operation & maintenance manualcustomers.waspinc.com/manuals/a227266d operations... · equipment...

Operation & Maintenance Manual

Passenger Stair / Crewstair(A227266D)

April, 2014Revision (0) Date

Ground Support Equipment

© WASP, Inc. PRINTED IN THE U.S.A. Model A227266D

TABLE OF CONTENTS

TABLE OF CONTENTS

FRONT MATTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

GENERAL INFORMATION AND OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .19

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

OVERHAUL PROCEDURES (NOT APPLICABLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

ILLUSTRATED PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

MANUFACTURER’S APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

Equipment Model A227266D I Operation & Maintenance Manual

Equipment Model A227266D II Operation & Maintenance Manual

FRONT MATTER

FRONT MATTER

This Operation & Maintenance Manual was written to give the owner / operator instructions on the safe operationand maintenance of the WASP Inc. equipment. READ AND UNDERSTAND THIS OPERATION & MAINTENANCEMANUAL BEFORE OPERATING YOUR WASP INC. EQUIPMENT.

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Compliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Equipment Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

TITLE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Manufacturer’s Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

RECORD OF REVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Safe Operation Is The Operator’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Safe Operation Needs A Qualified Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Use Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Spark Arrester Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

SAFETY IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

TECHNICAL ADVISORIES / BULLETINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

FEATURES AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Standard Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16Optional Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Equipment Model A227266D 1 Operation & Maintenance Manual

FRONT MATTER

INTRODUCTION

Thank you for your decision to purchase a passengerstair / crewstair assembly from WASP Inc. To ensuremaximum performance of your equipment, it ismandatory that you thoroughly read and understand theoperation & maintenance manual and follow itsrecommendations. Proper operation and maintenanceare essential to prevent injury or damage and tomaximize equipment life.

Continuous improvement and advancement of WASPInc. products may result in changes to your equipmentthat may not be reflected in this publication. WASP Inc.reserves the right to make product improvements at anytime. Although great care has been taken to ensure theaccuracy of this publication, WASP Inc. does not assumeany liability for errors or omissions.

Safety Notice

Operate and maintain this equipment in a safe mannerand in accordance with all applicable local, state, andfederal codes, regulations and/or laws, and incompliance with on-product labeling and theseinstructions.

Make sure that all personnel have read this operation &maintenance manual and thoroughly understand safeand correct operating and maintenance procedures.

Purpose

The passenger stair / crewstair is used to safely providea means for passenger(s) / crew(s) to get to and from thetarmac to the aircraft.

Scope

This document outlines the specific design andperformance requirements for the use of a WASPpassenger stair / crewstair assembly. The word “must” inthis document indicates a mandatory requirement. Theuse of “should” indicates a recommendation of that whichis advised but not required.

Terms

The terms of this equipment can be found in the warrantysection of this manual. (See WARRANTY on Page 109.)

Modifications

Compliances

This WASP Inc. equipment complies with:

• OSHA Standard: 29 CFR 1910.29 Manual Propelledmobile stands and scaffolds (towers).

• California Code of Regulations Title 8 - Subchapter 7General Industry Safety Orders:

Group 4. General Mobile Equipment and AuxiliariesArticle 23. Mobile Ladder Stands and Scaffolds(Towers)3622. General and3627. Mobile Ladder Stands

Group 1. General Physical Conditions and StructuresOrdersArticle 2. Standard Specification3209. Standard Guardrails and3210 Guardrails at Elevated Locations

Figure 1

The directions left, right, front and rear, as mentionedthroughout this manual, are as viewed from the rear ofthe equipment [Figure 1].

P00070

REARFRONT

LEFT

RIGHT


SERIAL NUMBER LOCATION

Equipment Serial Number

Figure 2

The serial number (Item 1) [Figure 2] is located in frontof the right front caster of the passenger stair / crewstairassembly. Always use the serial number of theequipment when requesting service information or whenordering parts. Early or later models (identification madeby serial number) may use different parts, or it may benecessary to use a different procedure in doing a specificservice operation.

P00073

1


FRONT MATTER

TITLE PAGE

Manufacturer’s Information

WASP Incorporated

PO Box 249

20631 State Highway 55

Glenwood, MN 56334

Equipment Name: Passenger Stair / Crewstair Assembly

Manual Revision: 0

Publication Date: April 2014


RECORD OF REVISIONS

CHANGE DATE

EDITIONREVISION NUMBER

EFFECTED PAGES

CHANGE DESCRIPTION


FRONT MATTER

SAFETY PRECAUTIONS

Safe Operation Is The Operator’s Responsibility

WARNINGOperator must have instructions before operatingthe machine. Untrained operators can cause injury ordeath.

W-2013-001

CAUTIONThis notice identifies procedures which must befollowed to avoid damage to the machine.

I-2013-001

DANGERThe signal word DANGER on the equipment and inthe manuals indicates a hazardous situation which, ifnot avoided, will result in death or serious injury.

D-2013-001

WARNINGThe signal word WARNING on the equipment and inthe manuals indicates a potentially hazardoussituation which, if not avoided, could result in deathor serious injury.

W-2013-007

The WASP Inc. equipment must be in good operatingcondition before use.

Safe Operation Needs A Qualified Operator

For an operator to be qualified, he or she must not usedrugs or alcoholic drinks which impair alertness orcoordination while working. An operator who is takingprescription drugs must get medical advice to determineif he or she can safely operate a machine and theequipment.

A Qualified Operator Must Do The Following:

Understand the Written Instructions, Rules andRegulations

• The written instructions from WASP Inc. in thisOperation & Maintenance Manual and machine signs(decals).

• Check the rules and regulations at your location. Therules may include an employer’s work safetyrequirements.

Have Training with Actual Operation

• Operator training must consist of a demonstration andverbal instruction. This training is given by yourdepartment supervisor before the equipment isoperated.

• The new operator must start in an area withoutbystanders and use all the controls until he or she canoperate the equipment safely under all conditions ofthe work area.

Know the Work Conditions

• Know the weight of the materials being handled.Avoid exceeding the equipment load capacities.Reduce the size of load if handling heavy material.

• The operator must know any prohibited uses or workareas.

• Wear tight fitting clothing. Always wear safety glasseswhen operating, doing maintenance or service.

This symbol with a warning statement means:“Warning, be alert! Your safety is involved!”Carefully read the message that follows.

Safety Alert Symbol


SAFETY PRECAUTIONS (CONT’D)

Use Safety Rules

• Read and follow instructions on the equipment and inthe equipment’s Operation & Maintenance Manualbefore operating.

• In addition to the design and configuration ofequipment, hazard control and accident preventionare dependent upon the awareness, concern,prudence and proper training of personnel involved inthe operation, transport, maintenance and storage ofequipment.

• Check that the equipment is securely fastened to thetow vehicle (if required).

• Make sure all the equipment controls are in theNEUTRAL position before operating the equipment.

• Operate the equipment according to the Operation &Maintenance Manual.

• When learning to operate the equipment, do it at aslow rate in an area clear of bystanders.

• DO NOT permit personnel to be in the work areawhen operating the equipment.

• DO NOT modify equipment.

