Aircraft Tug DNW V2 Manual

Reference Manual
DUAL NOSE WHEEL
Read manual carefully before operating machine
Rev. 8/24/21
Model Number:
Lindy’s AircraftCaddy DNW Serial Number:
1009 4th St. NW, Little Falls, MN 56345 • PH: 888-631-5011
www.djproducts.com
Safety Precautions
For Safety:
1. Do not operate, maintain, or service machine:
• Unless trained and authorized.
• Unless operation manual is read and understood.
• In flammable or explosive areas.
2. Before operating machine:
• Make sure all safety devices are in place and operate properly.
3. When maintaining or servicing machine:
• Disconnect battery connections before working on machine.
• Avoid contact with battery acid.
• Avoid moving parts. Do not wear loose jackets, shirts, ties, or sleeves when working on machine.
• Use Lindbergh Aircraft Tug Co. supplied or equivalent replacement parts.
4. Do not transport machine with cover up.
5. When brake lever is flipped and brake is disengaged, unit will not operate
using the hand or thumb controls. The disengaged mode allows the unit to be
moved manually. The motor is disengaged if it is in the most clockwise
position and engaged if in the most counterclockwise position.
Warning:
Batteries emit hydrogen gas. Explosion or fire can result. Keep sparks and open flame away.
Attention:
The battery charger supplied with the machine shall be grounded while in use to protect the
operator form electric shock. This charger is designed for use on a nominal 120 volt circuit and has a grounding plug that resembles the plug illustrated. Make sure the charger is con
nected to an outlet having the same configuration as the plug. No adapter should be used with this charger. The green conductor in the cord is the ground wire. Never connect this wire to anything other than the grounding pin of the attachment plug. Store this machine indoors, do not expose to rain. This product is intended for commercial use.
General Specifications:
Electric 36 V DC — (3) 105 Amp batteries
Charger, 110 VAC, 60 HZ
Power Train / Propelling System
36 V DC electric motor
36 V DC controller
Suspension System
Casters —(1) rear, 8 in. (150 mm) dia.
Drive — (2) front, 12 in. (305 mm) dia.
General Machine Dimensions
Length — 108 in. (2,743.2 mm)
Width — 56 in. (1,422.4 mm)
Height — 39 in. (990.6 mm)
Machine
Total Weight, with batteries— 975 lbs.
2
Additional
Specifications
Additional Specifications
Nominal Power
Mass of most useful configuration
Maximum draw bar pull
3 hp, 6 hp peak
950 lbs. (430.9 kg)
1000 lbs. (453.6 kg)
Use
ofMachinery
Machinery
Use of
The AircraftCaddy DNW is designed for one person to safely and easily maneuver aircraft with a
double nose wheel in/out of tight spaces in hangers or in staging on a ramp.The quietness of their
electric motors allow an operator to manipulate their airplane while having the full use of sound,
site, and touch.
Adjustments
Controls:
The handle assembly can easily be adjusted if the machine comes out of neutral and begins to creep.
By removing the (4) 5/16” self-threaded screws in the yellow control box, you will gain access to the
control potentiometer. Adjust the potentiometer with a 1/2 SAE wrench. Turning the potentiometer
towards the front of the machine will stop the machine from creeping backwards. Turning the potentiometer towards the rear of the machine will stop the machine from creeping forward.
3
Installing Batteries
1. Make sure the power switch is in the off (0) position.
2. Using the lift handles provided on the battery, place batteries in
the machine with the terminal posts as shown.
For Safety:
When maintaining or servicing the machine:
• Battery acid can cause burns. Avoid contact with battery acid.
• When working on or around batteries, wear protective
clothing, gloves, and safety glasses.
• Do not lay metal tools or metal objects on top of the batteries.
• Only install deep cycle marine style lead acid batteries in your AircraftCaddy. The charger is built specifically for lead acid
batteries. Any other battery may become overcharged and cause serious damage to the machine or operator.
• When replacing batteries, you should replace all three
batteries. This will assure the batteries will be kept in sync.
3. Remove the nuts from the terminal posts. Connect the wires as shown.
4. Make sure to attach the positive leads to the positive terminals.
Place the nuts on the terminal and tighten securely.
Black
Black
Red
Black
Accessory Panel
1. Power Switch
• The power switch controls the machine power.
• Turn key to (1) to turn on the power.
• Turn key to (O) to turn off the power.
• The machine batteries must be charged for the machine
to have power.
3
2. Accessory Circuit Breaker
• The circuit breaker protects control circuit form overload.
• There is a 100 amp fuse that protects the motor form overload. If the load is too high, the fuse will blow and the unit will stop. Replace fuse and reduce the load before resuming. Please review the load limit sections for recommended load limits.
