M a n u f a c t u r i n g S o l u t i o n s S i n c e 1 9 6 6 Page 1

727, 737, A319, A320 TOWBAR Towbar Specifications, Usage, Preventive Maintenance, and Parts

MANUAL (Includes Optional Hydraulic Lift, Soft Start, & Latch Stops)

For ordering New Towbars or Replacement Parts Please Contact:

Penny Shirk @ 724-752-2000 Or Fax @ 724-758-1558 Or Email service@hallindustries.com Hall Industries, Inc. 514 Mecklem Lane Ellwood City, PA 16117 July 6, 2012 724-752-2000 Revision 03

M a n u f a c t u r i n g S o l u t i o n s S i n c e 1 9 6 6 Page 2

0. Index

Section Description Page One Specifications 2 Two Operating Procedures 3 Three Preventive Maintenance 5 Four Replacement Part Kits / Assemblies 6 Five Ordering Info 7 Six Attachment List 8

1. Specifications

1.1. Physical Specifications Part Number Description Weight Length 1000-1X-20-3X-4X-50 Tube & Eye with Hardware 116 lb 13’-3 5/8” TB-8312 Towbar Head with Adapter 60 lb 20 11/16” TB-9267 Full Assembly (27” Height x 20” Wide) 208 lb 15’-5/16”

With Fixed Wheel Carriage TB-9267-HL Full Assembly (27” Height x 20.5” Wide) 272 lb 15’-5/16”

With Lift Kit Wheel Carriage

1.2. Shear Pin Info Shear Pin TB-8312-B6 Shear Value: 18,900 lbs

NOTE: Shear pins are produced in controlled batches; only use Hall Industries replacement shear pins. Shear pin testing and manufacturing records are permanently kept on file for reference.

1.3. Warranty: All parts are guaranteed against manufacturing defects for one year. If at any time this manual is not followed it will void the warranty (preventive maintenance logs are required for all warranty replacement parts). All replacement parts must be genuine Hall Industries parts.

M a n u f a c t u r i n g S o l u t i o n s S i n c e 1 9 6 6 Page 3

2. Operating Procedures NOTE: This must be done in accordance with the aircraft manual.

2.1. Inspect the Towbar (Prior to hooking up the towbar to the tug visually inspect):

2.1.1. Check for a bent or damaged frame and for worn or missing parts.

2.1.2. Check tires for damage.

2.1.3. Check that you have the correct towbar.

2.1.4. Check the shear pin to see if it is the correct pin for the towbar. Also check that

the shear pin is fully seated with washers and a nut securing it in place.

NOTE: DO NOT attempt to tow any aircraft with a damaged or incorrect towbar.

2.2. Responsibility

Operator of the tug must understand that it is his/her responsibility to move the aircraft

safely the entire time that they are connected to the plane.

NOTE: No speeding during push and pull.

2.3. Hooking Up to the Plane ~ Checks:

2.3.1. You are using the proper tug and towbar for the size aircraft being moved.

2.3.2. The towbar you are using is approximately level between the aircraft and the tug.

2.3.3.The eye end of the towbar must move freely on the hitch mounted on the tug.

2.4. Attach the Towbar to the Aircraft

2.4.1. First check that the towbar head latch is in the open position.

2.4.2. Line up towbar to nose pin of aircraft and slide head under the nose pin.

2.4.3. Lower the handle and lock the jaw to the nose pin. Due to the over-center

arrangement of the clamping mechanism, the jaws remain closed until the handle

is released by the operator. The head can only be disengaged by operation of the

handle. (If equipped make sure that the latch stop locking pin is inserted and is

M a n u f a c t u r i n g S o l u t i o n s S i n c e 1 9 6 6 Page 4

keeping the latch in the forward position. Or if equipped make sure the automatic

stop latch is functional.)

2.5. Attach the Towbar to the Tow Tractor

2.5.1. Lift to the level of the push backs hitch.

2.5.2. Position the push back tractor and install the hitch pin.

2.5.3. Tow or push the aircraft only if the tow bars tires are not touching the ground.

2.6. Push the Aircraft

NOTE: This must be done in accordance with the aircraft manual.

NOTE: If at any time the shear pin yields or breaks, carefully bring the aircraft to a stop.

Before pushing or towing can be continued a new shear pin must be inserted. Use only

Hall Industries shear pin (Part number ~ TB-8312-B6).

