate. Safety Systems

The driver can interrupt the sequence at any time, by either: a. Bringing the vehicle to standstill. b. Operating the joystick in any direction. c. Activating any emergency stop.

In summary, the following conditions must be met for this sequence to operate: * Cradle unloaded. * Forward gear selected (i.e., reverse when facing the aircraft). * Not stationary. * Joystick in the neutral position.

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TBL280 Mk 4 Issue 2 07-02-11

TBL MAINTENANCE TOWING

For Maintenance towing, attention shall be paid to aircraft stability. Stability may be affected by aircraft type, weight, centre of gravity location, weather conditions: including wind strength, runway roughness and slope. For Maintenance towing, the weight and balance of the aircraft should be in accordance with aircraft manufacturers’ recommendations; or the towing speed must be reduced accordingly, to ensure a stable tractor/aircraft combination. If a lateral instability is detected during towing operations, a margin of 5 km/h (3 mph) shall be maintained between the speed at the beginning of instability and the maximum towing speed. With minimal static load on the nose landing gear sufficient to move the aircraft, no pitch oscillation of the aircraft shall occur, such that it would extend the shock absorber beyond the allowable strut extension in the ground mode. Proper operational procedures as defined in SAE ARP5285 or airframe manufacturers’ recommendations shall be followed to ensure vehicle and aircraft stability. The following basic principles should be followed: 1. Always drive to the prevailing weather conditions (including wind strength), adjusting speed and braking action

as appropriate. 2. Reduce speed prior to making a turn, and avoid braking - when ever possible - during the turn. 3. 90 degree turns onto stand should be progressively initiated, to create as wide a turn as the area will permit. 4. Two-wheel/front axle steering must be used for towing operations and not four wheel steering, which is for

pushback operation only. Failure to follow the above instructions could result in serious damage to the Tractor/Aircraft.

Drive carefully. Drive cautiously. Be safe.

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TBL280 Mk 4 Issue 2 07-02-11

AIRCRAFT NOSE WHEEL OVERSTEER

NOTES:

Care must be taken not to exceed the nose wheel steering torque limit.

1. If the 80% over steer condition occurs, the driver’s display will flash amber, with the message “80% over steer”.

(When the 80% light is activated, this is an initial warning to the operator that he is going into an overseer situation or he might be faced with a stiff/tight nose gear. To extinguish the alarms, he only needs to steer out of the situation i.e. straighten up).

2. If the 100% over steer condition occurs, the driver’s display will flash red, with the message

“100 over steer”.

(When the 100% alarms are activated, he should again steer out of the situation and continue to tow the aircraft to a parking area. If he wishes to extinguish the audible alarm, he can lower the cradle, disconnect from the aircraft and then re-couple. He can then complete his towing operation, but the red flashing light will continue to be in an active state. The red light can only be extinguished by an authorised person who has access to the reset switch for the system).

3. The over steer warning buzzer (1) also indicates over steer while fault is maintained.

TBL280 CRADLE TRANSDUCERS

Wheel Size Transducers Should a problem occur with the wheel size transducers, all the wheel size indicator lights on the instrument panel will flash. The problem must be rectified. NOTE: It is only safe to move the vehicle. DO NOT USE TUG until problem has been rectified. Cradle Raise and Lower Transducers Should a problem occur with the cradle raise and lower transducers, both the raise and lower indicator lights on the instrument panel will flash. The problem must be rectified. NOTE: It is only safe to move the vehicle. DO NOT USE TUG until problem has been rectified.

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TBL280 Mk 4 Issue 2 07-02-11

MECHANICAL GATE LOCK

The nose wheel cradle is fitted with a mechanical gate lock. This is used to prevent the gate from opening when maintenance towing, should a hydraulic failure occur. The lock is situated on the left-hand side of the cradle (on top of the side structure).

To release the lock:

1. Release ALL pipe connections to the lock assembly. 2. Pull the handle up to its full extent. 3. Carefully open the gate. 4. Release the handle and let the plunger return to its closed position.

NOSE WHEEL COUPLING VIDEO CAMERAS

The TBL280 is fitted with two small wide-angled video cameras, together with an in-cab monitor screen (built into the driver’s display) to aid coupling of the Tugmaster to the aircraft's nose wheel.

One camera is fitted to the top, left-hand side of the cradle, viewing the cradle and gate assembly.

The second camera is positioned on the inside face of the left-hand support leg, viewing the cradle and scoop assembly and the gate locking mechanism. An optional third camera can be mounted on top of and at the rear of the left-hand support leg.