3. Voltmeter
• The voltmeter shows the state of charge of the batteries.
2
1
4
Pre-Operation Checklist
Before operating the machine:
1. Make sure the charge is OFF by unplugging the AC power cord from the wall outlet.
2. Lower the machine cover.
3. Make sure all controls are free and clear of any obstructions.
4. Turn the power switch ON.
5. Make sure the safety light is operating correctly. (Optional)
6. Now you are ready to operate. If any of the safety features were not operating correctly please contact:
• Your Manager
• Maintenance Personnel
• Your Service Representative
• Lindbergh Aircraft Tug Co.
Maintenance
The daily and monthly maintenance requirements listed here may be performed without tools by the
machine operators. Instructions for these maintenance requirements are provided in this section of
the manual.
Daily:
Perform all duties listed under Pre-Operation Checklist.
Every Month:
Add distilled water if needed. Water should be just over the top of the cells in the batteries.
Every Three Months:
Lubricate the castor bearings with grease.
Check and tighten all fasteners and hardware.
Check, tighten, and lubricate battery posts and cables.
Check transaxle for leaks, fill to level if required.
Service Policy
Whenever ordering parts or requesting any type of service, specify:
1. The model of the machine
2. Serial number
3. The part number
4. The part description
5
Charging Batteries
The batteries have approximately an eight hour run time when fully charged. The batteries take about
eight hours to charge after they have been fully discharged. The battery charger has an automatic timer that will turn off the charger when the batteries reach full charge. The batteries should be charged
after every eight hours of operation of the machine.
To charge the batteries:
1. Move the machine to a flat, dry surface in a well ventilated room.
2. Open the machine cover.
3. Check the water level in the battery cells. If the level is low, add just enough distilled
water to cover plates. DO NOT OVERFILL.
4. Wipe off tops of batteries with a cloth.
5. Connect this charge to the machine.
6. Plug the charger into a wall outlet.
This is an electrical device. When the key of the machine is turned on or left unused for a period of time, there
is a drain on the batteries. This drain could cause the batteries to become low. So low that our charger will not
charge the batteries. Whenever the machine is not in use, the machine should be plugged in. This will guarantee the machine is charged and ready for use the next time you need it. You need to check the status indicators
on the charger to make sure it’s functioning correctly. The time to do it is - When you plug it in and when you
disconnect it. By checking the charger during these two tasks, you will catch most problems before they become
an issue.
All of our chargers are UL approved, meaning once the battery gets below 8.5 volts it will not charge the battery and the charger will give you a fault alert. This is a safety feature of the charger and will guarantee that the
charger will not function in the case there is truly a problem with your batteries. When a fault is detected, please
review the trouble shooting guide.
Load Limits
The AircraftCaddy DNW is specifically designed to push/pull airplanes. You should never operate the
AircraftCaddy DNW:
• With an operator under the age of 16.
• With an operator sitting or riding on the AircraftCaddy or any aircraft it may be pushing.
• With added weight not specifically added by Lindbergh Aircraft Tug Co. or a certified
service rep.
• With the hood in the open position.
• Without being properly trained by a supervisor.
• In severe weather.
• With a known feature not working correctly.
• While on specific medicine that may impair your vision or reflexes.
By disregarding any of these limits, it may cause damage to the operator, aircraft,
the AircraftCaddy, or your building.
Disregarding any of these limits will void your warranty in case the AircraftCaddy is damaged.
6
A
B
ITEM
61
60
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QTY
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1
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1
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1
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7
PART NO.