• DO NOT make any adjustments or repairs on theequipment while the engine is running.

• Keep shields and guards in place. Replace ifdamaged.

FIRE PREVENTION

Maintenance

The equipment may have components that are at hightemperatures under normal operating conditions. Theprimary source of high temperatures is the engine andexhaust system. The electrical system, if damaged orincorrectly maintained, can be a source of arcs or sparks.

Flammable debris must be removed regularly. Ifflammable debris is allowed to accumulate, it can causea fire hazard.

All fuels, most lubricants and some coolant mixtures areflammable. Flammable fluids that are leaking or spilledonto hot surfaces or onto electrical components cancause a fire.

Operation

Do not use the equipment where exhaust, arcs, sparks orhot components can contact flammable material,explosive dust or gases.

Electrical

Check all electrical wiring and connections for damage.Keep the battery terminals clean and tight. Repair orreplace any damaged part or wires that are loose orfrayed.

Battery gas can explode and cause serious injury. Usethe procedure in the Operation & Maintenance Manualfor connecting the battery and for jump starting. Do notjump start or charge a frozen or damaged battery. Keepany open flames or sparks away from batteries. Do notsmoke in battery charging area.


FRONT MATTER

FIRE PREVENTION (CONT’D)

Hydraulic System

Check hydraulic tubes, hoses and fittings for damageand leakage. Never use open flame or bare skin to checkfor leaks. Hydraulic tubes and hoses must be properlyrouted and have adequate support and secure clamps.Tighten or replace any parts that show leakage.

Always clean fluid spills. Do not use gasoline or dieselfuel for cleaning parts. Use commercial nonflammablesolvents.

Fueling

Stop the engine and let it cool before adding fuel. Nosmoking! Do not refuel a machine near open flames orsparks. Fill the fuel tank outdoors.

Starting

Do not use ether or starting fluids on any engine that hasglow plugs. These starting aids can cause explosion andinjure you or bystanders.

Use the procedure in the Operation & MaintenanceManual for connecting the battery and for jump starting.

Spark Arrester Exhaust System

The spark arrester exhaust system is designed to controlthe emission of hot particles from the engine and exhaustsystem, but the muffler and the exhaust gases are stillhot.

Check the spark arrester exhaust system regularly tomake sure it is maintained and working properly. Use theprocedure in the Operation & Maintenance Manual forcleaning the spark arrester muffler (if equipped).

Welding And Grinding

Always clean the equipment, disconnect the battery, anddisconnect the wiring before welding. Cover rubberhoses, battery and all other flammable parts. Keep a fireextinguisher near the equipment when welding.

Have good ventilation when grinding or welding paintedparts. Wear dust mask when grinding painted parts.Toxic dust or gas can be produced.

Dust generated from repairing nonmetallic parts can beflammable or explosive. Repair such components in awell ventilated area away from open flames or sparks.

Fire Extinguishers

Know where fire extinguishers and first aid kits arelocated and how to use them. Inspect the fireextinguisher and service the fire extinguisher regularly.Obey the recommendations on the instructions plate.


SAFETY IDENTIFICATION

Safety Decals

P00070

P00074

12

13

14

4

1

11

P00071

1 2 3

1

2

10

11

4

9

8

71

1

4

5

61


FRONT MATTER

SAFETY IDENTIFICATION (CONT’D)

Safety Decals (Cont’d)

Safety signs are used to alert the equipment operator ormaintenance person to hazards and information that maybe encountered in the use and maintenance of theequipment. The location and description of the safetysigns are detailed in this section. Please becomefamiliarized with all safety signs installed on the machine/ equipment.

A safety sign may contain more than one hazard paneland more than one avoidance panel.

NOTE: See the numbered (See Safety Decals on Page10.) for the location of each correspondinglynumbered decal.

1. Pinch Point (P211804A)

This safety sign is located six places on the passengerstair / crewstair.

WARNING

CRUSHING HAZARD

Keep fingers and hands out of pinch points whenadjusting and / or moving the equipment.

W-2014-012

2. Towbar / Stabilizer Requirements (P227463A)

This caution sign is located two places on the passengerstair / crewstair towbar.

CAUTIONWhen the towbar is up - engage the stabilizers.When the towbar is down - disengage the stabilizers.

I-2014-002

3. Maximum Speed Limit (H005627)

This safety sign is located on the passenger stair /crewstair towbar.

WARNING

OVERSPEED HAZARD

Do not exceed 5 mph (8 kph) when moving thisequipment.

W-2014-013


SAFETY INSTRUCTIONS (CONT’D)


4. Do Not Use Due To Wind Speed (P227391A)

This safety sign is located on the passenger stair /crewstair side panel (operator side).

WARNING

AVOID INJURY OR DEATH

Do not use the equipment when wind speeds meet orexceed 52 mph (83.7 kph).

W-2014-015

5. Do Not Move (P227479A)


WARNING


Do not move the equipment with occupants onboard.W-2014-014


FRONT MATTER



6. Stair Operation (P227479A)


1. Turn on lights (if needed). (See Turn Lights On onPage 29.)

2. Fully retract right and left sliding guardrails. (SeeSliding Guardrail Extension And Retraction on Page30.)

3. Set platform height to minimum height level for correctaircraft model. (See Stair Raising And Lowering onPage 31.)

4. Position stair at aircraft. (See Stair Positioning AtAircraft on Page 33.)

5. Engage stabilizers. (See Stabilizers Setting AndReleasing on Page 30.)

6. Adjust platform height to aircraft sill. (See StairRaising And Lowering on Page 31.)

7. Fully extend right sliding guardrail. (See SlidingGuardrail Extension And Retraction on Page 30.)

8. Open aircraft door. (See the aircraft’s Operation AndMaintenance Manual.)

9. Extend left sliding guardrail so it does not interferewith the aircraft door. (See Sliding GuardrailExtension And Retraction on Page 30.)


11. Remove stair from aircraft. (See Stair Positioning AtAircraft on Page 33.)

12. Turn off lights. (See Turn Lights On on Page 29.)

7. Open / Close Hydraulic Valve (P227474A)

This decal is located on the passenger stair / crewstairhydraulic tank.

For correct operation. (See Stabilizers Setting AndReleasing on Page 30.) or (See Stair Raising AndLowering on Page 31.)




8. Hydraulic Fluid Level (P227484A)

This decal is located on the passenger stair / crewstairhydraulic tank.

For correct hydraulic fluid level. (See Hydraulic FluidLevel Check on Page 49.)

9. Handle Latch Decal (P061252A)

This safety sign is located on the passenger stair /crewstair height latch handle (both sides).

For correct operation. (See Stair Raising And Loweringon Page 31.)

10. Stair Load Warning (P065750A)

This safety sign is located on the sliding guardrails(platform side).


This safety sign is located on the sliding guardrails(platform side).

WARNING


Do not exceed platform maximum weight of 500 lb.(226.8 kg) and complete stair maximum weight of2500 lb. (1133.9 kg).

W-2014-016


This safety sign is located on the passenger stair /crewstair five stairs from the platform.

WARNING



W-2014-016


FRONT MATTER


This safety sign is located on the passenger stair /crewstair six stairs from the platform.