TO CONTROL THE CAMERAS:

The camera control switch is positioned on the driver’s display panel.

Both cameras can be turned on and off and switched from one to another, using this switch. The cameras will also operate and switch automatically when the cradle is operated using the joystick.

GATE LOCK

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TBL280 Mk 4 Issue 2 07-02-11


UNDOCKING FROM AIRCRAFT NOSE WHEEL


PROCEDURE

After positioning the aircraft for undocking:

1. Apply the handbrake.

2. Rotate seat/console to the required position, i.e. facing aircraft, using seat release button.

3. Lower cradle by pushing the cradle control joystick (1) forward. When the cradle is fully lowered, the indicator light (2) will illuminate.

NOTE 1: It is recommended that the aircraft’s brakes are applied once the cradle is fully lowered.

4. Release the handbrake and open the gate by pushing the joystick (1) to the left. When the gate is

fully open, the indicator light (5) will illuminate.

5. Withdraw Tugmaster from aircraft, taking care to keep in a straight line.

NOTE 2: When driving with cradle down and gate open, the warning buzzer will sound.

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TBL280 Mk 4 Issue 2 07-02-11


UNDOCKING FROM AIRCRAFT NOSE WHEEL Continued...


6. When clear of the aircraft, close the gate - by pushing the cradle control joystick (1) to the right, until indicator light (3) is illuminated and cradle locking bars close.

7. Raise the cradle by pulling the cradle operating joystick (1) back, until indicator light (4), is

illuminated.

NOTE 3: The TBL280 is fitted with an automatic cradle lift system for undocking from aircraft. Refer to relevant pages for details.

8. Rotate the seat to face the front of the tractor, using the seat release button.

The Tugmaster can now be driven away.

NOTE 4: To rotate seat, the handbrake must be applied and neutral selected on the transmission. Prope

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TBL280 Mk 4 Issue 2 07-02-11


EMERGENCY UNDOCKING - ENGINE FAILURE (Refer to illustration CL48)

In the event of engine failure or the cradle becoming jammed in the up position, the cradle can be released as follows: (Two-man operation: One person to operate emergency hydraulic controls and another person operating the manual gate lock release and carrying out visual checks).

PROCEDURE The external hydraulic controls are situated under a cover on the L.H. leg. The manual

hydraulic pump lever is stowed under a cover adjacent to the batteries and should be slotted into the pump body, prior to operation.

1. Switch ON the ignition.

2. Press cradle override button, positioned adjacent to cradle hydraulic controls and hold down. This will operate the emergency pump, automatically.

3. Push the CRADLE LOWER lever (1) downwards, to lower the aircraft nose wheel to the ground.

Allow aircraft and tractor to settle, i.e. cradle and suspension.

4. Release the gate lock pin, by lifting up the release button - this is positioned adjacent to the pin (on left-hand leg of the Tugmaster), then manually release the gate by pulling the lock pin up.

5. Operate the rear safety bars lever (7) to open position and fully open the safety bars. 6. Operate the hook open lever (3) and fully open the hook.

7a. Operate the GATE OPEN lever (2) to the open position, then hold until gate is open 40 - 45

degrees, then stop.

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TBL280 Mk 4 Issue 2 07-02-11


EMERGENCY UNDOCKING - ENGINE FAILURE (Refer to illustration CL48) 7b. Operate the rear safety bar lever (1) to close the safety bars. 7c. Ensure the gate mechanism is clear of the nose wheel, then continue to fully open the gate.

A second person must visually check that the clearances between cradle components, tractor chassis frame and the aircraft is maintained.

8. Close the gate and hook. 9. Switch OFF ignition.

10. Aircraft is now released. Remove tractor.

11. Call the emergency services to repair or remove the tractor (see “Vehicle Recovery”).

12. Reset the gate lock release button. WARNING!: Stand well clear of all moving parts.

VEHICLE RECOVERY

In the event of a breakdown or engine failure, the Tug must be recovered as follows: Due to the hydraulic system of the transmission, the Tug should NOT be towed over long distances with the drive wheels turning. These should be raised clear of the ground and the propeller shaft disconnected from the axle flange.

NOTE: The Tug cannot be started by towing.

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TBL280 Mk 4 Issue 2 07-02-11


EMERGENCY UNDOCKING - ELECTRICAL SYSTEM FAILURE

(Refer to illustration CL48)

In the event of electrical failure or the cradle becoming jammed in the up position, the cradle can be released as follows: (Two-man operation: One person to operate emergency hydraulic controls and another person operating the manual gate lock release and carrying out visual checks).

