Tronair JP30 Operation & Service Manual
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Tronair JP30 Operation & Service Manual

Electric towbarless tug
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1740 Eber Rd
Holland, OH 43528-9794
USA
Operation & Service Manual
Models: JP30, JP30L
Electric
Towbarless Tug
07/2015  Rev. 10
Tronair, Inc.
www.tronair.com
Email: sales@tronair.com
Phone: (419) 866-6301
800-426-6301
Fax: (419) 867-0634

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Gregory Hamilton
March 12, 2025

Can you send me a copy / picture of the battery terminal connections for a JP30 aircraft tug? This is a 16 battery system.

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1 comments:
Mr. Anderson
March 12, 2025

The Tronair JP30 aircraft tug with a 16-battery system refers to the JP30L model. The JP30L has sixteen 6-volt batteries connected in series and parallel to provide 48 volts and 470 Ah (20-hour rate).

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Summary of Contents for Tronair JP30

  • Page 1 Operation & Service Manual Models: JP30, JP30L Electric Towbarless Tug 07/2015  Rev. 10 Tronair, Inc. 1740 Eber Rd Phone: (419) 866-6301 Holland, OH 43528-9794 www.tronair.com 800-426-6301 Email: sales@tronair.com Fax: (419) 867-0634...
  • Page 2 REVISION DATE TEXT AFFECTED 05/2006 Original Release 03/2007 Major Revision 04/2007 Major Revision 12/2008 Modified 2.4 Capacity Modified Parts Lists Modified Appendices 03/2009 Modified Parts Lists 11/2010 Modified 2.5 Standard Equipment, 4.0 Operating Instructions, Parts List Removed Controller Operation, Added Appendix VI 08/2011 Modified Parts Lists 01/2013...

  • Page 3: Table Of Contents

    Models: JP30, JP30L Electric Towbarless Tug TABLE OF CONTENTS PAGE PRODUCT INFORMATION ............................1 DESCRIPTION ................................1 MODEL & SERIAL NUMBER ............................. 1 MANUFACTURER ..............................1 GENERAL .................................. 1 SAFETY INFORMATION............................... 1 USAGE AND SAFETY INFORMATION ........................1 OPERATING SAFETY GUIDELINES......................... 1 BATTERY SAFETY GUIDELINES ..........................

  • Page 4: Table Of Contents

    Models: JP30, JP30L Electric Towbarless Tug 11.0 PRE-SHIFT CHECKLIST............................. 12 12.0 PROVISION OF SPARES ............................13 12.1 SOURCE OF SPARE PARTS ..........................13 12.2 RECOMMENDED SPARE PARTS LISTS ....................... 13 13.0 IN SERVICE SUPPORT .............................. 13 14.0 GUARANTEES/LIMITATION OF LIABILITY ......................13 15.0...

  • Page 5: Product Information

    Models: JP30, JP30L Electric Towbarless Tug This product can not be modified without the written approval of Tronair, Inc. Any modifications done without written approval voids all warranties and releases Tronair, Inc., its suppliers, distributors, employees, or financial institutions from any liability from consequences that may occur.

  • Page 6: Battery Safety Guidelines

    If this should happen, force the eye open and flood it with cool, clean water for approximately fifteen minutes. A doctor should be called immediately when the accident occurs. If you have any doubts or questions, contact Tronair. GROUND POWER UNIT SAFETY GUIDELINES Read 6.4 “Safety Precautions”...

  • Page 7: Training

    14. Read Section 6 and review and understand safety procedures for working around batteries. 15. When moving in reverse direction, look both ways and clear the area of other traffic and obstacles. 16. Contact Tronair before making substitutions of any parts. TRAINING TRAINING REQUIREMENTS The employer of the operator is responsible for providing a training program sufficient for the safe operation of the tug.