WARNING



W-2014-016


This safety sign is located on the passenger stair /crewstair seven stairs from the platform.

WARNING



W-2014-016


TECHNICAL ADVISORIES / BULLETINS

NOT APPLICABLE AT

THIS TIME


FRONT MATTER

FEATURES AND ACCESSORIES

Standard Items

The passenger stair / crewstair assembly is equippedwith the following standard items:

• Hydraulic Operated Stabilizers

• Adjustable Sliding Guardrails

• Hydraulic Operated Lift Cylinder

• Battery Operated Aircraft Light And Stair Lights

Optional Items

The passenger stair / crewstair assembly is equippedwith the following optional items:

• Swivel Bumper


GENERAL INFORMATION AND OPERATING INSTRUCTIONS


GENERAL INFORMATION AND OPERATING INSTRUCTION SAFETY PRECAUTIONS . .21

PURPOSE OF EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

EQUIPMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

NORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Pre Operation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Towbar To Tow Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Turn Lights On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29Sliding Guardrail Extension And Retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30Stabilizers Setting And Releasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30Stair Raising And Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Stair Positioning At Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33Charging Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

SHIPPING AND TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36Equipment Preparation For Shipping And Transportation . . . . . . . . . . . . . . . . . . . . . . . . .36Lifting The Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36Fastening To Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

STORAGE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Re-Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39



GENERAL INFORMATION AND OPERATING INSTRUCTION SAFETY PRECAUTIONS

DANGERAVOID SERIOUS INJURY OR DEATH

Before moving the passenger stair / crewstair awayfrom an aircraft, close the aircraft door or place theapproved strap across the aircraft doorway.

D-2014-002

WARNING

CRUSHING HAZARD

• Before moving the tow vehicle / equipment, lookin all directions and make sure no bystanders arein the work area.

• Do not allow anyone between the tow vehicle andthe equipment when backing up to the equipmentfor connecting.

W-2014-005

WARNING


DO NOT move equipment with occupants onboard.W-2014-017

WARNING

CRUSHING HAZARD

Keep fingers and hands out of pinch points whenconnecting and disconnecting equipment.

W-2014-002

WARNING


Use of an unapproved hitch or tow vehicle can resultin loss of control, leading to serious injury or death.Tow vehicle and hitch must have the rated capacityto tow equipment.

W-2014-004

WARNINGVerify that the equipment is securely fastened to thetow vehicle before moving the tow vehicle andequipment.

W-2014-006

WARNING


Confirm the auto latch is firmly in a slot, slidingguardrail latches are in place and the stabilizers areset before passengers or crew are allowed on thepassenger stair / crewstair.

W-2014-019


GENERAL INFORMATION AND OPERATING INSTRUCTION SAFETY PRECAUTIONS (CONT’D)

WARNING


As people go onto or come off of the aircraft, theaircraft height may go down (loading) or up(unloading), pay close attention to the following:• The height distance between the aircraft floor

and the stair platform.• The distance between the aircraft door and the

stair platform.W-2014-020

WARNING


DO NOT adjust the stair height with anyone on thestairs.

W-2014-021

WARNING


When external power (110 V) is required, confirm theequipment it is being used for and where theextension cord is being placed is not in water.

W-2014-023

WARNING


Pay attention to surrounding areas to prevent beingcrushed between two pieces of equipment.

W-2013-020

WARNING


Before positioning stairs at the aircraft, confirm theaircraft is properly grounded.

W-2014-022

IMPORTANTThis Passenger Stair / Crewstair is only approved onthe following aircraft models:

• MD-80, B737-800, A319, A321, 757I-2014-003



PURPOSE OF EQUIPMENT

The passenger stair / crewstair is used to safely providea means for passenger(s) / crew(s) to get to and from thetarmac to the aircraft.

GENERAL DESCRIPTION

For more information on:

• Major Components (See Page 24).

• Dimensions (See Page 25).

• Performance (See Page 26).

This equipment is:

• Approved to provide a means for passenger(s) /crew(s) to get to and from the tarmac to the aircraft.


MAJOR COMPONENTS

P00070

CYLINDER

BATTERY CHARGER

AUTO LATCH HANDLE

STABILIZERS (2)

STEP LIGHT (16)

STEP(16)

P00077

P00071

PLATFORM

SLIDING GUARDRAIL

BUMPER

SOLID TIRES (2) HYDRAULIC

TANKELECTRICAL

BOX

SWIVEL CASTERS (2)

HANDRAILS

TOWBAR

SILL HEIGHT INDICATOR

SLIDING GUARDRAIL

PIVOTING PLATFORM

BUMPER

SUPPORT TUBE STORAGE BOX

AIRCRAFT LIGHT

SUPPORT TUBES



EQUIPMENT SPECIFICATIONS

Dimensions

• Where applicable, specifications conform to SAE and ISO standards and are subject to change without notice.

DESCRIPTION MODEL A227266D

Length, Stair (Towbar Retracted) (A) 232.5 in. (5906 mm)

Length, Towbar (B) 53.5 (1359 mm)

Width, Overall (C) 84.5 in. (2146 mm)

Height (Maximum) (D) 195 in. (4953 mm)

Height, Platform (Minimum) (E) 85 in. (2159 mm)

P00082

CA

E

DB


EQUIPMENT SPECIFICATIONS (CONT’D)

Performance

DESCRIPTION MODEL A224777D

Weight 3337 lb. (1513.6 kg)

Capacity 2500lb. (1134 kg) = 500 lb. (227kg) Platform + 2000 lb. (907kg) Staircase

Steering Front Caster Wheels

Running Gear Front Caster Wheels, Rigid Rear Wheels

Tires 4:00 x 8, 3 Stage Solid Tire

Construction Structural Steel Main Frame With Morton Tread Steps

Stabilizing Jacks Hydraulic Stabilizers

Hydraulic Fluid Capacity 2.5 Gal. (9.47 L)

Tow Speed (Maximum) 5 mph (8 kph)

Wind Speed Stability (Maximum) 52 mph (84 kph)



NORMAL OPERATION

Pre Operation Checklist

WARNING

CRUSHING HAZARD

When any activities are performed under the stair orplatform, the stair must be lowered onto the supporttube holders or support tubes installed.

W-2014-028

1. To check the hydraulic fluid level and tire operation,release the stabilizers. (See Stabilizers Setting AndReleasing on Page 30.)

2. Check hydraulic fluid level. (See Hydraulic Fluid LevelCheck on Page 49.)

3. Check the tires and casters for ease of operation.

4. Install support tubes. (See Support Tubes InstallationAnd Removal on Page 44.)

5. Check the battery connections for tightness and nocorrosion is found.

6. Turn on the lights and check lights for properoperation. (See Turn Lights On on Page 29.) Checkall the lights for proper operation.

7. Check all mounting hardware for all componentsassociated with the passenger stair / crewstair.

8. Check the stair and platform to make sure there areno tripping or slipping hazards.

9. Check the sliding guardrails for proper operation.(See Sliding Guardrail Extension And Retraction onPage 30.)

10. Confirm the rubber pivot bumper operates freely.

11. Remove support tubes. (See Support TubesInstallation And Removal on Page 44.)


NORMAL OPERATION (CONT’D)

Towbar To Tow Vehicle

WARNING


Pay attention to surrounding areas to prevent beingcrushed between two pieces of equipment.