500519-07
300250
705051
705050
705049
300198
300197
300196
705045
705044
705041
705039
300081
705040
500187
500262
500416
500406-02
500414
501287
501288
500345-03
500345-02
500129-041
705034
705033
590182
590183
704048
705025
705026
705010
501229
506801-410
704095
MMC-704077
705035
704027
500138
300188
300084
500297
500142
500140
500140-01
500137
500139
500296
500152
500147
500146-03
500145-01
500125
500149
506011-01
506009
501218
590177
590172
590173
705003
4
B
D
L
H
D
D
F
A
A
A
A
-
A
A
a
A
P
J
A
A
B
B
B
B
B
B
A
C
B
C
B
E
B
A
H
B
A
A
-
B
REV
A
A
A
B
B
A
B
B
A
A
B
B
A
A
-
4
DESCRIPTION
3 BANK BATTERY CHARGER, 15A
3hp Controler
HD ACC WHEEL STOP, BOLT ON
RIGHT SIDE SINGLE WHEEL ADAPTER
LEFT SIDE SINGLE WHEEL ADAPTER
AXLE SHAFT EXTENSION
STANDARD 9 TOOTH GEAR 1IN BORE 60LB CHAIN
AXLE SHAFT ADAPTER COLLAR
STABILIZER JACK BOLT
STABILIZER JACK BASE WELDMENT
GEAR BEARING BRACKET, LEFT SIDE
GEAR BEARING BRACKET, RIGHT
F2B-SC -Inch - SC 2 Bolt Flange Bearings -(Normal Duty)
STABILIZER BRACKET WELDMENT
E-STOP ASSY
E- STOP GAURD
SWITCH MOUNTING PANEL PLUG
HORN SWITCH
SWITCH, MOUNTING PANEL END
CONTROL COVER TOP
CONTROL BOX BOTTOM
100 AMP FUSE BLOCK
100A FUSE
12" SOLID TIRE
GEAR EXTENSION SHROUD, LEFT SIDE
GEAR EXTENSION SHROUD, RIGHT SIDE
FRONT CHAIN GUARD, TOP
CHAIN SHROUD FRONT, SIDE PLATE
GROUND SPACER
ROLLER SHAFT
FRAME MOUNT SPRING TAB
SPRING RAMP WELDMENT
TRANSAXLE BRACE 3HP, CC5W
3HP TRANSAXLE
HOOD WELDMENT
HD ACC WHEEL STOP, BOLT ON
WHEEL TRAP BASE WELDMENT, ACC HD
STEERING ARM WELDMENT
HANDLE BAR
2000LB POLY ON CAST IRON CASTER
FVPDC24
1" HANDLE BAR GEAR SPACER
POT AND HARNESS ASSY
HANDLE BAR GEAR-222079
TORSION SPRING CENTERING BOLT
HANDLE BAR GEAR BUSHING
POT GEAR
TORSION SPRING
Handle Bar Grip
10AMP CRICUIT BRAKER (RE CIRK IT)
40AMP CURUIT BRAKER
KEY ASSY (CHROME) UL RATED
36 VDC VOLTMETER
SOLENOID
BATTERY FRONT STOP
3 horse Power Transaxle Clamp
TRANSAXLE BRACKET WELDMENT 3HP
40 TOOTH GEAR WHEEL HUB WELDMENT
CHAIN SHROUD WELDMENT, RIGHT
LEFT SIDE CHAIN SHROUD
HD AIR CRAFT CADDY FRAME WELDMENT
Parts LIST
3
3
2
B
SHEET SIZE:
PROJECT:
NAME:
MATERIAL:
AIR PLANE PUSHER ASSEMBLY
WHEEL LOCK OPTION
DATE
5/24/10
7/6/10
1/14/10
11/21/12
1/30/13
9/18/13
2
C:\Work\Engineering Designs\10 Unit Folder\705000 AIR CRAFT CADDY HD\705001 AIR CRAFT CADDY HD 3HP ASSEMBLY\705001.iam
FILENAME AND PATH:
08Dec09 - 8:13am
TIME STAMP
FINISH PART:
.1
.03
.010
3
3
-INCHESBY ACCEPTING THIS
DRAWING THE RECIPIENT
ACKNOWLEDGES AND
.0:
STIPULATES THAT PRDUCT
DESIGNS DISCLOSED ARE
.00:
PROPRIETARY AND
.000:
BELONGS SOLELY TO DJ
PRODUCTS. ALL RIGHTS OF
ANGLES:
DESIGN OR INVENTION ARE
RESERVED.
DRAFT:
DJ PRODUCTS Inc.
1009 4TH STREET N.W.
LITTLE FALLS MN 56345
REVISION BLOCK
DESCRIPTION
NEW RELEASE
FRAME AND CRADLE CHANGES
UPATE FOR TENSION BOLT ON GEARS
UDPATE FOR HOOD CHANGES
UPDATE FOR FRAME LENGTH
UPDATE FOR NEW 3HP CONTROLER
UNLESS OTHERWISE SPECIFIED:
-TOLERANCE-
REV.
A
B
C
D
E
F
1
1
SHEET
1&2
ALL
ALL
ALL
ALL
ALL
Sheet:
1
OF
2
F
REV. NO:
5/17/2010
DATE:
PAT H
705001
PART NO.