PROCEDURE The external hydraulic controls are situated under a cover on the L.H. leg. The manual

hydraulic pump lever is stowed under a cover adjacent to the batteries and should be slotted into the pump body, prior to operation.

1. Switch ON the ignition.

2. Press cradle override button (positioned adjacent to cradle levers), and hold down.

3. Whilst pumping the manual hydraulic pump lever, operate the CRADLE LOWER lever (1) to lower

the aircraft nose wheel to the ground.

4. Release the gate lock pin, by lifting up the release button (positioned adjacent to the cradle override button), then manually release the gate by pulling the lock pin up.

5. Operate the rear safety bars lever (7) to the open position and fully open the safety bars.

6. Operate the hook open lever (3) and fully open the hook.

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TBL280 Mk 4 Issue 2 07-02-11


EMERGENCY UNDOCKING - ELECTRICAL SYSTEM FAILURE Continued…

(Refer to illustration CL48)

7a. Operate the gate lever (2) to the open position and pump the hand lever until gate is open 40-45 degrees, then stop.

7b. Operate the rear safety bars lever (7) to close the safety bars.

8. Ensure the gate mechanism is clear of the nose wheel, then continue to fully open the gate.

A second person must visually check that the clearances between cradle components, tractor chassis frame and the aircraft is maintained.

9. Close the gate and hook. 10. Aircraft is now released. Remove tractor.

11. Call the emergency services, to repair or remove the tractor (see “Vehicle Recovery”).

12. Reset the gate lock release button.

WARNING!: Stand well clear of all moving parts.

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TBL280 Mk 4 Issue 2 07-02-11

VEHICLE RECOVERY

In the event of a breakdown or engine failure, the Tug must be recovered as follows:

Due to the hydraulic system of the transmission, the Tug should NOT be towed over long distances with the drive wheels turning. These should be raised clear of the ground and the propeller shaft disconnected from the axle flange.

NOTE: The Tug cannot be started by towing.

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TBL280 Mk 4 Issue 2 07-02-11

PBTO1 - RECOMMENDED PRACTICE (TOWING)

FOR USING THE TBL50, TBL180, TBL200, TBL280, TBL400 & TBL600 TRACTORS

1. Prior to connecting the Tug to the aircraft, ensure main wheels are chocked before removing chocks from nose wheels.

2. Insert steering lockout pin and lock pin.

NOTE: The TBL50 is fitted with a rotating Nose Landing Gear support platform, which overcomes the differing requirements with regards to isolating the aircraft’s steering system.

3. When arriving at the aircraft, line up with nose wheel approximately 10 metres away and drive

slowly to the aircraft. Check ground power cable is clear of tractor wheels.

4. Select cradle joystick to CRADLE LOWER position, until CRADLE DOWN indicator light is illuminated.

5. (With a responsible person in a position to view the connection of tractor to aircraft).

The responsible person must have authority to stop the tractor at any time he/she believes that damage could occur to the aircraft. Select correct wheel size.

6. Open gate by operating the cradle joystick to GATE OPEN position and hold in position until gate

is fully open and GATE OPEN indicator is illuminated. 7. Drive the Tug forward onto nose wheel until the cradle has touched the nose wheel size

adjuster and cradle scoop. Check NOSE WHEEL IN POSITION light is illuminated.

CAUTION! When positioning with cradle lowered, beware of ground obstructions.

8. Move cradle joystick to the GATE CLOSED position and hold until the green indicator light illuminates, then release joystick.

9. Apply Tug hand brake and select NEUTRAL.

WARNING! Ensure the Tug hand brake is ON, before removal of all chocks.

10. Remove chocks from main wheels. 11. Check that ALL equipment is removed from aircraft, except for steps/jetty and ground power.

12. Ensure aircraft park brake is selected OFF.

13. Pressurise brake hydraulic system, if required.

14. Select ground power OFF, check DV window is closed, ensure aircraft is safe to tow.

15. Check doors are closed, remove steps/jetty.

16. Switch off and make safe aircraft electrical systems, as required. Refer to applicable Towing Drills

(Internal) section. Remove ground power.

17. On clearance from Ground Movement Control, select Tug strobe lights ON and other lighting as required for towing.

18. Select cradle joystick to CRADLE RAISE position and hold until cradle stops at the FULLY

RAISED position and green indicator light is illuminated. Release joystick to neutral position.