W-2013-020

WARNING

CRUSHING HAZARD


W-2014-002

WARNING


Always have the stabilizers set when the stairway isnot being moved.

W-2014-018

Connect Towbar To Tow Vehicle:

Figure 3

1. Rotate the towbar (Item 1) [Figure 3] forward, to theextended position.

2. Position the tow vehicle hitch in front of the passengerstair / crewstair towbar.

3. Attach the towbar to the tow vehicle hitch.

4. Release the stabilizers. (See Stabilizers Setting AndReleasing on Page 30.)

P00075

1




Towbar To Tow Vehicle (Cont’d)

Disconnect Towbar From Tow Vehicle:

1. Disconnect the towbar from the tow vehicle.

2. Set the stabilizers. (See Stabilizers Setting AndReleasing on Page 30.)

Figure 4

3. Rotate the towbar (Item 1) [Figure 4] back, into theretracted position.

Turn Lights On

Figure 5

Rotate the light timer (Item 1) [Figure 5] to the desiredamount of time that lights are required.

NOTE: Do not force the timer to zero (0), this maydamage the timer.

P00076

1

P00101

1



Sliding Guardrail Extension And Retraction

Figure 6

Push and hold the sliding guardrail latch (Item 1) downuntil the sliding guardrail latch is above the slidingguardrail slot (Item 2) [Figure 6]].

Figure 7

Move the sliding guardrail (Item 1) [Figure 7] to thedesired location.

Stabilizers Setting And Releasing

Setting:

Figure 8

Place the priority valve handle (Item 1) in theSTABILIZERS position and close the release valve (Item2) [Figure 8].

Figure 9

Pump the hydraulic hand pump (Item 1) [Figure 9] untilthe front casters are slightly off the ground.

Releasing:

Place the priority valve handle (Item 1) in theSTABILIZER position and slowly open the release valve(Item 2) [Figure 8].

NOTE: As the release valve is opened, the stabilizersprings will retract and raise the stabilizers.

P00083

1

2

P00084

1

P00078

1

P00086

1

2

P00079

1




Stair Raising And Lowering

Raising Stair:

WARNING



W-2014-021

Figure 10

Place the priority valve handle (Item 1) in thePLATFORM position and close the release valve (Item 2)[Figure 10].

Figure 11

Pump the hydraulic hand pump (Item 1) [Figure 11] untilthe platform is at the desired height.

WARNING



W-2014-019

Figure 12

Confirm the auto latches (Item 1) [Figure 12] are fullyengaged into the slots (both sides) on the X-Frame.

Slowly open the release valve (Item 2) [Figure 10] tolower the X-Frame slot onto the auto latch (Item 1)[Figure 12]. Close the release valve.

NOTE: Do not open the release valve more than 1/2turn when lowering the stair.

P00078

12

P00079

1

P00080

1



Raising And Lowering Stair (Cont’d)

Lowering Stair:

WARNING



W-2014-021

Figure 13

Place the priority valve handle (Item 1) in thePLATFORM position and close the release valve (Item 2)[Figure 13].

Figure 14

Figure 15

Pump the hydraulic hand pump (Item 1) [Figure 14] untilthe auto latch (Item 1) [Figure 15] is free.

Pull down on the handle (Item 2) [Figure 15] to releasethe auto latch.

Slowly open the release valve (Item 2) [Figure 13] andlower the stair to the desired location.

NOTE: Do not open the release valve more then 1/2turn when lowering the stair. If release valve isopened more than 1/2 turn the pressure reliefvalve may set and prevent the stair fromlowering.

P00078

12

P00079

1

P00081

1

2




Stair Positioning At Aircraft



D-2014-002

WARNING


As people go onto or come off of the aircraft, theaircraft height may go down (loading) or up(unloading), pay close attention to the following:• The height distance between the aircraft floor

and the stair platform.• The distance between the aircraft door and the

stair platform.W-2014-020

WARNING



W-2014-019

WARNING



W-2014-021

WARNING


Before positioning stairs at the aircraft, confirm theaircraft is properly grounded.

W-2014-022

IMPORTANTThis Passenger Stair / Crewstair is only approved onthe following aircraft models:

• MD-80, B737-800, A319, A321, 757I-2014-003

IMPORTANTWhen the passenger stair / crewstair is not in use,position the passenger stair / crewstair safely awayfrom aircraft.

I-2014-004



Stair Positioning At Aircraft (Cont’d)

Placing Passenger Stair / Crewstair To Aircraft:

1. Turn on lights (if needed). (See Turn Lights On onPage 29.)


Figure 16

3. Set platform height to minimum height level (Item 1)[Figure 16] for correct aircraft model. (See StairRaising And Lowering on Page 31.)

NOTE: The example above shows the platform heightindicator (Item 1) [Figure 16] set for a MD-80with the platform at it’s lowest setting for thataircraft type.

4. Position stair at aircraft.

5. Set stabilizers. (See Stabilizers Setting AndReleasing on Page 30.)

6. Adjust platform height to aircraft sill. (See StairRaising And Lowering on Page 31.)

7. Fully extend right sliding guardrail. (See SlidingGuardrail Extension And Retraction on Page 30.)

8. Open aircraft door. (See the aircraft’s Operation AndMaintenance Manual for correct procedure.)

9. Extend left sliding guardrail so it does not interferewith the aircraft door. (See Sliding GuardrailExtension And Retraction on Page 30.)

The passenger stair / crewstair is ready for use.

Remove Passenger Stair / Crewstair From Aircraft:



D-2014-002


2. Release stabilizers. (See Stabilizers Setting AndReleasing on Page 30.)

3. Move stair from aircraft.

4. Lower the stair. (See Lowering Stair: on Page 32.)

5. Set stabilizers. (See Stabilizers Setting AndReleasing on Page 30.)

NOTE: The lights will turn off automatically.P00085

1




Charging Batteries

WARNING


When external power (110 V) is required, confirm theequipment it is being used for and where theextension cord is being placed is not in water.

W-2014-023

NOTE: The battery charger is removed to easily showhow to operate it.

Figure 17

NOTE: The battery charger knob (Item 1) [Figure 17]has been placed and set (unable to move) byWASP Inc.

Figure 18

Plug an extension cord (110 V) into the battery box (Item1) [Figure 18].

After plugging in the extension cord, through the batterybox window (Item 2) [Figure 18] the following may beseen:

• Normal Charging: Green light (Item 2) flashing andDC ampere meter (Item 3) [Figure 17] indicates morethan zero amps.

• Normal Full Charged: Green light (Item 2) on and DCampere meter (Item 3) [Figure 17] indicates zeroamps. Disconnect extension cord.

• Abnormal Charging: Red light (Item 4) flashing andDC ampere meter (Item 3) [Figure 17] indicates morethan zero amps.

• Abnormal Charging: Red light (Item 4) on and DCampere meter (Item 3) [Figure 17] indicates morethan zero amps.