SCALE:
DRAFTER/DESIGNER:
PRODUCT MANAGER / ENGINEER:
BY
PH
PH
PH
PH
PH
PH
A
B
A
B
46
47
44
45
42
43
41
8
A
4
4
24
61
9
11
12
10
8
27
1
40
22
7
39
60
29
5
6
21
37
36
2
51
55
3
B
3
3
34
35
38
48
52
4
53
25
31
30
58
26
32
33
57
59
2
B
SHEET SIZE:
PROJECT:
NAME:
MATERIAL:
55
17
13
23
2
A
1
BY
PH
PH
PH
PH
PH
PH
B
AIR PLANE PUSHER ASSEMBLY
WHEEL LOCK OPTION
1
SHEET
1&2
ALL
ALL
ALL
ALL
ALL
Sheet:
2
705001
PART NO.
SCALE:
OF
2
F
REV. NO:
5/17/2010
DATE:
DRAFTER/DESIGNER:
PRODUCT MANAGER / ENGINEER:
SCALE 1 / 8
DETAIL
SCALE 1 / 4
DETAIL
DJ PRODUCTS Inc.
1009 4TH STREET N.W.
LITTLE FALLS MN 56345
50 54
49
56
19
18
DATE
5/24/10
7/6/10
1/14/10
11/21/12
1/30/13
9/18/13
C:\Work\Engineering Designs\10 Unit Folder\705000 AIR CRAFT CADDY HD\705001 AIR CRAFT CADDY HD 3HP ASSEMBLY\705001.iam
FILENAME AND PATH:
08Dec09 - 8:13am
TIME STAMP
FINISH PART:
.1
.03
.010
3
3
-INCHESBY ACCEPTING THIS
DRAWING THE RECIPIENT
ACKNOWLEDGES AND
.0:
STIPULATES THAT PRDUCT
DESIGNS DISCLOSED ARE
.00:
PROPRIETARY AND
.000:
BELONGS SOLELY TO DJ
PRODUCTS. ALL RIGHTS OF
ANGLES:
DESIGN OR INVENTION ARE
RESERVED.
DRAFT:
15
14
20
16
REVISION BLOCK
DESCRIPTION
NEW RELEASE
FRAME AND CRADLE CHANGES
UPATE FOR TENSION BOLT ON GEARS
UDPATE FOR HOOD CHANGES
UPDATE FOR FRAME LENGTH
UPDATE FOR NEW 3HP CONTROLER
UNLESS OTHERWISE SPECIFIED:
-TOLERANCE-
REV.
A
B
C
D
E
F
A
B
SPEED
SWITCH
WIRE 15
20
PIN 7 WIRE ___
4
2
FWD/REV
POTENTIOMETER
2
1
PIN 9 WIRE ___
I GAUGE
1
20
WIRE ___
3
1
1
WIRE _____
WINCH
SWITCH
BRAKE
WINCH
(optional)
WIRE 11
WIRE 28
WIRE 24
35
WIRE _____
HORN
SWITCH
WIRE 23
STROBE
LIGHT
ACTUATOR
HORN
PIN 12 WIRE 10
_
WIRE 26
FIELD
PIN 16 WIRE 14A
BATTERY POST
NEG. -
__3
E
IR
E-STOP
PIN 10 WIRE 16
18
19
WIRE ___
MOTOR
B-
B- WIRE 3A
BATTERIES
WIRE 42
W
KEY SWITCH
PIN 4 WIRE 13
B+
Fuse
WIRE 23
3
WIRE ___
36
WIRE ___
5
WIRE ___
20 AMP CB
WIRE 27
Connector A
Sigma Drive
DJ Products
Pin Name
Name
WIRE
1
FWD
2
REV
3 Footswitch
4
Tiller SW Brake Micro Switch
13
5
Speed 1
6
Speed 2
7
Speed 3
Speed Switch
20
8 THR Wiper
9
Footpedal
Pot Wiper
1
10 Key Switch
Key Switch
18
11 Cont. P.S.
Front of Coil
11
12 Cont. DRVR
Back of Coil
10
13
EMBRK
Brake Wire
8
14 P. ST. DRVR
15 +12 DC O/P'
16 +5V POT HI
Pot
14
16
WIRE ___
PIN 13 WIRE 8
PIN 12 WIRE 13
11
PIN 11 WIRE ___
9
Troubleshooting Guide (Questions and Answers)
Q. When I turn the key on, nothing happens at all.
A. If the voltmeter doesn’t come on or you don’t hear the contactor click one of three things could be
bad. Check the battery voltage across all three batteries; you should have at least 36 volts. If that is
OK either the contactor is not working or the key switch is not working. To bypass the key switch take
the two wires going to the key switch and touch them together, if the key switch is bad the machine
should turn on. To bypass the contactor please call Lindbergh Aircraft Tug Co. service dept. for further
tests.