  • Page 8: Ground Power Unit

    Stand Off Arm For Aircraft With Wheel Pants K-4094 Jumper Cables (For GPU) K-4101 On-Board Air Compressor K-4052 Westwind Adapter K-4054 PC-12 Adapter (JP30 Only) K-4055 Falcon 50/900/2000 Adapter (Required) K-4056 Lear 40/45 Adapter (Required) K-4177 Sabreliner Adapter K-4222 Falcon 10/20/100/200 Adapter...

  • Page 9: Batteries

    BATTERIES The JP30 has eight 6 volt batteries connected in series for 48 volts and 235 Ah (20 hr rate). The JP30L has sixteen 6 volt batteries connected in series and parallel for 48 volts and 470 Ah (20 hr rate).

  • Page 10: Operating Instructions

    Models: JP30, JP30L Electric Towbarless Tug OPERATING INSTRUCTIONS Stand on Operator Platform and pull the E-stop up. Turn the “Off-On-Start” switch to the “Start” position and then release. When operating the JETporter, stand firmly on the operator’s platform, with legs spread slightly apart and body braced against the backrest.

  • Page 11: Unloading Aircraft

    Models: JP30, JP30L Electric Towbarless Tug LOADING AIRCRAFT (continued) Secure the aircraft nose wheel with the safety strap. The safety strap is a strap with a ratchet mechanism and spring clip hooks at each end. On either side of the forward end of the cradle are brackets that have a hole in each of them.

  • Page 12: Connection To Aircraft

    Models: JP30, JP30L Electric Towbarless Tug GROUND POWER UNIT (continued) CONNECTION TO AIRCRAFT Adapters are included with JETporter. Position JETporter so the power socket on the aircraft is in a location that will allow the engine to be started safely. Be sure the “Master” switch in the aircraft is off prior to starting the engines. Boost voltage could damage the aircraft’s electrical system.

  • Page 13: Precautions

    If necessary, for location operational purposes, the length of the charging cycle (gassing period) can shortened. Contact Tronair or contact Quick Charge direct from the information located in the Quick Charge Manual (Appendix V).

  • Page 14: Maintenance

    Models: JP30, JP30L Electric Towbarless Tug 10.0 MAINTENANCE WARNING All work on the JETporter tug should be performed by competent repair personnel. Before performing maintenance, review all safety procedures. 10.1 GENERAL MAINTENANCE After the JETporter has been in operation for (4) months the steering chain should be tightened to take up the slack from initial chain stretch.

  • Page 15: Nylon Straps

    Do not substitute a higher or lower Amp/hour rated battery. All batteries should be replaced at the same time. Do not attempt to repair the electronic controller. Contact Tronair for proper repair procedures. Contact Tronair before making substitutions of any parts.

  • Page 16: Pre-Shift Checklist

    Models: JP30, JP30L Electric Towbarless Tug 11.0 PRE-SHIFT CHECKLIST Perform this check every day prior to the first shift. Place X if ok. Do NOT operate any JETporter unit until all discrepancies have been corrected Week Of: ________________ Date Inspected...