Basic Rules:

2.6.1. Prior to moving, make sure that the hydraulic steering bypass pin is engaged (if

applicable). Also double check that all the tie downs and chocks are removed and

aircraft brakes are released.

NOTE: This must be done in accordance with the aircraft manual. 2.6.2. Tow Slow, max speed is a brisk walk (Approximately 5 MPH). This will help to

minimize the chance of a jack-knife.

2.6.3. Do not exceed Aircraft nose wheel angle of towing limits. If not marked or not

known, do not exceed 30° from center. Be extra cautious on snow and ice.

2.6.4. If you are driving make sure that you have plenty of help; “wing walkers” are

helpful.

2.6.5. Make sure the operator / driver has direct contact with the pilot at all times while

moving the aircraft.

M a n u f a c t u r i n g S o l u t i o n s S i n c e 1 9 6 6 Page 5

NOTE: Thousand of dollars in damage can occur in a few seconds while towing. It is

estimated that 90% of towing damage is due to operator negligence / error. Accidents

can be fatal.

2.7. Disconnect the Towbar from the Tug

2.8. Disconnect the Towbar from the Aircraft

If equipped pull the locking pin or ASL and move the handle into the open position.

Carefully lower the tow bar to the ground (use hydraulic lift if installed), and then move

push back tractor and towbar clear of the aircraft.

3. Preventive Maintenance NOTE: Hall Industries recommends using this maintenance procedure monthly (or as required in your airlines maintenance procedure if sooner). Replace worn or damaged parts as needed.

3.1. Check Pivot, Capture, and Shear bolts (Part numbers TB-8312-B11 or B12, B6, B7); they

should be snug but not tight. They should not spin freely, but should be able to spin with the aid of a wrench. Over-tightening will clamp the adapter to the head, and the shear pin will not provide adequate safety protection. With the shear bolt removed, the head must be able to slide within the adapter plates.

NOTE: Do not over-tighten adapter bolts.

3.2. Check wheels and wheel carriage for bent, broken, or worn parts and security. Lubricate pivot points using Hall dry lubricant (Part number TB-LUBE).

3.3. Check head assembly for operation of lock mechanism; look for bending, security, etc. Lubricate pivot points using Hall dry lubricant (Part number TB-LUBE).

3.4. Inspect jaw assembly for worn or damaged parts and security.

3.5. Check latch mechanism to ensure proper travel back and forth. If equipped check stop latch locks. Lubricate pivot points.

3.6. Check latch mechanism locking force. The release force on the handle is set at the factory to a minimum of 20 pounds when clamped to an aircraft replacement Nose Pin. When performing PM you can lock it on to one of your Aircraft and/or a Test Pin (Part number TB-8312-TESTPIN) supplied by Hall Industries (do not use a regular hot rolled bolt as a test pin). To adjust the pressure, remove TB-8312-J4, turn the Swing Bolt TB-8312-J2 half of a revolution (clockwise to decrease pressure, counter-clockwise to increase pressure), and replace and retighten TB-8312-J4. Check the release force and repeat if necessary. With daily use, the some wear / increased clearances will be noticed the components of this adjustment are available as a kit (see kit section).

M a n u f a c t u r i n g S o l u t i o n s S i n c e 1 9 6 6 Page 6

NOTE: When closing/ locking of the handle force is too light, the attachment to the aircraft nose pin will be sloppy and excessive play will result. This can result in the handle opening during a push and loss of aircraft control.

3.7. Check tow eye and hardware (tug attachment) for condition and security. If the drag plate is worn and towbar head or eye is dragging purchase replacement drag plate kit (Part number AV1009-0001).

3.8. Check main body tube for bending or cracking.

3.9. Check shear pin and bushings for breakage, wear and security.

NOTE: If bushings are to be replaced, replace them as a set. Never replace only one bushing.

3.10. Clean, repaint or touch-up paint as required.

3.11. Inspect tags and labels; if damaged or missing replace (see the drawings in the attachment section for labels and placements).

3.12. If the towbar is equipped with a hydraulic lift; check the fluid reservoir (in the down / collapsed position). Add fluid if necessary (Part number TB-LUBE-L).