NOTE: Any abnormal charging, troubleshoot thecharger. (See Battery ChargerTroubleshooting (Model 1JYV1A) onPage 104.)

P00087

1

2

3

4

P00100

12


SHIPPING AND TRANSPORTATION

Equipment Preparation For Shipping And Transportation

Use a proper lifting device to support the weight of stairand platform.

Figure 19

Remove the mounting hardware (Item 1) from the upperx-frame. Lower the x-frame (Item 2) [Figure 19].

Remove the mounting hardware (Item 3) [Figure 19]from the upper cylinder mount. Lower the cylinder (Item4) [Figure 19].

Lifting The Equipment

NOTE: It is recommended to have a second person toguide the forklift / passenger stair/crewstairinto place.

Fully lower the stair. (See Lowering Stair: on Page 32.)

NOTE: Use a properly rated forklift while liftingpassenger stair / crewstair. (See the forklift’sOperation And Maintenance manual.) and(See EQUIPMENT SPECIFICATIONS onPage 25.)

For forklift operation, (See the forklift’s Operation AndMaintenance Manual.)

Figure 20

Spread the forklift tines (Item 1) [Figure 20] to themaximum width.

Align the center of the forklift with the electrical box (Item2) [Figure 20]. Drive the forklift forward until the forklifttines are under the opposite side of the running gear.

P00160

11

3

24

P00158

1

2



SHIPPING AND TRANSPORTATION (CONT’D)

Lifting The Equipment (Cont’d)

Figure 21

Lift the stair (Item 1) [Figure 21] slightly off the ground.

Confirm the stair is balanced on the forklift tines. Ifnecessary, lower the stair and adjust the forklift to thestair.

Raise the stair to the desired height.

Fastening To Trailer

WARNINGAVOID INJURY OR DEATH

Follow all federal, state and local laws andregulations while transporting equipment.

W-2014-011


Use proper straps to prevent the stair from moving duringtransportation.

Figure 22

Rotate both casters (Item 1) [Figure 22] parallel to thelength of the trailer.

Place planks (Item 2) [Figure 22] on the front and rearsides of the casters (Item 1). Fasten the planks onto thetrailer bed.

Properly secure the towbar (Item 3) to the running gear(Item 4) [Figure 22].

P00159

1

P00154

1

2

4

3


SHIPPING AND TRANSPORTATION (CONT’D)

Fastening To Trailer (Cont’d)

Figure 23

Place a strap in front of the rear tires, over the runninggear (Item 1) [Figure 23].

Figure 24

Place a strap behind the front casters, over the runninggear (Item 1) [Figure 23].

NOTE: Be careful not to damage the hydraulic hoseswhen securing the stair to the trailer.

Figure 25

Place a strap through the sliding guardrails (Item 1)[Figure 25].

Secure and tighten all straps to the trailer.

P00156

1

P00155

1

P00157

1



STORAGE INSTRUCTIONS

Storage

Sometimes it may be necessary to store your WASP Inc.equipment for an extended period of time. Below is a listof items to perform before storage.

• Thoroughly clean the equipment.

• Lubricate the equipment.

• Inspect all welds on the equipment for wear anddamage.

• Check for loose hardware, missing guards, ordamaged parts.

• Check for damaged or missing decals. Replace ifnecessary.

• Place the equipment in a dry protected shelter.

• Place the equipment flat on the ground.

Re-Commissioning

After the WASP Inc. equipment has been in storage, it isnecessary to follow a list of items to return the equipmentto service.

• Be sure all shields and guards are in place.

• Lubricate the equipment.

• Operate equipment, check for correct function.


MAINTENANCE AND REPAIR

PREVENTIVE MAINTENANCE

MAINTENANCE AND REPAIR SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .43

GENERAL OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43Passenger Stair / Crewstair Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

PREPARE FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44Support Tubes Installation And Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Battery Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Decal, Reflector Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47Steps, Sliding Guardrail And Platform Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47Hydraulic Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49Hydraulic System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Electrical System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Towbar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Towbar Hold-Up Device Adjustment Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57Stabilizer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58Light Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65



MAINTENANCE AND REPAIR SAFETY PRECAUTIONS

WARNING

CRUSHING HAZARD


W-2014-002

WARNING

CRUSHING HAZARD

When any activities are performed under the stair orplatform, the stair must be lowered onto the supporttube holders or support tubes installed.

W-2014-028

WARNING


Use of an unapproved hitch or tow vehicle can resultin loss of control, leading to serious injury or death.Tow vehicle and hitch must have the rated capacityto tow equipment.

W-2014-004

GENERAL OVERVIEW

The following are the major components that allow safeand efficient aircraft entering and exiting of passengersand crew.

Passenger Stair / Crewstair Components

Steps:

Sixteen steps allow aircraft entering and exiting ofpassengers and crew.

Hydraulic Lift:

Hydraulic lift allows the passenger stair / crewstair to beused on several different aircraft types.

Stabilizers:

Two stabilizers prevent the passenger stair / crewstairfrom moving when passengers / crew are using the stair.

Electrical System:

Battery powered electrical system provides lighting onthe steps and lighting below the platform.

Tires:

Four solid tires allow for ease of transportation of thepassenger stair / crewstair.

Towbar:

The towbar connects the passenger stair / crewstair to atow vehicle.


PREPARE FOR MAINTENANCE

Support Tubes Installation And Removal

Installation:

NOTE: Always install the support tubes whenperforming service or maintenanceunderneath the passenger stair / crewstairwhen it is in the raised position.

Park the stair on flat level surface.

Raise the stair until the support tubes can be installed.(See Stair Raising And Lowering on Page 31.)

Figure 26

Remove the support tubes (Item 1) [Figure 26] from thesupport tube storage box.

Figure 27

Place the support tubes (Item 1) onto the support tubeholders (Item 2) [Figure 27].

Lower the stair (Item 3) [Figure 27] onto the supporttubes. (See Lowering Stair: on Page 32.)

Removal:

Raise the stair until the support tubes can be removed.(See Stair Raising And Lowering on Page 31.)

Figure 28

Remove the support tubes (Item 1) from the support tubeholders (Item 2) [Figure 28].

Figure 29

Place the support tubes (Item 1) [Figure 29] into thesupport tube storage box.

P00108

1

P00107

1

2

P00112

3

P00107

1

2

P00107

1

2

P00108

1



PREVENTATIVE MAINTENANCE

NOTE: The preventative maintenance schedule isbased on the passenger stair / crewstair useof 200 hours or 8 weeks whichever comesfirst. Except the battery condition checkwhich is done monthly.

Battery Condition Check

Prepare stair for maintenance. (See PREPARE FORMAINTENANCE on Page 44.)

Figure 30

Open electrical box cover (Item 1) [Figure 30].

WARNING


• Always disconnect the negative battery terminalsfirst.

• Always connect the positive battery terminalsfirst.

W-2014-025

Figure 31

NOTE: Mark all wires for ease of reconnectingterminals to the battery.

Disconnect all wiring from batteries terminals (Item 1)[Figure 31].

Remove the batteries from the electrical box.