Q. When I plug the onboard charger into the wall one or more of the banks say check connection.
A. Check the fuse on that bank(s) to see if it is blown. Check the connection to the battery terminal. If
both of these things are OK the battery voltage on the bank(s) is probably below 9 volts. The charger
has a safety feature on it, when the battery voltage drops below 9 volts the charger says check connection and shuts down that bank. Either charge that battery with an external charger to bring the
voltage up or cycle the power on the charger by plugging in the charger and unplugging it every 5 to
10 minutes until that bank shows it in charging mode.
Q. When I plug in my onboard charger no lights come on at all.
A. Try plugging it into a different outlet, if that doesn’t work call Lindbergh Aircraft Tug Co., you may
need a new charger.
Q. When I press the optional horn button the horn does not sound.
A. Check the connections to the horn and the horn switch. If OK you can hook the horn directly to 36
volts, if the horn sounds then your switch is bad.
Q. When I rotate the handle bar it does not snap back into the center position.
A. The torsion spring has either slipped off the centering bolt or the spring has broke. Take the screws
out of the control box to and pull the box apart, the bottom part will pull completely off and the top
part can rotate up. Inspect the torsion spring to make sure it is in the proper position.
Q. The AircraftCaddy shows full power until I start using it, then the needle on the voltmeter drops
down into the red.
A. You probably have one or more bad batteries. You can check the batteries with a multi-meter but a
load cell tester is preferred. You should have 12 volts on each of the batteries; you may have a bad cell
in one or more of the batteries causing the machine to loose power.
10
Instructions For Use Of The AircraftCaddy
Wheel Guide and Spring Ramp Configuration
The AircraftCaddy has a “lazy susan” or “fifth wheel” arrangement where the aircraft nose wheel goes. This
allows for greater maneuverability when moving the airplane, as the tug can be turned through a wide
range of angles without turning the aircraft nose wheel. However, this doesn’t work so well if the nose
wheel has fairings (wheel pants), as there can be interference between the fairings and the tug structure.
So the lazy susan can be locked in the centered position for use with fairings, or unlocked to rotate freely
if there are no fairings. Looking at the front of the tug, you will notice a hollow bolt looking thing with a
right-angle pin sticking out. This is the locking pin. To unlock, pull it up and rotate to the side so it stays up.
To lock the lazy susan, rotate it until it is centered with the open end toward the front, then drop the locking pin. Verify that the lazy susan is actually locked and won’t rotate.
Now see the structure on the lazy susan that looks like a truncated V. This is the wheel chock. It is only three
inches high to allow clearance below some wheel fairings. For wheels with no fairings or high-clearance
fairings, there is a drop-on chock extender that increases the chock height to six inches. The higher chock
provides greater security of the nose wheel on the tug and should be used only when no fairings are present.
1. Unplug the power cord and wrap it around the brackets provided at the rear of the base, or just wrap it
around the handle.
2. Turn on the battery power using the Power Switch at the left rear of the tug. The key has a yellow hang
tag. You will hear the battery relay click. The voltmeter should show a full charge.
NOTE: When power is turned on, the tug’s motor controller performs some internal diagnostics to ensure
proper operation and thus safety. Please allow at least five seconds for completion of these diagnostics,
during which the tug will be unresponsive to commands from the handlebars. Also, as a safety feature,
if the handlebars are rotated out of the neutral position when power is applied or during the diagnostic
period, the controller will not respond until the handlebars are returned to their neutral position. This is
to prevent a surge of motion if the machine is turned on with a high-speed command present from the
handlebars.
3. Grasp the handlebars and slowly rotate them forward and backwards. The handlebars are a variable
speed, which means the further you turn them the faster the tug will go.
NOTE: If at any time you are uncomfortable with how the tug is moving, just let go of the handlebars. It will
come to a quick but smooth stop and will remain in place. It has an electric brake that operates in a smooth
and controlled manner when the handlebars return to their neutral position.
4. Maneuver the tug to your airplane. If this is your first time using it, practice maneuvering it around on
the hangar, both forward and backward, at various speeds, stopping and starting, and turning both ways,
before connecting it to your airplane.
NOTE: Never allow anyone to ride on the tug.
5. Maneuver the tug to a position directly in front of and pointed at the airplane’s nose wheel. Stop with
(continued on next page)
11
Instructions For Use Of The AircraftCaddy Continued
the front of the tug a foot or so from the wheel, or even with the spring ramp touching the nose tire if you
have enough working room. Make sure the spring lock on the lazy susan is in place if you are working with
a wheel pant over the nose wheel, and remove it if it’s a retractable wheel or just doesn’t have a wheel pant.
6. Now you need to load the airplane nose wheel onto the tug using the electric or hand winch mounted to
the tug hood.
