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Tronair eJP-3 Operation & Service Manual

Electric towbarless tug
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OPERATION & SERVICE MANUAL
Models: eJP-3, eJP-3L
Electric Towbarless Tug
03/2018  Rev. 01
Tronair, Inc.
Phone: (419) 866-6301 | 800-426-6301
1 Air Cargo Pkwy East
Web: www.tronair.com
Swanton, OH 43558
Email: sales@tronair.com

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  • Page 1 OPERATION & SERVICE MANUAL Models: eJP-3, eJP-3L Electric Towbarless Tug 03/2018  Rev. 01 Tronair, Inc. Phone: (419) 866-6301 | 800-426-6301 1 Air Cargo Pkwy East Web: www.tronair.com Swanton, OH 43558 Email: sales@tronair.com...
  • Page 2 REVISION DATE TEXT AFFECTED 03/2018 Original Release...

  • Page 3: Table Of Contents

    Models: eJP-3, eJP-3L 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 Models: eJP-3, eJP-3L Electric Towbarless Tug 11.0 PRE-SHIFT CHECKLIST ..............................13 12.0 PROVISION OF SPARES ............................... 14 12.1 SOURCE OF SPARE PARTS ........................... 14 12.2 RECOMMENDED SPARE PARTS LISTS ......................14 13.0 IN SERVICE SUPPORT ..............................14 14.0 GUARANTEES/LIMITATION OF LIABILITY ........................14 15.0...

  • Page 5: Product Information

    Models: eJP-3, eJP-3L 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: Specifications

    Electric Towbarless Tug SPECIFICATIONS DIMENSIONS Weight: 2,450 lbs (1,111.3 kg) eJP-3 3,000 lbs (1,360.5 kg) eJP-3L Length: 134 3/16 in (340.8 cm) eJP-3 170 9/16 in (433.2 cm) eJP-3L Height: 49 7/16 in (125.7 cm) Width: 40 in (101-6 cm) Ground Clearance: 3 5/16 in (8.4 cm)

  • Page 9: Technical Data

    BATTERIES The eJP-3 has eight 6 volt batteries connected in series for 48 volts and 235 Ah (20 hr rate). The eJP-3L has sixteen 6 volt batteries connected in series and parallel for 48 volts and 470 Ah (20 hr rate).

  • Page 10: Lighting

    Models: eJP-3, eJP-3L Electric Towbarless Tug TECHNICAL DATA (continued) 5.14 LIGHTING Forward and rear LED headlights are included. Headlights are turned on with toggle switch. Strobe comes on when tug is started. 5.15 DRIVE TIRES Drive tires are 16 x 6-8 solid rubber traction tires.

  • Page 11: Unloading Aircraft

    Models: eJP-3, eJP-3L Electric Towbarless Tug LOADING AIRCRAFT (continued) Position the tug in front of the aircraft nose wheel and lower the lift cradle to the ground. Winch the nose wheel onto the lift cradle, utilizing the strut strap or appropriate attachment.

  • Page 12: Ground Power Unit

    Models: eJP-3, eJP-3L Electric Towbarless Tug GROUND POWER UNIT DESCRIPTION The ground power unit (GPU) is an integral part of tug. The traction batteries serve as the source of power to start the aircraft. The black terminal is the negative, terminal. Always connect the black plug into the black terminal. This provides the ground connection to the aircraft.

  • Page 13: Battery Care

    Models: eJP-3, eJP-3L Electric Towbarless Tug BATTERY CARE This section provides general instructions for good battery care. Please refer to Appendix in this section for additional information on battery care. WATER Add approved water only to a fully charged battery. You can use local tap water as long as it is not high in mineral deposits or other hard deposits.

  • Page 14: Troubleshooting

    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 15: Maintenance

    Models: eJP-3, eJP-3L Electric Towbarless Tug 10.0 MAINTENANCE WARNING All work on the tug should be performed by competent repair personnel. Before performing maintenance, review all safety procedures. 10.1 GENERAL MAINTENANCE After the tug has been in operation for (4) months the steering chain should be tightened to take up the slack from initial chain stretch.