Using water and clean towel, clean the battery box.Check the battery box for damage.

Figure 32

Using water, baking soda and a brush, clean the batteryposts (Item 1) [Figure 32].

Remove the battery caps (Item 2) [Figure 32].

P00106

1

P00106

1

1

P00109

1

2


PREVENTATIVE MAINTENANCE (CONT’D)

Battery Condition Check (Cont’d)

Figure 33

Check the water level in each cell (Item 1) [Figure 33].

If any of the cells are low fill with distilled water to thebottom of the hole(s).

Figure 34

Install the battery caps (Item 1) [Figure 34].

WARNING


• Always disconnect the negative battery terminalsfirst.

• Always connect the positive battery terminalsfirst.

W-2014-025

Figure 35

Install the batteries into the electrical box.

Connect all wiring to both the batteries terminals (Item 1)[Figure 35].

Close electrical box cover.

P00110

1

P00109

1

P00106

1

1




Decal, Reflector Inspection

Check all decals and reflectors for condition. (See SafetyDecals on Page 10.)

Replace decals and reflectors as necessary.

Steps, Sliding Guardrail And Platform Inspection


Figure 36

Remove the five screws (Item 1) and tread grip sheet(Item 2) [Figure 36].

Figure 37

Flip over the tread grip sheet (Item 1) [Figure 37].

Check rub strip (Item 2) [Figure 37] for any areas thatare worn or damaged.

Measure the thickness of the rub strip (Item 2) [Figure37] using one of the following procedures:

• Measure the thickness of the tread grip sheet and rubstrip (Item 3) [Figure 37] together. The minimumthickness allowed is 0.50 in. (12.7 mm).

• Measure the thickness of the rub strip (Item 4)[Figure 37] together. The minimum thickness allowedis 0.18 in. (4.6 mm).

Replace rub strip if damaged or does not meet theminimum thickness.

Installation: Install tread grip sheet (Item 2) and fivescrews (Item 1) [Figure 36].

P00152

2

11111

A

DETAIL A OF SECTION AA

P00153

1

2

2 43

A A



Steps, Sliding Guardrail And Platform Inspection (Cont’d)

Figure 38

Inspect the bumper (Item 1) and pivot (Item 2) [Figure38] operation. Ensure all components are secure andthat all hardware is thoroughly tightened. Replace anydamaged or worn parts.

Figure 39

Inspect the bumpers (Item 1) and sliding guardrails (Item2) [Figure 39] mounting hardware for being loose,damaged or missing.

Check the sliding guardrails (Item 2) [Figure 39] foroperations. (See Sliding Guardrail Extension AndRetraction on Page 30.)

Figure 40

Inspect the following components of the x-frame / autolatch area:

• Auto latch system: Inspect the latch (Item 1), springsand handle (Item 2) [Figure 40] operation. Ensure allcomponents are secure and that all hardware isthoroughly tightened. Replace any damaged or wornparts.

• X-frame: Inspect the x-frame (Item 4) [Figure 40] forcracked and/or damaged structure. Ensure allcomponents are secure and that all hardware isthoroughly tightened. Replace any damaged or wornparts.

Figure 41

Inspect stairs (Item 1) [Figure 41] for loose, damaged,missing mounting hardware or worn non-skid material.

Inspect the two guardrails (Item 2) [Figure 41] andmounting hardware for being loose, damaged or missing.

P00113

2

1

P00084

1 2

P00114

1

2

34

P00115

1

2




Hydraulic Fluid Level Check

Park the stair on flat level surface.


Fully release the stabilizers. (See Stabilizers Setting AndReleasing on Page 30.)

Figure 42

Open the hydraulic tank cap (Item 1) [Figure 42].

Figure 43

Visually check the hydraulic fluid level. Fill hydraulic fluidlevel as required with Dexron® III or equivalent.

NOTE: Hydraulic fluid level should be up to thebottom of the hydraulic tank filler (Item 1)[Figure 43].

Close the hydraulic tank cap (Item 1) [Figure 42].P00105

1

P00151

1



Hydraulic System Inspection


Figure 44

Inspect the stabilizers (Item 1) (both) and hydraulic hoses(Item 2) [Figure 44] for signs of leaks and for mountinghardware being loose, damaged or missing.

Figure 45

Inspect the cylinder (Item 1) [Figure 45] and hydraulichose for signs of leaks and for mounting hardware beingloose, damaged or missing.

NOTE: When inspecting the cylinder, check there isno oil dripping from breather (Item 2) [Figure45]. It may be a sign of internal leakage.Replace cylinder or install repair kit.

Figure 46

Inspect the hydraulic tank (Item 1), release valve (Item2), priority valve (Item 3) and hand pump (Item 4) [Figure46] and hydraulic hoses for signs of leaks or damage.Ensure all components are secure and that all hardwareis thoroughly tightened. Replace any damaged parts.P00116

1 2

P00117

1

2

P000794

1

23




Electrical System Inspection

Figure 47

Rotate the light timer (Item 1) [Figure 47] clockwise tothe desired setting for light operation.

NOTE: It is recommended not to force the timer tozero (0), this may damage the timer.

Figure 48

Check the stair lights (Item 1) [Figure 48] (16) foroperation and mounting hardware for being loose,damaged or missing.

Figure 49

Check the aircraft light (Item 1) [Figure 49] for operationand mounting hardware for being loose, damaged ormissing.

P00101

1

P00115

1

P00118

1



Towbar Inspection

Figure 50

Check the towbar (Item 1) [Figure 50] for operation andmounting hardware for being loose, damaged or missing.

Extend the towbar (Item 1) [Figure 50] and check thatthe towbar is parallel with the ground. Adjust ifnecessary. (See Towbar Hold-Up Device AdjustmentLeveling on .)

Figure 51

Check the towbar leveling spring (Item 1) [Figure 51] foroperation and mounting hardware for being loose,damaged or missing.

Tire Inspection

Set the stabilizers to have the tires off the ground. (SeeStabilizers Setting And Releasing on Page 30.)

Figure 52

Check both caster tires (Item 1) [Figure 52] for excessivewear, tire rotation and caster rotation. Replace asnecessary. (See Wheel Replacement on Page 57.)

Figure 53

Check both rear tires (Item 1) [Figure 53] for excessivewear. Replace or rotate tires as necessary. (See WheelReplacement on Page 57.)

NOTE: When the tire is worn beyond the wearindicator (Item 2) [Figure 53], tire replacementis required.

Check the torque on the wheel lug nuts (Item 3) [Figure53]. Lug nut torque is 100 ft.-lb. (135.6 N•m).

P00076

1

P00111

1

P00142

1

P00141

1

3

2




Lubrication Locations

Always use premium high temperature grease EP-2 or equivalent when lubricating the equipment. Grease each ofthe grease zerk with two pumps of the grease gun throughout the lubrication section. Wipe off excess grease.

Prepare stair for maintenance. (See PREPARE FOR MAINTENANCE on Page 44.)

Figure 54

IMPORTANTFluid such as engine oil, hydraulic fluid, coolants, grease, etc. must bedisposed of in an environmentally safe manner. Some regulations requirethat certain spills and leaks on the ground must be cleaned in a specificmanner. See local, state and federal regulations for the correct disposal.