19. Select gear and release hand brake to commence tow.

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TBL280 Mk 4 Issue 2 07-02-11

PBTO1 - RECOMMENDED PRACTICE (TOWING) Continued…


WARNING!

DO NOT APPLY THE AIRCRAFT BRAKES WHEN AIRCRAFT IS BEING TOWED WITH A

TOWBARLESS TOW VEHICLE. IF BRAKES ARE APPLIED, DAMAGE WILL OCCUR TO THE NOSE LANDING GEAR, TOWING VEHICLE AND MAINTENANCE PERSONNEL CAN BE INJURED.

20. With a responsible person in a position to view and ensure the steering angles are not

exceeded, commence tow. The responsible person must have authority to stop the tractor at any time he/she believes that damage could occur to the aircraft.

21. Responsible person monitors steering angle for exceedance throughout tow.

CAUTION! WHEN 80%OVERSTEER WARNING SYSTEM ACTIVATES, REDUCE THE STEERING ANGLE IMMEDIATELY.

22. If the aircraft over steer (100%) limit is exceeded or weight is more than specified, carry out

Exceeding Maximum Nose Gear Towing Angle Conditional Inspection. This inspection MUST be carried out before next flight and an entry made in aircraft Tech Log to this effect.

23. After completion of tow, select strobe lighting switch to OFF.

24. Select Tug hand brake ON, put gear lever in NEUTRAL and position cab to face aircraft for

disconnection.

25. Select cradle joystick to CRADLE LOWER position and hold until cradle is on the ground, release cradle joystick. Position chocks forward and aft of wheels on left and right Main Gear.

26. Select cradle joystick to GATE OPEN position and hold until gate is fully open and red indicator light

is illuminated. Release joystick to neutral position.

27. Move clear of nose leg and close gate. Raise cradle and rotate cab for normal driving.

28. Remove pins from aircraft.

29. Check that there is no damage to nose wheel hubs or tyres.

30. Record completion of successful tow.

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TBL280 Mk 4 Issue 2 07-02-11

PBTO2 - RECOMMENDED PRACTICE (PUSH BACK)

FOR USING THE TBL50 TBL180, TBL200, TBL280, TBL400 & TBL600 TRACTORS 1. Prior to connecting the Tug to the aircraft, ensure main wheels are chocked before

removing chocks from nose wheels.

2. Insert steering lockout pin and lock pin.

NOTE: The TBL50 is fitted with a rotating Nose Landing Gear support platform, which overcomes the differing requirements with regards to isolating the aircraft’s steering system.

3. Ensure Tug driver’s seat/console is in the push-out position.

4. Line up Tug with nose wheel approximately 10 metres away, then drive to aircraft. Check ground

power cable is clear of tractor wheels.

5. Select cradle joystick to CRADLE LOWER position, until CRADLE DOWN indicator light is illuminated.

6. (With a responsible person in a position to view the connection of tractor to aircraft).

The responsible person must have authority to stop the tractor at any time he/she believes that damage could occur to the aircraft. Select correct wheel size.

7. Open gate by operating the cradle joystick to GATE OPEN position and hold in position until gate is

fully open and GATE OPEN indicator is illuminated.

8. Drive the Tug forward onto nose wheel until the cradle has touched the nose wheel size adjuster and cradle scoop. Check NOSE WHEEL IN POSITION light is illuminated.

CAUTION! When positioning with cradle lowered, beware of ground obstructions.

9. Move cradle joystick to the GATE CLOSED position and hold until the green indicator light

illuminates, then release joystick.

10. Apply Tug hand brake and select NEUTRAL.

WARNING! Ensure the Tug hand brake is ON, before removal of all chocks.

11. Remove chocks from main wheels.

12. Check ALL equipment removed from aircraft except for steps/jetty and ground power.

13. When ground equipment clear, the ground crew will request the flight crew to release the aircraft brakes. Flight crew indicate to the ground crew that the brakes have been released and the aircraft is ready for lift and push back.

A320 ONLY Flight crew check ECAM display for message "N WHEEL STEERING DISC" or "NW STRG DISC" before giving go-ahead for push back.

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TBL280 Mk 4 Issue 2 07-02-11

PBTO2 - RECOMMENDED PRACTICE (PUSH BACK) Continued...


14. On clearance from flight crew for push back, Tug driver will select cradle joystick to CRADLE RAISE position and hold until cradle stops at fully up position and the green indicator light is illuminated. Release joystick to neutral position and commence push back when ready.

15. The responsible person must have authority to stop the tractor at any time he/she believes the

steering angle is being exceeded or damage could occur to the aircraft.