  • Page 16: 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 17 Models: eJP-3, eJP-3L 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 tug until all discrepancies have been corrected Week Of: ________________ Date Inspected Function...
  • Page 18 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 19 Models: eJP-3, eJP-3L Electric Towbarless Tug This page left blank intentionally. 07/2015 | Rev. 11 Page | 15...
  • Page 20 Models: eJP-3, eJP-3L Electric Towbarless Tug Parts List Illustration - eJP-3 When ordering replacement parts/kits, please specify model, serial number and color of your unit. 07/2015 | Rev. 11 Page | 16...
  • Page 21 Models: eJP-3, eJP-3L Electric Towbarless Tug Parts List - eJP-3 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 22 Models: eJP-3, eJP-3L Electric Towbarless Tug Parts List Illustration - eJP-3 When ordering replacement parts/kits, please specify model, serial number and color of your unit. 07/2015 | Rev. 11 Page | 18...
  • Page 23 Models: eJP-3, eJP-3L Electric Towbarless Tug Parts List Illustration - eJP-3 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 HC-2746 Cylinder, Hydraulic 1”...
  • Page 24 Models: eJP-3, eJP-3L Electric Towbarless Tug Parts List When ordering replacement parts/kits, please specify model, serial number and color of your unit. 07/2015 | Rev. 11 Page | 20...
  • Page 25 Models: eJP-3, eJP-3L 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 26 Models: eJP-3, eJP-3L 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 27 Models: eJP-3, eJP-3L 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 (for Turn Signal Option) Screw, Pan HD CRS REC, #6 – 32...
  • Page 28 Models: eJP-3, eJP-3L 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 29 Models: eJP-3, eJP-3L 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 30 Models: eJP-3, eJP-3L Electric Towbarless Tug Parts List - eJP-3 When ordering replacement parts/kits, please specify model, serial number and color of your unit. 07/2015 | Rev. 11 Page | 26...
  • Page 31 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 eJP-3 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 32 Models: eJP-3, eJP-3L 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-2001-06-S-B Elbow, Straight Thread 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 Assembly, Hose TF-1037-27*14.0...
  • Page 33 Models: eJP-3, eJP-3L Electric Towbarless Tug This page left blank intentionally. 07/2015 | Rev. 11 Page | 29...
  • Page 34 Models: eJP-3, eJP-3L Electric Towbarless Tug Axle Assembly 07/2015 | Rev. 11 Page | 30...
  • Page 35 Models: eJP-3, eJP-3L 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 36 Models: eJP-3, eJP-3L Electric Towbarless Tug Parts List – Cables When ordering Replacement Parts/Kits, please specify Model & Serial Number of your product. 07/2015 | Rev. 11 Page | 32...
  • Page 37 Models: eJP-3, eJP-3L 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 38 Use AW46 Oil V-2191 Caution Hands/Feet V-1814 Warning Keep 5 Ft Clear V-2452 Label, Charging Power Level V-2455 Label, Charger Inlet, 13 AMP eJP-3 V-2456 Label, Charger Inlet, 20 AMP eJP-3L V-2580 Label, Brake Panel V-2583 Label, Control Panel V-2579 Label, Signal Panel (Turn Signal Option Only) 07/2015 | Rev.
  • Page 39 Models: eJP-3, eJP-3L Electric Towbarless Tug This page left blank intentionally 07/2015 | Rev. 11 Page | 35...
  • Page 40 Models: eJP-3, eJP-3L Electric Towbarless Tug Parts List Illustration - eJP-3L Reference Parts List on following page 07/2015 | Rev. 11 Page | 36...
  • Page 41 Models: eJP-3, eJP-3L Electric Towbarless Tug Parts List - eJP-3L 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 42 Models: eJP-3, eJP-3L Electric Towbarless Tug Parts List - eJP-3L When ordering replacement parts/kits, please specify model, serial number and color of your unit. 07/2015 | Rev. 11 Page | 38...
  • Page 43 Models: eJP-3, eJP-3L Electric Towbarless Tug Parts List - eJP-3L 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 HC-2746 Cylinder, Hydraulic 1”...
  • Page 44 Models: eJP-3, eJP-3L Electric Towbarless Tug Parts List - eJP-3L When ordering replacement parts/kits, please specify model, serial number and color of your unit. 07/2015 | Rev. 11 Page | 40...
  • Page 45 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 eJP-3 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 46 Models: eJP-3, eJP-3L Electric Towbarless Tug Parts List When ordering replacement parts/kits, please specify model, serial number and color of your unit. 07/2015 | Rev. 11 Page | 42...
  • Page 47 Models: eJP-3, eJP-3L 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 48 Models: eJP-3, eJP-3L Electric Towbarless Tug Parts List – Turn Signal Kit Option When ordering replacement parts/kits, please specify model, serial number and color of your unit. 07/2015 | Rev. 11 Page | 44...
  • Page 49 Models: eJP-3, eJP-3L 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 50 Models: eJP-3, eJP-3L 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 51 APPENDIX I Hydraulic Schematic INS-1857...
  • Page 53 APPENDIX II Electrical Schematic INS-2276...
  • Page 55 APPENDIX III Wiring Diagrams INS-2277, INS-2278...
  • Page 57 APPENDIX IV Deep Cycle Battery Handling, Maintenance and Test Procedures...
  • Page 67 APPENDIX V Battery Charger Operating Instructions & Warranty...
  • Page 69 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 70 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 71 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 72 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 73 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 74 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 75 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 76 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 77 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 79 APPENDIX VI Honeywell Battery and Time Controller Operating Instructions...
  • Page 83 APPENDIX VII Declaration of Conformity...
  • Page 85 DECLARATION of CONFORMITY The design, development and manufacture is in accordance with European Community guidelines Towbarless Tug eJP-3 eJP-3L 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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