OPERATION AND MAINTENANCE MANUAL

WASP, Inc.
UPS 757 Towbar
Model No. A03812D
 WASP RECORD OF REVISIONS
REV. ISSUE DATE BY REV. ISSUE DATE BY
NO. DATE INSERTED NO. DATE INSERTED

Original Nov. 13/97

001 Oct. 10/02

002 July 19/05

003 Mar. 09/06

004 Nov. 07/11

005 Apr. 10/13

006 Oct. 17/14

LIST OF EFFECTIVE PAGES

SECTION PAGE DATE

R List of Effective Pages 3 Oct. 17/14

Table of Contents 4 Apr. 10/13
Warranty 5
Operations 6 Nov. 13/97
R Operations/Maintenance 7 Apr. 04/02
R Operations/Maintenance 7A Aug. 08/00
R Overcenter Clamp Adjustment Procedure 8 Nov. 07/11
R Retainer Bolt Tightening Procedure 9 Apr. 10/13
Illustrated Parts List 10 Nov. 13/97
R Illustration (Main Assembly) 11B July 19/05
R Parts List 11 Mar. 09/06
R Illustration (Towing Pin Head Assembly) 12B Oct. 10/02
R Parts List 12 Oct. 10/02
Illustration (Swivel Lunette Assembly) 13A Nov. 13/97
Parts List 13 Nov. 13/97
R Illustration (Wheel Carriage Assembly) 14A Oct. 17/14
R Parts List 14 Oct. 17/14
Notes 15

List of Effective Pages

Oct. 17/14
Page 3
TABLE OF CONTENTS

PAGE

Title Page
Record of Revisions
List of Effective Pages
Table of Contents

Warranty 5
Operations 6
Operations/Maintenance 7
Operations/Maintenance 7A
Overcenter Clamp Adjustment Procedure 8
Retainer Bolt Tightening Procedure 9
Illustrated Parts List 10
Illustration (Main Assembly) 11B
Parts List 11
Illustration (Towing Pin Head Assembly) 12B
Parts List 12
Illustration (Swivel Lunette Assembly) 13A
Parts List 13
Illustration (Wheel Carriage Assembly) 14A
Parts List 14
Notes 15

Table of Contents
Apr. 10/13
Page 4
 SPECIAL WASP/UPS GSE WARRANTY
WASP, Inc. warrants, to United Parcel Service, each of its new ground support equipment products to
be free from defects in material and workmanship under normal and recommended use and service,
subject to the conditions and qualifications herein set forth. The obligation of WASP, Inc. hereunder is
limited to the repair or replacement, both parts and labor, of those parts which WASP, Inc., at its sole
reasonable discretion, determines to have failed as a result of defects in material or workmanship within
a period of thirty-six (36) months after the date the unit is put into service. WASP, Inc. further
warrants all major structural components produced by WASP, Inc. to be free from defects in material
and workmanship under normal and recommended use and service for a period of sixty (60) months,
subject to the conditions and qualifications herein set forth. This warranty is effective on all equipment
built after August 1, 2004 and serial number 168814.

No warranty of any kind, statutory, implied or otherwise is made or shall be imposed upon WASP, Inc.
with respect to:

1. Second-hand parts or components if not installed or authorized by Wasp.

2. New parts or components which, after shipment from the factory of it's origin, have been subject
to operation in excess of the recommended capacities, misuse, abuse, negligence, or accident, or have
been altered or repaired in any manner not authorized by WASP, Inc.

3. Failures resulting from the use of attachments not sold or approved by WASP, Inc.

4. Tires, batteries, motors, engines, hydraulic and electrical components, and other expendable
components, except that WASP, Inc. agrees to make available to UPS whatever warranty benefits may
be made available from the original manufacturer to WASP, Inc. for these purchased components.
WASP’s obligation shall be limited to the extent of the warranties received from the manufacturer.

WASP, Inc. will repair, or at its option replace any part of its new products which under normal use
and service fail to conform to this Warranty, providing that such part shall be returned to WASP, Inc.
or to an Authorized Representative or Dealer of WASP, Inc. transportation charges prepaid.

This Warranty is express in lieu of any other Warranties, expressed or implied, including any Warranty
of merchantability or fitness for a particular purpose.

This Warranty shall immediately become void if any service other than normal maintenance, is
performed by anyone other than WASP, United Parcel Service or its authorized service personnel; or if
any alteration or modification is made that materially effects the failure without the prior consent of
WASP, or if, in the sole discretion of WASP, Inc., the failure is due to abuse or neglect in the operation
or maintenance of the product due to failure to follow the provisions set forth in the Operator's Manual.

This Warranty shall cover parts and labor with labor to be reimbursed to United Parcel Service at a
rate of $52.00 per hour.

For Warranty Help Call 1-320-634-5126 Ask For Warranty Department.