16. With a responsible person in a position to view and ensure steering angles are not exceeded, release tractor park brake, select a gear, commence push back. The responsible person monitors steering angle for exceedance throughout push back.

CAUTION! WHEN THE 80% OVERSTEER WARNING SYSTEM ACTIVATES, REDUCE THE STEERING ANGLE IMMEDIATELY.

17. If the aircraft over steer (100%) limit is exceeded or weight is more than specified, carry out

Exceeding Maximum Nose Gear Towing Angle Conditional Inspection. This inspection MUST be carried out before next flight and entry made in the aircraft Tech Log to this effect.

18. On completion of push back, apply Tug hand brake. Tug driver will select cradle joystick to CRADLE

LOWER position and holds until cradle is fully down and red indicator light is illuminated. Release joystick and request aircraft brakes ON.

19. On confirmation from the flight crew that the aircraft brakes are applied, the Tug driver selects cradle

joystick to GATE OPEN position and holds until gate is fully open and red indicator light illuminated. Release joystick to neutral position.

20. Tug will complete disconnection sequence and reverse just sufficiently to allow steering lock-out pin to

be removed, while Tug acts as a safety restraint to prevent aircraft from rolling in the event of the aircraft brakes not being fully applied.

21. Tug will reverse off until clear of nose leg, close gate and raise cradle for normal driving.

22. Check that there is no damage to nose wheel hubs or tyres.

23. Driver informs flight deck crew Tug disconnected, steering lockout pin is removed from aircraft.

Wingman removes communication lead from receptacle and closes aircraft access panel. Tug to remain in full view of flight deck crew and is to select seat/console to normal driving mode.

24. Ground crew to show steering lockout pin removed to flight deck crew.

25. Tug driver is to ensure Tug strobe lighting is NOT USED at any time for push-backs and normal

driving.

EMERGENCY ENGINE SHUTDOWN BUTTONS The TBL280 is fitted with five Engine Shutdown Buttons (RED), to enable crew-members to stop the Tugmaster’s engine immediately, should an emergency situation arise. Two of the buttons are externally positioned on either side of the vehicle, (near the front): on the left and right hand bonnets. A further button is located inside the cab, on an overhead central instrument panel. Additional buttons can be found on either side of the vehicle, at the rear, on top of both support legs. All the emergency stop buttons are illuminated. In the event of a button being activated, that button will flash to indicate it has been depressed. In addition - the in-cab emergency stop button will flash when any stop button is pressed. TO RESET - pull the relevant button out.

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TBL280 Mk 4 Issue 2 07-02-11

ISOLATION SWITCH

The MAIN ISOLATION SWITCH is situated under a cover on top of the right-hand leg of the vehicle, above the fuel tank (approximately half way along the side of the tractor). The isolation switch lever can be accessed through a hole in the side of the chassis.

WARNING LIGHTS When the ignition is switched on, the relevant warning lights will illuminate, i.e: No Charge, Nose Wheel Cradle Up or Down and Open or Closed, Wheel Size. All other warning lights can be tested by using the Warning Light Test Switch, located on the overhead switch panel. This switch also tests the buzzers and lights.

CIRCUIT BREAKERS Should there be a malfunction in any of the electrical circuits and/or electrical components, one of the circuit breaker/reset buttons will throw out. To reset the system, press the relevant reset button. There are two circuit breaker panels. One in the cab (relating to cab functions), located behind a panel to the rear of the crew seat. The second panel is located in the main junction box. NOTE: Should the button throw out again, report the fault to the maintenance engineer.

IMPORTANT

The engine is fitted with an Alternator. Observe the following:

1. Never break the circuit between the alternator and the battery while the engine is running. If a master

switch is fitted, this should not be switched off before the engine has finally stopped.

2. Before carrying out any repairs on the alternator equipment, first always disconnect both battery cables. If a rapid charging of the battery is to be carried out, the battery cables must also first be disconnected. (Never test with a screwdriver or suchlike against any connection to see if it emits sparks).

3. The battery, battery-cables and terminals should be checked regularly. The battery terminal studs should

be thoroughly cleaned and the cable terminals always tightened and well greased so as to prevent any breakdown in the circuit. All the cables should be well tightened, there must be no loose connections.

WARNING Never confuse the battery positive and negative poles when the batteries are being installed. Check belt tension at regular intervals.

4. When starting with a spare battery, first check that the spare battery has the same voltage as the standard

battery. Connect the spare battery to the standard battery with + to + and - to -. Remove the spare battery when the engine has started.