  • Page 17: Provision Of Spares

    Tronair Platinum Warranty Tronair products are warranted to be free of manufacturing or material defects for a period of two years after shipment to the original customer. This is solely limited to the repair or replacement of defective components. This warranty does not cover the...
  • Page 18 Models: JP30, JP30L Electric Towbarless Tug Parts List Illustration - JP30 When ordering replacement parts/kits, please specify model, serial number and color of your unit. 07/2015 | Rev. 10 Page | 14...
  • Page 19 Models: JP30, JP30L Electric Towbarless Tug Parts List - JP30 When ordering replacement parts/kits, please specify model, serial number and color of your unit. Item Part Number Description H-2948 Mat, Platform Z-6329 Cover, Motor Bay (Coated) Z-6328 Assembly, Battery Cover (Coated)
  • Page 20 Models: JP30, JP30L Electric Towbarless Tug Parts List Illustration - JP30 When ordering replacement parts/kits, please specify model, serial number and color of your unit. 07/2015 | Rev. 10 Page | 16...
  • Page 21 Models: JP30, JP30L Electric Towbarless Tug Parts List Illustration - JP30 When ordering replacement parts/kits, please specify model, serial number and color of your unit. Item Part Number Description Z-6266 Weldment, Lift Cradle JP-115 Indexing Plunger JP-114 Linch Pin JP-059 Cylinder, Hydraulic 1”...
  • Page 22 Models: JP30, JP30L Electric Towbarless Tug Parts List When ordering replacement parts/kits, please specify model, serial number and color of your unit. 07/2015 | Rev. 10 Page | 18...
  • Page 23 Models: JP30, JP30L Electric Towbarless Tug Parts List When ordering replacement parts/kits, please specify model, serial number and color of your unit. Item Part Number Description Nut, Stainless (¾” – 16) JP-027 G-1250-1110N Flatwasher, Narrow ¾ JP-024 Steering Wheel S-2111-01 Plate, Bottom Rod, STL Plate THD ⅜...
  • Page 24 Models: JP30, JP30L Electric Towbarless Tug Parts List When ordering replacement parts/kits, please specify model, serial number and color of your unit. Item Part Number Description EC-2827 Assembly, Din Rail EC-2259 Socket, Relay EC-2258 Relay EC-2260 Relay, Clip EC-2060 Diode EC-1710-10-12.0...
  • Page 25 Models: JP30, JP30L Electric Towbarless Tug Parts List When ordering replacement parts/kits, please specify model, serial number and color of your unit. Item Part Number Description EC-2824 Flasher, Solid State 9-32 Volts Screw, Pan HD CRS REC, #6 – 32...
  • Page 26 Models: JP30, JP30L Electric Towbarless Tug Parts List When ordering replacement parts/kits, please specify model, serial number and color of your unit. Item Part Number Description S-2751-01 Panel, Accelerator V-2583 Label, Control Panel EC-2096 Meter, Hour EC-2740 Switch, 3 Position Spring R/L...
  • Page 27 Models: JP30, JP30L Electric Towbarless Tug Parts List When ordering replacement parts/kits, please specify model, serial number and color of your unit. Item Part Number Description S-2747-01 Panel, Switch 14142 Flange, Latch 14144 Block, Contact Red EC-2817 Switch, Push Button...
  • Page 28 Models: JP30, JP30L Electric Towbarless Tug Parts List - JP30 When ordering replacement parts/kits, please specify model, serial number and color of your unit. 07/2015 | Rev. 10 Page | 24...
  • Page 29 Socket, Female JP-058 Battery, 6V Z-8592 Assembly, Controller EC-2110 Battery, Terminal Insulator Black EC-2837 TSX500 Harness, 11 ft. Z-8597 Assembly, Suppression Diode JP30 Pump Motor G-1503-1050W Flatwasher, ¼ EC-2835 Kit, Power Cable Z-6260 Frame EC-2707 Assembly, Light Side Marker (Amber) EC-2708 Assembly, Light Side Marker (Red) Screw, 10 –...
  • Page 30 Models: JP30, JP30L Electric Towbarless Tug Hydraulics Assembly When ordering replacement parts/kits, please specify model, serial number and color of your unit. Item Part Number Description N-2005-30-S Elbow, ¼ Tube x 3/8 NPT TF-1037-28*30.0 Assembly, Hose TF-1037-28*20.0 Assembly, Hose TF-1037-27*16.0 Assembly, Hose TF-1037-28*15.0...
  • Page 31 Models: JP30, JP30L Electric Towbarless Tug This page left blank intentionally. 07/2015 | Rev. 10 Page | 27...