(Note if using an electric winch that the winch has a red handle on a knob on the left side. Turning this
knob counterclockwise will release the spool and allow it to free spool, useful for pulling cable out. Turning
it clockwise will engage the gearing and allow the spool to be turned under power. Never turn the knob
when the cable is under tension or when the spool is moving under power. A rocker switch having a center
off position and two spring-return operating positions is mounted near the tug handlebars. Pressing the
upper part of the switch will cause the winch to turn in the direction that pays out cable, and pushing the
bottom part of the switch will cause the winch to take in cable. When the cable is slack, guide it by hand
until it begins to take up tension, to avoid a cable snarl on the spool. Be very careful of your hands and
fingers around the winch! )
a. If the nose wheel has no wheel pant, install the 6” chock extender, otherwise you will need to use the 3”
chock extender for planes with wheel pants. Pull out some winch cable and connect the strap around the
strut and to the winch cable hook. Take up the slack and winch the wheel up onto the cradle until the tire
contacts the stop (“chock”). Be sure the airplane brakes are off and that there are no chocks in front of the
main wheels. The winch is powerful, so exercise caution to make sure the airplane can move freely, to avoid
damage to the strut.
7. Once the nose wheel is on the tug platform, you need to secure it there for transport to keep it from
rolling back off or bouncing up and possibly over the chock. A Velcro strap is provided to go over the nose
wheel or nose wheel pant to prevent the wheel from rising up and/or rolling over the chock when the
airplane main wheels encounter some obstacle such as a lip at the hangar entrance when you are pushing
it back into the hangar. Keep the winch connected with tension in the cable so that the nose wheel is tight
against the chock.
8. Ensure that the airplane brakes are off and there are no chocks in front of the wheels. Maneuver the
airplane to the desired location, starting and stopping slowly. Enlist the assistance of a ground guide if
possible to watch wing and tail clearance. Carefully monitor for any interference between the tug and any
wheel fairings during turns.
9. Chock the airplane main wheels front and back. (Once you have some experience doing this, you may
find that you can dispense with that.) Disconnect the winch cable and the security strap. Wind up the
winch cable, keeping some tension on the cable so that it winds smoothly. Now slowly back the tug out
from under the nose wheel, allowing it to roll down the spring ramp as you back away. When the airplane is
down, back away enough to give yourself some working room.
12. Turn off the power switch. REPEAT: TURN OFF THE POWER SWITCH!
13. Plug in the power cord.
12
Instructions For Use Of The AircraftCaddy
Wheel Cradle Configuration
The AircraftCaddy has an easy on/off wheel cradle that scoops up the aircraft nose wheel. Scooping up
the nose wheel reduces the time and energy involved in the capturing of the aircrafts nose without using a winching system. Under the wheel cradle there is a turn table that resembles a “lazy susan” or “5th
wheel turning” that results in greater maneuverability when moving the airplane, as the tug can be turned
through a wide range of angles without turning the aircraft nose wheel. However, this doesn’t work so
well if the nose wheel has fairings (wheel pants), as there can be interference between the fairings and the
cradle itself. If your aircraft has a fairing (wheel pant) then you should be looking at our wheel guide and
spring ramp configuration.
Loading procedure:
1. Unplug the power cord and wrap it around the brackets provided at the rear of the base, or just wrap it
around the handle.
2. Turn on the battery power using the Power Switch at the left rear of the tug. The key has a yellow hang
tag. You will hear the battery relay click. The voltmeter should show a full charge.
NOTE: When power is turned on, the tug’s motor controller performs some internal diagnostics to ensure
proper operation and thus safety. Please allow at least five seconds for completion of these diagnostics,
during which the tug will be unresponsive to commands from the handlebars. Also, as a safety feature,
if the handlebars are rotated out of the neutral position when power is applied or during the diagnostic
period, the controller will not respond until the handlebars are returned to their neutral position. This is
to prevent a surge of motion if the machine is turned on with a high-speed command present from the
handlebars.
3. Grasp the handlebars and slowly rotate them forward and backwards. The handlebars are a variable
speed, which means the further you turn them the faster the tug will go.
NOTE: If at any time you are uncomfortable with how the tug is moving, just let go of the handlebars. It will
come to a quick but smooth stop and will remain in place. It has an electric brake that operates in a smooth
and controlled manner when the handlebars return to their neutral position.
4. Maneuver the tug to your airplane. If this is your first time using it, practice maneuvering it around on
the hangar, both forward and backward, at various speeds, stopping and starting, and turning both ways,
before connecting it to your airplane.
NOTE: Never allow anyone to ride on the tug.