I-2013-003

P00071

43

2

1

5 6



Lubrication

IMPORTANTThe average hand pump grease gun gives 2 oz. (60cl) of grease per stroke. See the grease gunmanfacturer for quantity of grease per pump.

I-2014-005

NOTE: Grease each of the grease zerk with twopumps of the grease gun throughout thelubrication section.

Figure 55

Lubricate the wheel (Item 1) [Figure 54] and [Figure 55](both sides).

Figure 56

Figure 57

Lubricate the caster (Item 2) [Figure 54], [Figure 56]and [Figure 57] (both sides).

P00121

1

P00122

2

P00142

2




Lubrication (Cont’d)

Figure 58

Lubricate the lower pivots (Item 3) [Figure 54] and[Figure 58] (both sides).

Figure 59

Lubricate the lower pivots (Item 4) [Figure 54] and[Figure 59] (both sides).

Figure 60

Lubricate the upper pivot (Item 5) [Figure 54] and[Figure 60] (both sides).

WARNING

CRUSHING HAZARD

Do not work between the stair risers without placingblocks between risers.

W-2014-026

Fully raise the stair. (See Stair Raising And Lowering onPage 31.)

Place blocks between riser channels.

Figure 61

Lubricate the upper pivot (Item 6) [Figure 54] and[Figure 61] (both sides).

P00120

3

P00123

4

P00124

5

P00140

6


MAINTENANCE PROCEDURES

WARNINGCheck for correct function after adjustments, repairsor service. Failure to make correct repairs oradjustments can cause injury or death.

W-2013-003

Towbar Hold-Up Device Adjustment Leveling

Figure 62

Figure 63

Loosen the jam nut (Item 1), turn the nuts (Item 2)[Figure 62] equally to adjust the towbar height (Item 1)[Figure 63] until the towbar is parallel to the ground.

Tighten the jam nut (Item 1) [Figure 62].

P00111

12

2

P00076

1



MAINTENANCE PROCEDURES (CONT’D)

Wheel Replacement

Rear Tire:

Properly lift the stair. (See Equipment Preparation ForShipping And Transportation on Page 36.)

Place jackstands under the stair frame.

Figure 64

Remove the lug nuts (Item 1) and remove the tire (Item 2)[Figure 64].

Installation: Install the tire and install and tighten the lugnuts to 100 ft.-lb. (135.6 N•m) torque.

Front Caster:

Properly lift the stair. (See Equipment Preparation ForShipping And Transportation on Page 36.)

Place jackstands under the stair frame.

Figure 65

Remove the cotter pin, nut and bolt (Item 1) and removethe tire (Item 2) [Figure 65].

Installation: Install the tire and install the bolt, nut andcotter pin.

P00141

1

2

P00142

1

2



Stabilizer Replacement

NOTE: The stabilizer, cylinder, springs, mountingbracket and mounting hardware are replacedas an assembly.


DO NOT attempt to remove the stabilizer springs /cap without using the proper lifting device andchains or straps. The stabilizer springs are underheavy tension when the stabilizer is in the releasedposition.

D-2014-003

Release the stabilizers. (See Stabilizers Setting AndReleasing on Page 30.)

Figure 66

Attach proper chains and hooks (Item 1) to the stabilizercap (Item 2) [Figure 66]. Attach chains to a proper liftingdevice.

NOTE: Always use chains, hooks and straps that areof adequate size and strength when replacingstabilizers. 115 lb. (52.1 kg) of force isrequired to overcome the spring tension.

Installation: Lift the stabilizer cap onto the cylinder.

Figure 67

Lift the cap and springs (Item 1) [Figure 67] and placenext to stabilizer.

Installation: Attach chains with hooks onto the stabilizercap.

Figure 68

Disconnect the hydraulic hose (Item 1) [Figure 68].

Installation: Connect the hydraulic hose.

P00143

11

2

P00144

1

P00145

1




Stabilizer Replacement (Cont’d)

Figure 69

Remove the mounting hardware (Item 1) and stabilizerassembly (Item 2) [Figure 69].

Installation: Install the stabilizer and mounting hardware.

P00148

11

2



Light Assembly Replacement

Figure 70

Confirm the light switch (Item 1) [Figure 70] is set tozero.

NOTE: It is recommended not to force the timer tozero (0), this may damage the timer.

Installation: Check the lights. Turn on the lights.

Figure 71

Disconnect the negative (-) (Item 1) [Figure 71] batteryterminals.

Installation: Connect the negative battery terminals.

NOTE: The aircraft light is being used as an example.The procedure is the same for all lights.

Figure 72

Remove light assembly (Item 1) from the rubber grommet(Item 2) [Figure 72].

Installation: Install the light assembly into the rubbergrommet.

Figure 73

Disconnect the wires (Item 1) [Figure 73].

Installation: Connect the wires.

P00101

1

P00106

1

P00118

1

2

P00126

1



SPECIFICATIONS

Settings

Not Applicable

Lubricants

Use premium high temperature grease EP-2 orequivalent.

Hydraulic fluid use Dexron® II or equivalent.


SPECIFICATIONS (CONT’D)

Torque Values

The following table shows standard torque specifications for bolts.

ThreadSize SAE Grade 5 SAE Grade 8

in-lb(N•m)

0.250 80 - 90(9.0 - 10.2)

110 - 120(12.4 - 13.6)

0.3125 180 - 200(20.3 - 22.6)

215 - 240(24.2 - 27.1)

ft-lb(N•m)

0.375 25 - 28(34 - 38)

35 - 40(47 - 54)

0.4375 40 - 45(54 - 61)

60 - 65(81 - 88)

0.500 65 - 70(88 - 95)

90 - 100(122 - 136)

0.5625 90 - 100(122 - 136)

125 - 140(170 - 190)

0.625 125 - 140(170 - 190)

175 - 190(240 - 260)

0.750 220 - 245(300 - 330)

300 - 330(410 - 450)

0.875 330 - 360(450 - 490)

475 - 525(645 - 710)

1.000 475 - 525(645 - 710)

725 - 800(985 - 1085)

1.125 650 - 720(880 - 975)

1050 - 1175(1425 - 1600)

1.250 900 - 1000(1200 - 1360)

1475 - 1625(2000 - 2200)

1.375 1200 - 1350(1630 - 1830)

2000 - 2200(2720 - 2980)

1.500 1500 - 1650(2040 - 2240)

2600 - 2850(3530 - 3870)

1.625 2000 - 2800(2720 - 2980)

3450 - 3800(4680 - 5150)

1.750 2500 - 2750(3390 - 3730)

4300 - 4800(5830 - 6500)

1.875 3150 - 3500(4270 - 4750)

5500 - 6100(7450 - 8300)

2.000 3800 - 4200(5150 - 5700)

6500 - 7200(8800 - 9800)



TROUBLESHOOTING

Chart

Use the following troubleshooting chart to locate and correct problems which most often occur with the equipment.

PROBLEM CAUSE CORRECTION

Light does not work. Faulty or damaged light. Replace the light assembly. (See Light Assembly Replacement on Page 60.)