  • Page 32 Models: JP30, JP30L Electric Towbarless Tug Axle Assembly 07/2015 | Rev. 10 Page | 28...
  • Page 33 Models: JP30, JP30L Electric Towbarless Tug Parts List – Axle Assembly When ordering replacement parts/kits, please specify model, serial number and color of your unit. Item Part Number Description Z-6312 Peerless Axle Housing (includes axle bearings) JP-054 Peerless 2 Speed Transaxle...
  • Page 34 Models: JP30, JP30L Electric Towbarless Tug Parts List – Cables When ordering Replacement Parts/Kits, please specify Model & Serial Number of your product. 07/2015 | Rev. 10 Page | 30...
  • Page 35 Models: JP30, JP30L Electric Towbarless Tug Parts List – Cables When ordering replacement parts/kits, please specify model, serial number and color of your unit. Item Part Number Description EC-1185-04*144 Cable, Welding 1/0 EC-2004 Plug, Male Negative (Black) JP-031 Plug, Male Positive (Red)
  • Page 36 Caution Hands/Feet V-1814 Warning Keep 5 Ft Clear V-2268-01 Tronair V-2452 Label, Charging Power Level V-2455 Label, Charger Inlet, 13 AMP JP30 V-2456 Label, Charger Inlet, 20 AMP JP30L V-2580 Label, Brake Panel V-2583 Label, Control Panel V-2579 Label, Signal Panel (Turn Signal Option Only) 07/2015 | Rev.
  • Page 37 Models: JP30, JP30L Electric Towbarless Tug This page left blank intentionally 07/2015 | Rev. 10 Page | 33...
  • Page 38 Models: JP30, JP30L Electric Towbarless Tug Parts List Illustration - JP30L Reference Parts List on following page 07/2015 | Rev. 10 Page | 34...
  • Page 39 Models: JP30, JP30L Electric Towbarless Tug Parts List - JP30L When ordering replacement parts/kits, please specify model, serial number and color of your unit. Item Part Number Description H-2948 Mat, Platform Z-6329 Cover, Motor Bay (Coated) Z-6328 Assembly, Battery Cover (Coated)
  • Page 40 Models: JP30, JP30L Electric Towbarless Tug Parts List - JP30L When ordering replacement parts/kits, please specify model, serial number and color of your unit. 07/2015 | Rev. 10 Page | 36...
  • Page 41 Models: JP30, JP30L Electric Towbarless Tug Parts List - JP30L When ordering replacement parts/kits, please specify model, serial number and color of your unit. Item Part Number Description Z-6266 Weldment, Lift Cradle JP-115 Indexing Plunger JP-114 Linch Pin JP-059 Cylinder, Hydraulic 1”...
  • Page 42 Models: JP30, JP30L Electric Towbarless Tug Parts List - JP30L When ordering replacement parts/kits, please specify model, serial number and color of your unit. 07/2015 | Rev. 10 Page | 38...
  • Page 43 JP-058 Battery, 6V Z-8585 Assembly, Controller EC-2110 Battery, Terminal Insulator Black EC-2837 TSX500 Harness, 11 ft Long Z-8597 Assembly, Suppression Diode JP30 Pump Motor G-1503-1050N Flatwasher, ¼ EC-2836 Kit, Power Cable Z-6296 Frame EC-2707 Assembly, Light Side Marker (Amber) EC-2708 Assembly, Light Side Marker (Red) Screw, 10 –...
  • Page 44 Models: JP30, JP30L Electric Towbarless Tug Parts List When ordering replacement parts/kits, please specify model, serial number and color of your unit. 07/2015 | Rev. 10 Page | 40...
  • Page 45 Models: JP30, JP30L Electric Towbarless Tug Parts List When ordering replacement parts/kits, please specify model, serial number and color of your unit. Item Part Number Description J-5815 Plate, Heat Shrink EC-2090 Controller EC-1618 Fuse Block, ANL Limiters H-3808 Standoff, Female Thread 5 Long...
  • Page 46 Models: JP30, JP30L Electric Towbarless Tug Parts List When ordering replacement parts/kits, please specify model, serial number and color of your unit. 07/2015 | Rev. 10 Page | 42...
  • Page 47 Models: JP30, JP30L Electric Towbarless Tug Parts List When ordering replacement parts/kits, please specify model, serial number and color of your unit. Item Part Number Description S-2733-01 Panel, Switch 14142 Flange, Latch 14144 Block, Contact Red 14143 Block, Contact Green...
  • Page 48 Models: JP30, JP30L Electric Towbarless Tug Parts List When ordering replacement parts/kits, please specify model, serial number and color of your unit. Item Part Number Description EC-2819 Light, LED Red H-3804 Bracket, Gasket H-3805 Bracket, LED Holder EC-2820 Harness, LED Light G-1476-105010 Screw, Socket Button head Cap, ¼...