4. Replacement Part Kits / Assemblies

Part Number QTY (in Kit) Description

4.1. TB-8312-B6-KIT Shear Pin Kit

4.1.1. TB-8312-B6 1 Shear Pin

4.1.2. TB-8312-B9 1 Nut

4.1.3. TB-8312-B10 2 Washer

4.2. TB-9267-WL-BSH-KIT Bushing and Shear Pin Kit

4.2.1. TB-8312-B3 2 Shear Pin Bushing Adapter

4.2.2. TB-8312-MB6 1 Shear Pin Bushing Head

4.2.3. TB-8312-B6 1 Shear Pin

4.2.4. TB-8312-B9 1 Nut

M a n u f a c t u r i n g S o l u t i o n s S i n c e 1 9 6 6 Page 7

4.2.5. TB-8312-B10 2 Washer

4.3. TB-8312-J2-J3-KIT Swing Bolt / Toggle Hinge Kit (For Lock Mechanism)

4.3.1. TB-8312-J2 1 Swing Bolt

4.3.2. TB-8312-J3 1 Toggle Hinge

4.3.3. TB-8312-J2-N 1 Coupling Nut

4.4. TB-8312-BSH-KIT Bushing Kit

4.4.1. TB-8312-B3 2 Shear Pin Bushing Adapter

4.4.2. TB-8312-MB6 1 Shear Pin Bushing Head

4.5. TB-8312-TESTPIN 1 Pin for Checking Clamp Force

4.6. 1000-20 Eye Bolt Assembly

4.6.1. WH0110000SS0000 1 Flat Washer

4.6.2. 1000-1005 1 Curved Washer

4.6.3. 1000-1003 1 Shoulder Bolt

4.6.4. CN08C0000SS0000 1 Castle Nut

4.6.5. CP4280048SS0000 1 Cotter Pin

4.6.6. HRJ-145-12-7 1 Eye Bolt

5. Ordering Info

5.1. Accepted Payments Include (but not limited to):

5.1.1. Visa

5.1.2. MasterCard

5.1.3. American Express

5.1.4. Company Check Wire Transfer

5.2. Standard terms ~ NET 30 with approved credit

5.3. Minimum Orders ~ $50

M a n u f a c t u r i n g S o l u t i o n s S i n c e 1 9 6 6 Page 8

5.4. The Order Form is listed in the attachments of this document.

6. Attachment List

6.1. TB-9267 Full Assembly with Subcomponent Callouts

6.2. 1000-1X-20-3X-4X-50 Tube & Eye with Hardware

6.3. TB-8312 Head Assembly

6.4. TB-8898-2 Fixed Wheel Carriage

6.5. LIFT-15 4” O.D. Towbar Lift

6.6. TB-8898-10 Handle Assembly

6.7. TB-8312-LHA Latch Handle Assembly

6.8. TS-737-ASL Automatic Safety Latch

6.9. AV1009-0001 Drag Plate 4” Bolted

6.10. Soft Start Brochure

6.11. Order Form

6.12. Other Products and Custom Design Services

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M a n u f a c t u r i n g S o l u t i o n s S i n c e 1 9 6 6 Page 1

Other Products and Custom Design Services:

Hall Industries provides a number of additional products beyond our towbar line. Some of the custom projects that we have done are shown below. We have our own engineering staff along with machine, fabrication, and GSE maintenance shops. We can design and build your ideas to increase safety, productivity, and profits.

0017-0001 Custom Towbar (Solve a Problem) <<This project involved designing and manufacturing a custom towbar to be used in the Nuclear Industry. This towbar shipped complete with custom shear pins calibrated to the application.

IA-8980 Preconditioned Air Inlet (PCA) Adapters << Our PCA Inlet Adapters are part of our GSE product line. We inventory all of the parts and can ship usually the same day as ordered.>>

0010-0001 Certified Transmission Lifting Bracket (Meet a Demand) A customer came to us with a lifting problem. They needed a tested and certified lifting bracket to prevent them from getting cited by OSHA. We designed, tested, and fabricated a solution. >>

<<1000-3002 Adapter 8312 to Tronair 1000-0001 Hydro Adapter Assembly>> Hall Industries offers adapters for nearly every towbar (even competitors) that allow you to use our towbar tubes / heads with your existing equipment.

Besides the products listed above some of the other things that we sell include PCA ducting, Solid PBB tires, and baggage cart tires.

Feel free to contact us about your GSE problems; after all we are “The Problem Solvers”.