Warranty
Page 5
OPERATIONS

This towbar is designed to push or pull all Boeing 757 Aircraft equipped with a 1.50 inch
diameter nose gear cross pin. The following operational instructions are only intended to
familiarize the operator with the basic functions of the towbar. They are not intended to
teach actual pushback procedures or techniques.

RAISING AND LOWERING

The towbar is equipped with a hand operated hydraulic pump/tank, which supplies a flow
of hydraulic oil to a single acting hydraulic cylinder. This cylinder raises or lowers the
wheel carriage assembly to which the tires are attached. To raise the towbar, first make
sure the fill cap on the tank is in the “vent” position and the small control valve located on
the side of the pump is in the complete closed (clockwise) position. Actuate the pump
handle until the desired elevation is achieved. To lower the unit, turn the control valve
handle counter-clockwise until hydraulic oil flows back into the tank and allows the
cylinder to retract. Close the valve when the towbar has reached the desired elevation.

ATTACHING TO THE AIRCRAFT

The towbar is equipped with a “jaw” type attachment head. When attached properly it
will allow the aircraft to be pushed or pulled safely. To attach the towbar to the aircraft,
raise or lower the towbar so that it is level to the ground and at the same height as the nose
gear attachment point. Open the jaws by pulling the black knob outward and opening the
center jaw by pulling up on the large handle. Position the lower jaws under the nose gear
cross shaft and clamp the middle jaw around the shaft by pushing back down on the large
handle until the black knob moves back into the locked position.

SHEAR BOLTS

The towbar is also equipped with shear bolts that are designed to shear when the design
limits of the aircraft nose gear are exceeded. One set of spare shear bolts has been
provided with the towbar.

Operations
Nov. 13/97
Page 6
 IMPORTANT !!
NEVER use other bolts in place of factory supplied shear bolts - aircraft damage may
result !! In the event that the shear bolts should fail during operation, carefully inspect all
parts of the towbar for damage before replacing the shear bolts and returning the towbar
to service.

ATTACHING TO TRACTOR

The towbar is equipped with a towing eye that swivels to eliminate any possible binding
due to irregular terrain or camber changes in the aircraft nose gear during pushback or
towing operations. To attach the towbar to the tractor, raise or lower the towbar so that it
is level with the ground and at the same height as the tractor hitch point. Position the
lunette eye into the hitch opening and secure the hitch pin according to the tractor
manufacturer’s instructions. The towbar can be safely towed on typical ramp surfaces up
to 15 MPH. Exceeding this speed may result in damage to the towbar.

MAINTENANCE

Towbar maintenance should be done at least once every three months or sooner depending
on usage.

1. Check shear bolts for wear or a partial shear and replace if necessary. Check bolts by
rotating them and looking for movement of the shear plates at the same time.
2. Check shear plates for seizing from corrosion and apply a fresh coating of Permatex
Anti-seize lubricant or equivalent to assure free movement and proper shearing of
Shear bolts. Apply Permatex anti-seize lubricant or equivalent when installing a
new head assembly or shear bolts.
3. Check tire pressure and inspect for wear or damage.
4. Check the hydraulic fluid in the reservoir and maintain at the correct level.
5. Check for hydraulic leaks.
6. Check all nuts, bolts, and screws for tightness.
7. Check the unit overall for wear or damage.
8. Grease hubs through zerk provided in hub.

Operations/Maintenance
Apr. 04/02
Page 7
Operations/Maintenance
Overcenter Clamp Adjustment Procedure
Nov. 07/11
Page 8
Retainer Bolt Tightening Procedure
Apr. 10/13
Page 9
ILLUSTRATED PARTS LIST

The following illustration and parts list should be used to order parts for repairs. When
ordering parts, match the item number in the illustration with the item number on the
parts list, and then order using the part number following the item number in the parts
list.

Illustrated Parts List

Nov. 13/97
Page 10
MAIN ASSEMBLY PARTS LIST

ITEM QTY. PART # DESCRIPTION

1 1 W005222B Chassis Tube Weldment

2 1 A002574A Swivel Lunette Assembly, See Page 10
3 1 A003811B Towing Pin Head Assembly, See Page 9
4 1 H006322 Hand Pump
5 1 A003683A Wheel Carriage Assembly, See Page 11
R 6 1 H002112 1/4” x 1/4” Str. Hydraulic Street Swivel
7 1 A003021A 1/4” x 38” Lg. Hyd. Hose Assembly
8 1 H005115 Hydraulic Cylinder
9 2 H005116 Spring
10 1 H001445 1/4” x 90 deg. Hydraulic Street Swivel
11 1 P054191A 1” Cylinder Mount Pin
R 12 2 H001148 3/16” x 1-1/2” Lg. Cotter Pin
R 13 4 H001251 3/8” NC x 1.25” Lg. Capscrew
14 4 H001388 1/2” x 6” Lg. Capscrew
15 4 H001001 1/2” NC Nylok Nut
16 4 H005184 5/16” NF x 2-1/2” Lg. Shearbolt
17 4 H002587 5/16” NF Nut
18 4 H004560 1/16” x 1” Lg. Cotter Pin
19 1 H001424 3/4” NC x 3-1/2” Lg. Capscrew
20 1 H001051 3/4” NC Nylok Nut
21 4 H001010 3/8” NC Nylok Nut
22 4 H005881 5/16” x 3/4” x 1/2” Lg. Headless Press Bushing
23 2 P057367A Spacer Flat
24 3 H005871 “Shearbolt” Decal
25 1 H005872 “Open Valve Before Towing” Decal
R 26 1 P060934A “757” Decal
R 27 4 H001008 3/8” Flat Washer
R 28 1 H005650 1/4” x 1.00” Lg. AB Sheet Metal Screw
R 29 1 H001300 1/2” Vinyl Coated Clamp
R 30 1 P065280A “ONLY” Decal
R 31 6 H007369 Decal, Asset Numbers 0-9
R 32 2 H007370 Decal, Asset Letters UPS
R 33 1 H007373 Decal, UPS Shield