NOTE: The cables connecting the standard battery must not be disconnected.

5. If electrical welding is to be done on the engine or on any of the installation components, disconnect and

insulate the voltage regulator cables. Also, disconnect the earthed battery cable terminal.

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TBL280 Mk 4 Issue 2 07-02-11

IP79 – OPERATIONAL FUNCTIONS DISPLAY PANEL

DRIVE INHIBIT OVERRIDE


1. Apply foot brake.

2. Press the override button (9), located on the right hand side of the display panel.

3. Release foot brake.

4. Keeping the button depressed, drive in the normal manner.

5. Call emergency services to repair or remove Tugmaster.

NOTE: This procedure should only be used in an emergency to remove the Tugmaster from an aircraft or from the runway.

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TBL280 Mk 4 Issue 2 07-02-11

INTEGRAL JACKING SYSTEM

INTEGRAL JACKING SYSTEM

This vehicle is available with a four-point hydraulic jacking system. The jacks are positioned near each of the vehicle’s four wheels, to facilitate maintenance work/puncture repairs etc. The Integral Jacking Switch can be found inside the main junction box, which is situated above the batteries. The junction box is positioned under covers on the right-hand leg of the tractor (looking from the rear). To operate this system, the following instructions should be followed:

1. Switch ON the ignition. 2. Switch ON the Integral Jacking Switch. 3. Ensure the park brake is OFF and the opposing wheels are lightly chocked. 4. Operate the jacking button to raise the tractor, one axle only.

NOTE: The buttons to operate the jacks are located behind the engine side cover. The buttons will illuminate when the system is energised. The two buttons on the left operate the rear jacks. The two buttons on the right operate the front jacks.

5. Apply the park brake. 6. To lower the jacks; Release the park brake and operate the jacks. 7. On completion of work, raise the jacks and turn OFF the jacking switch immediately.

WARNING! ON NO ACCOUNT raise the front and rear axles together.

DRIVE WHEEL & SUPPORT WHEEL JACKING BUTTON

INTEGRAL JACKING SWITCH

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TBL280 Mk 4 Issue 2 07-02-11

JACKING POINTS

Recommended jacking points/areas are shown on the illustration below:

EXTENDABLE JACKING POINTS (x 2) NOTE: UNDER NO CIRCUMSTANCES should jacks be positioned under the cab support structure. Failure to observe this rule will result in serious damage to the Tugmaster.

FLAT TYRE CONDITIONS - DRIVE AXLE

In the event of a flat tyre, use the extendable jacking points, situated immediately in front of the drive wheels, as follows:

1. Remove the pin retaining nut. 2. Remove the pin. 3. Pull out the extendable jacking point, to line-up with hole. 4. Insert the pin and secure with retaining bolt. 5. Position the jack correctly under the jacking point.

After repairs have been made, ALWAYS stow the jacking points away BEFORE driving away.

FITTING ROAD WHEELS

When fitting road wheels to the axles, ensure that: The mating faces, the cones of the wheel nuts, collets (if fitted) and the counter bores of the road wheels are free of all foreign matter including paint.

All the threads should be clean and the wheel nut torque figures carefully adhered to:

Drive Axle: 650 Nm. Support Wheels: 650 Nm.

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TBL280 Mk 4 Issue 2 07-02-11

RECOMMENDED LUBRICANTS

UNIT TYPE GALLS. LITRES

Engine (with filter): Rimula X15 W40 4.00 18.18

Transmission: Rimula X15 W40 6.50 29.55

Steer/drive axle differential: Spirax HD85-140 5.50 25.00 Steer/drive axle hub (each): Spirax HD85-140 0.56 2.50 Brake cooling fluid: Donax TD As required Brake fluid: Tellus R10 As required Cooling system: (50% water/50% antifreeze) 2.64 12.00 Hydraulic system (approximate): Tellus T46 19.80 90.00 approx

(top up as required)

General lubrication: Retinax LX As required

Automatic lubrication (if fitted): Grease spec. NLG1-0 4.40 lbs 2.00 kgs

Tyre pressures: Drive wheel: 145 psi 10 Bar Support wheel: 145 psi 10 Bar

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TBL280 Mk 4 Issue 2 07-02-11

OPERATOR NOTES

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TBL280 Mk 4 Issue 2 07-02-11

OPERATOR NOTES

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Documents

DOUGLAS TUGMASTER Type TBL280 Property of American Airlines · exposed rotating parts. All items are only accessible by lifting covers etc. However, certain items can be reached from