5. Maneuver the tug to a position directly in front of and pointed at the airplane’s nose wheel. Stop with
the front of the tug a foot or so from the wheel, or even with the bottom of the wheel cradle (in the down
position) touching the nose tire.
(continued on next page)
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Instructions For Use Of The AircraftCaddy Continued
6. Now you need to load the airplane nose wheel onto the tug by slowing driving the tug forward while
the nose wheel turns up the ramp, rocking the cradle ramps backwards until it’s in the locked position. This
loading can also be accomplished with an electric or manual winch.
(Note: if using an electric winch that the winch has a red handle on a knob on the left side. Turning this
knob counterclockwise will release the spool and allow it to free spool, useful for pulling cable out. Turning
it clockwise will engage the gearing and allow the spool to be turned under power. Never turn the knob
when the cable is under tension or when the spool is moving under power. A rocker switch having a center
off position and two spring-return operating positions is mounted near the tug handlebars. Pressing the
upper part of the switch will cause the winch to turn in the direction that pays out cable, and pushing the
bottom part of the switch will cause the winch to take in cable. When the cable is slack, guide it by hand
until it begins to take up tension, to avoid a cable snarl on the spool. Be very careful of your hands and
fingers around the winch! )
7. Once the nose wheel is on the tug platform, you need to secure it there for transport to keep it from
rolling back off or bouncing up and possibly over the chock. A Velcro strap is provided to go over the nose
wheel or nose wheel pant to prevent the wheel from rising up and/or rolling over the cradle when the
airplane main wheels encounter some obstacle such as a lip at the hangar entrance when you are pushing
it back into the hangar.
8. Ensure that the airplane brakes are off and there are no chocks in front of the wheels. Maneuver the
airplane to the desired location, starting and stopping slowly. Enlist the assistance of a ground guide if
possible to watch wing and tail clearance. Carefully monitor for any interference between the tug and any
apperattis on the strut of the airplane.
9. Chock the airplane main wheels front and back. (Once you have some experience releasing the aircrafts
nose wheel, you may find that you can eliminate the chocking procedure.) Disconnect the winch cable
and the security strap if you used one. Wind up the winch cable, keeping some tension on the cable so that
it winds smoothly. Line the AircraftCaddy directly parallel with the front of the aircraft so the front of the
wheel cradle is in the 12 o’clock position. Pull the lever handle located just forward from the handlebars
towards you and the cable should release the locks of the wheel cradle to allow the nose wheel to drop
down the front cradle ramp (Note: the cable operates two paddles that lift two latches that lower the front
wheel ramp. These have to be lined up for the latches to activate). Now slowly back the tug out from under
the nose wheel, allowing it to roll down the cradle ramp as you back away. When the airplane is down, back
away enough to give yourself some working room.
12. Turn off the power switch. REPEAT: TURN OFF THE POWER SWITCH!
13. Plug in the power cord.
14
Warranty
IMPORTANT: Read this entire Limited Warranty before using the DJProducts product. The
DJProducts product (or other DJ Products Inc. product-collectively referred to herein as the
"Product" whether it be a unit or major product component part) manufactured by DJ Products Inc., a Minnesota corporation ("Manufacturer") is believed to be reliable if the directions
for its use, maintenance, and operating procedures are followed carefully. However, it is impossible to eliminate all risks inherently associated with the use of this Product. Risk of failure,
including personal injury, dismemberment, injury to property or even death, may result from
misuse, abuse, neglect, negligent use, accidental or intentional damage, ordinary wear and
tear, violation or omission of standard operating procedures, improper maintenance, failure
to perform routine and preventive maintenance, alterations, additions and/or modifications
to the Product, use by any individual not fully trained and fully authorized operator, and
improper training of the operator, all of which are beyond the control of the Manufacturer. All
such risks are fully assumed by the purchaser/customer of the Product referred to herein as
the ("Customer").
Manufacturer offers a limited warranty (the "Limited Warranty") to each Customer who is the
original purchaser of this Product that, effective for a period of one year ("Limited Warranty
Period") from the date of shipment of the Product to the Customer, that the Product is free
from defects in material or workmanship in normal use and service. Should any major Product component part prove not to conform to foregoing Limited Warranty, the remedies of
Customer for any breach of the foregoing Limited Warranty shall be limited to the repair or
replacement of the major Product component part.