  • Page 49 APPENDIX - I INS-1857 Hydraulic Schematic...
  • Page 51 APPENDIX - II INS-2276 Electrical Schematic...
  • Page 53 APPENDIX - III INS-2277 INS-2278 Wiring Diagrams...
  • Page 55 APPENDIX - IV Deep Cycle Battery Handling, Maintenance Test Procedures...
  • Page 65 APPENDIX - V Battery Charger Operating Instructions & Warranty...
  • Page 67 O P E R A T I N G I N S T R U C T I O N S OBWXU4825TA, OBWXU4840TA Battery Chargers For Industrial Use: Designed for gel, wet cell, AGM, and Lithium Ion Batteries (Lithium ion applications must be factory programmed) Quick Charge Corp.
  • Page 68 QUICK START INSTRUCTIONS: The charger is programmable to charge different battery types and is preset at the factory to match the batteries installed. If batteries are replaced with a different style or brand, the program may need to be changed. See section on reprogramming. The charger will work from a 120 or 230 volt 50-60HZ supply.
  • Page 69 By switching the meter to amps, the charge current is displayed. In this case, 25. 40 for a 40 amp charger. Will be less on partially discharged batteries. NOTE: It does not matter what position the meter switch is in. It is for viewing and not operating. As the batteries become charged, the amps will decrease and the voltage will increase.
  • Page 70 EQUALIZATION: When using multiple batteries in a series string, cells become uneven during charge and discharge cycles. At least once a month perform two charge cycles back to back, this will give a chance for cells that are lagging behind to catch up, and is important to overall battery performance. NOTE: This only needs to be done when using the wet cell or AGM settings with a standard, or extended gassing/absorption cycle.
  • Page 71 BATTERY SAFETY & CARE INFORMATION: Always wear protective eye shields and clothing when working with batteries. Batteries contain acids which can cause bodily harm. Do not put wrenches or other metal objects across the battery terminal or battery top. Arcing or explosion of the battery can result. Do not wear jewelry when working around batteries.
  • Page 72 REPROGRAMMING: Remove sheet metal screws holding cover on. Select the switch configuration that most closely matches your application. Whether choosing maintenance mode, or shut off is a personal preference, however the maintenance mode assures batteries will remain charged and won’t self discharge. IMPORTANT: Use switch numbers as a guide, as some boards may be upside down, and reversed.
  • Page 73 TROUBLESHOOTING: Symptom Cause Corrective Action No voltage reading on meter Connected reverse to battery, Correct polarity, or connect to when connected to battery, and or not connected to battery. battery. On chargers having a the LED flashes red/green. white and black wire, white is positive.
  • Page 74 Symptom Cause Corrective Action The charger blows the branch The branch circuit is too Relocate charger to a branch circuit fuse/circuit breaker a small. circuit with a heavier rating, or short while after being switched remove other loads on the circuit. Batteries use water, get hot, or One or more dead cells.
  • Page 75 QUICK CHARGE OBWXU Battery Chargers “LIMITED WARRANTY” Quick Charge Corporation warrants the OBWXU line of chargers for three (3) years from the date of purchase. After the warranty period, chargers returned to the factory for repair will be charged a minimum rate of $25.00. Charger will be returned, freight and repair charges, C.O.D. unless other arrangements have been made.
  • Page 77 APPENDIX - VI Honeywell Battery and Time Controller Operating Instructions...
  • Page 81 APPENDIX - VII Declaration Conformity...
  • Page 83 DECLARATION of CONFORMITY The design, development and manufacture is in accordance with European Community guidelines Towbarless Tug JP30 JP30L Relevant provisions complied with by the machinery: 2006/42/EC EN 1915-1 EN 12312-7 Relevant standards complied with by the machinery: EN ISO 12100-1...

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