Main Assembly Parts List

Mar. 09/06
Page 11
TOWING PIN HEAD ASSEMBLY PARTS LIST

ITEM QTY. PART # DESCRIPTION

1 1 W005346B Head Weldment

2 1 P060332A Towing Pin Pivot Head
R 3 1 W006847A Actuator Weldment
R 4 1 A005131A Turnbuckle Assembly
R 5 -- --- ---
6 2 P054534A Actuator Spacer
7 2 P057170A Actuator Spacer
8 2 H002826 3/8” x 1-1/2” Lg. Roll Pin
R 9 1 H002228 5/8” NC x 5” Lg. Capscrew
R 10 1 H002716 5/8” NC Jam Nylok Nut
R 11 1 H001000 1/2” NC x 5” Lg. Capscrew
R 12 1 H002714 1/2” NC Nylok Jam Nut
13 1 P059271A Lockpin
R 14 1 H005112 Lockpin Spring
15 1 H005186 Lockpin Knob
16 1 H002634 3/8” NC Jam Nut
17 1 H001251 3/8” NC x 1-1/4” Lg. Capscrew
R 18 -- --- ---
R 19 1 H001299 Black Handle Grip
R 20 REF. H005184 5/16” NF x 2-1/2” Lg. Shearbolt
R 21 REF. H002587 5/16” NF Nut
R 22 REF. H004560 1/16” x 1” Lg. Cotter Pin
R 23 REF. H005881 Headless Press Bushing

NOTE: Complete assembly can be ordered by part number A003811B.

Towing Pin Head Assembly Parts List

Oct. 10/02
Page 12
SWIVEL LUNETTE ASSEMBLY PARTS LIST

ITEM QTY. PART # DESCRIPTION

1 1 W003887A Hitch Pin Weldment

2 1 W003888A Pin Block Weldment
3 2 P054190A Pivot Washer
4 1 H001177 1-1/4” NF Slotted Nut
5 1 H001219 3/16” x 2” Lg. Cotter Pin
6 1 H004701 1-1/4” SAE Washer

NOTE: Complete assembly can be ordered by part number A002574A.

Swivel Lunette Assembly Parts List

Nov. 13/97
Page 13
WHEEL CARRIAGE ASSEMBLY PARTS LIST

ITEM QTY. PART # DESCRIPTION

1 1 W003889A LH Wheel Plate Weldment

2 1 W003890A RH Wheel Plate Weldment
3 2 P054192A Hydraulic Cylinder Mounting Plate
4 1 P054193A Spindle Tube Connector
5 1 P054194A Cylinder Mounting Pin
6 2 P054195A Spacer Mounting Rod
7 4 H001001 1/2” NC Nylok Nut
8 2 P054196A Spacer Tube
9 4 P054197A Spacer Tube
10 2 P054198A Wheel Assembly Washer
11 2 P054199A Sleeve Bushing
12 1 P054200A Wheel Assembly Mounting Rod
13 2 H001251 3/8” NC x 1-1/4” Lg. Capscrew
14 2 H006193 Wheel, 12” Dia x 3” Rubber on Iron
15 6 H001154 1/4” NC x 1-3/4” Lg. Capscrew
16 6 H001027 1/4” NC Nylok Nut
17 2 P059732A Spindle Round
18 2 H001286 3/4” NF Slotted Nut
R 19 2 H001148 3/16” x 1-1/2” Lg. Cotter Pin
20 2 H005060 Plug, 1” Plastic
21 2 H001056 3/4” Flat Washer
R 22 2 H001005 1/8” x 2” Lg. Cotter Pin
23 2 H004977 3/8” Lock Washer
R 24 - -- ---

NOTE: Complete assembly can be ordered by part number A003683A.

Wheel Carriage Assembly Parts List

Oct. 17/14
Page 14
 WASP, INC.

20631 STATE HWY. 55 - P.O. BOX 249

GLENWOOD, MN 56334
320-634-5886

NOTES