IN NO EVENT SHALL MANUFACTURER'S OBLIGATIONS PURSUANT TO THIS LIMITED WARRANTY
EXCEED THE PURCHASE PAID TO THE MANUFACTURER BY THE CUSTOMER FOR THE PARTICULAR PRODUCT INVOLVED, TO THE EXCLUSION OF ALL OTHER REMEDIES OR LIMITATIONS, INCIDENTAL OR CONSEQUENTIAL DAMAGES. The Limited warranty, which is Customer's EXCLUSIVE REMEDY, shall be FURTHER LIMITED as follows:
1. If the defect in material or workmanship of the major Product component part is disclosed to the Manufacturer by the Customer prior to the expiration of the Limited Warranty
Period, the Limited Warranty shall be the manufacturer's cost of replacing the defective major
Product component part with a factory certified major Product component part (excluding
repair labor). Any replacement of major Products component parts shall occur at the Manufacturer's (or authorized service provider) place of business. In order to obtain a warranty service, the Customer must return the defective component part to the Manufacturer within the
Warranty Period, together with proof of purchase by Customer establishing date of delivery,
with freight charges and applicable costs of repair, if any, prepaid, any repaired or replaced
component part covered by the Limited Warranty, to the Customer’s facility located within
the continental United States. After the component part has been repaired or replaced, the
original Limited Warranty is still in effect on the replaced or repaired component part.
(continued on next page)
15
Warranty Continued
The Limited Warranty is invalid if the factory-applied serial number has been altered or removed from the Product. The Limited Warranty does not cover cosmetic damage or damage
due to acts of God, accident, misuse, abuse, neglect, negligent use, accidental or intentional
damage, ordinary wear and tear, violation or omission of standard operating procedures,
improper maintenance, failure to perform routine and preventative maintenance, alterations,
additions and/or modifications to the Product, use by any individual not a fully trained and
fully authorized operator, and improper training of the operator, or repair or attempted repair by anyone other than Manufacturer or its authorized agents, nor to any Product which is
leased or used as rental equipment. The occurrence of any of the foregoing voids the Limited
Warranty.
This Limited Warranty does not cover Customer instruction or training. THIS LIMITED WARRANTY PROGRAM IS EXCLUSIVE AND IS GIVEN AND ACCEPTED IN LIEU OF ANY AND ALL OTHER
WARRANTIES, WHETHER WRITTEN OR ORAL, EXPRESSED OR IMPLIED OR INFERABLE FROM THE
COURSE OF DEALING OR USAGE OF TRADE, INCLUDING, WITHOUT LIMITATION, THE IMPLIED
WARRANTY OF MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND ANY IMPLIED WARRANTY ARISING FROM PERFORMANCE, COURSE OF
DEALING OR USAGE OF TRADE, AND ALL OTHER OBLIGATIONS, LIABILITIES, RIGHTS, CLAIMS
OR REMEDIES, INCLUDING ANY RIGHT IN CONTRACT, TORT, STRICT LIABILITY OR ANY RIGHT
ARISING FROM MANUFACTURER'S NEGLIGENCE, ACTUAL OR IMPUTED FOR CLARIFICATION
ONLY (AND NOT IN ANY WAY TO EXPAND THE FOREGOING EXCLUISVE REMEDIES):
A) UNDER NO CIRCUMSTANCES WILL MANUFACTURER BE LIABLE FOR LOST PROFITS OR
ANY OTHER INCIDENTAL, CONSEQUENTIAL, SPECIAL OR INDIRECT DAMAGES RESULTING
FROM THE PURCHASE OR USE OF THIS PRODUCT, INCLUDING, WITHOUT LIMITATION, ECONOMIC LOSS, COST OF CAPITAL, CLAIMS OF CUSTOMERS FOR FAILURE OF SUPPLY OR LOSS OF
USE OR DAMAGE TO PERSONS OR TO OTHER PROPERTY, NOTWITHSTANDING THE FACT THAT
THE MANUFACTURER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES;
B) THE TOTAL LIABILTIY OF THE MANUFACTURER TO CUSTOMER SHALL NOT EXCEED THE
TOTAL PURCHASE PRICE PAID BY THE CUSTOMER TO MANUFACTURER FOR THE PARTICULAR
PRODUCT INVOLVED; AND (C) NO AGREEMENT VARYING OR EXTENDING THE FOREGOING
WARRANTIES, REMEDIES OR LIMITATIONS WILL BE BINDING UPON THE MANUFACTURER UNLESS IN WRITING AND SIGNED BY A DULY AUTHORIZED CORPORATE OFFICER OF THE MANUFACTURER.
If any terms or conditions of this Limited Warranty program is in violation of applicable local, state, or federal law, this Limited Warranty program shall not be voided in its entirety, but
rather, the court, or other appropriate authority having jurisdiction in the matter, shall rewrite
and reform the Limited Warranty to the minimum extent required so as to be permitted under
applicable law.
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