Faulty battery or batteries. Check batteries condition. (See Battery Condition Check on Page 45.)

Wiring problem. Troubleshoot the electrical system. (See Electrical Schematic on Page 64.)

All the lights do not work. Batteries not charged. Charge the batteries. (See Charging Batteries on Page 35.)

Faulty battery or batteries. Check batteries condition. (See Battery Condition Check on Page 45.)

Wiring problem. Troubleshoot the electrical system. (See Electrical Schematic on Page 64.)

Stair will not lower. Pressure relief valve set (closed). Reset pressure relief valve. (See Stair Raising And Lowering on Page 31.)

Stair lowers when release valve is closed.

Hydraulic fluid level low. Check and fill the hydraulic tank. (See Hydraulic Fluid Level Check on Page 49.)

Cylinder is bypassing inside (should see hydraulic fluid at the breather).

Reset pressure relief valve. (See Hydraulic Fluid Level Check on Page 49.)

Hydraulic system leak. Check hydraulic system for leaks.

Stabilizer(s) will not set or release. Hydraulic fluid level low. Check and fill the hydraulic tank. (See Hydraulic Fluid Level Check on Page 49.)

Stabilizer(s) are bypassing inside. Reset pressure relief valve. (See Hydraulic Fluid Level Check on Page 49.)

Stabilizer(s) have broken spring. Replace stabilizer. (See Stabilizer Replacement on Page 58.)

Instructions are necessary before operating or servicing equipment. Readand understand the Operation & Maintenance Manual, signs (decals) onequipment. Follow warnings and instructions in the manuals when makingrepairs, adjustments or servicing. Check for correct function afteradjustments, repairs or service. Untrained operators and failure to followinstructions can cause injury or death. W-2013-002


SYSTEM SCHEMATICS

Electrical Schematic

P00103

STAIR LED LIGHT ASSEMBLY (16 EA.)

WHITE WIRE

RED WIRE

AIRCRAFT LED LIGHT ASSEMBLY

WHITE WIRE

BLACK WIRE

RELAY

RELAY

TIMER

LINE

LOAD

BLACK WIRE

BATTERIES (2) (12 V EACH)BATTERY

CHARGER

RED WIRE

RED WIRE

CHARGER CORD



SYSTEM SCHEMATICS (CONT’D)

Hydraulic Schematic

P00104

RELIEF VALVE

STABLIZERS

PLATFORM CYLINDER

BREATHER

HYDRAULIC TANK

RELEASE VALVE

PRIORITY VALVE

HAND HYDRAULIC

PUMP


OVERHAUL PROCEDURES

OVERHAUL PROCEDURES (NOT APPLICABLE)

THIS SECTION IS NOT REQUIRED

FOR THIS EQUIPMENT.


ILLUSTRATED PARTS LIST

ILLUSTRATED PARTS LISTS

ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71Part Procurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71Explanation Of Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71Passenger Stair / Crewstair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72Rear Wheel Hub And Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73Step Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74Platform, Sliding Guardrail Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76Platform Bumper Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78Front Caster Assembly (A004839A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80X-Frame Assembly (A227273B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82Towbar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84Running Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86Electrical Schematic (A227550B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88Hydraulic Schematic (A229376B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90Hydraulic Tank Assembly (A227557B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92




Introduction

These parts lists are broken down into ten subassemblies. For locations of the parts lists see page 72.

Part Procurement

To order parts have the serial number of the equipmentavailable. (See Equipment Serial Number on Page 4.)Contact:

WASP Incorporated

PO Box 249

20631 State Highway 55

Glenwood, MN 56334

320-634-5886

Explanation Of Parts Lists

The parts lists are broken down into four columns:

• ITEM NO. - These numbers are found on theillustration associated with the parts list.

• PART NO. - These are the part numbers associatedto the ITEM NO.

• DESCRIPTION - This is the description of the part.

• QTY. - This is the quantity of parts needed in anassembly.


ILLUSTRATED PARTS LIST (CONT’D)

Passenger Stair / Crewstair

ITEM NO. DESCRIPTION PAGE #

1 REAR WHEEL HUB AND SPINDLE ASSEMBLY 73

2 STEP ASSEMBLY 74

3 PLATFORM SLIDING GUARDRAIL ASSEMBLY 76

4 PLATFORM BUMPER SWIVEL ASSEMBLY 78

5 FRONT CASTER ASSEMBLY (A004839A) 80

6 X-FRAME ASSEMBLY (A227273B) 82

7 TOWBAR ASSEMBLY 84

8 RUNNING GEAR ASSEMBLY 85

9 DECALS 86

10 ELECTRICAL SCHEMATIC (A227550B) 88

11 HYDRAULIC SCHEMATIC (A229376B) 90

12 HYDRAULIC TANK ASSEMBLY (A227557B) 92

P00127

8

5

1

36

4 9

2

8

410

11 12




Rear Wheel Hub And Spindle Assembly

ITEM NO.

PART NO. DESCRIPTION QTY.

1 P057493A SPINDLE 1

2 H006212 DUST COVER 1

3 P002022A NUT, MODIFIED 1

4 H001005 COTTER PIN, 1/8IN. X 2IN. LG. 1

5 H001091 HUB ASSEMBLY 1

5A H001977 BEARING CONE 1

5B H001978 BEARING CONE 1

5C H001980 GREASE SEAL 1

5D H001980 GREASE SEAL 1

5E H001982 LUG NUT 5

5F H001296 DRIVE GREASE ZERK, 3/16 IN. 1

5G H005310 WASHER, 1.81 IN. OD X 0.765 IN. ID 9 GA. 1

P00149

5

5E

5A

5G

5F2

34

5D

1

5B5C



Step Assembly

P00146

1

23

4

5

6

78

9

10 11

12

13

141516

17

18 19

20

21

2220

2123

24




Step Assembly (Cont’d)

ITEM NO.


1 W215400B LH HANDRAIL WELDMENT 1

2 W215576A STAIR PANEL WELDMENT 1


4 W216474B LOWER STAIR CHANNEL WELDMENT 2

5 W215386B RH HANDRAIL WELDMENT 1

6 P066386A ROD 2

7 H001033 CAPSCREW,.50 NC X 1.50, GR 5 4

8 H006541 GREASE ZERK,.188 STR DRIVE 4

9 P066425A SHIM 4

10 W006852A LOWER STEP WELDMENT 1

11 H001251 CAPSCREW,.375 NC X 1.25, GR 5 60

12 H003062 CAPSCREW,.75 NC X 6.50, GR 5 4

13 W214930B PIVOT SPANNER BUSHING 4

14 H001051 NUT, NYLOK,.75 NC 4

15 A215405A STEP ASSEMBLY 15

16 H001010 NUT, NYLOK,.38 NC 60

17 H001008 WASHER, FLAT,.375, ZP 60

18 W216486A UPPER DRIP PAN WELDMENT 1

19 W216308B CYLINDER MOUNT WELDMENT 1

20 H004977 WASHER, LOCK,.375, ZP 14

21 H001015 CAPSCREW,.38 NC X 1.00, GRD 5 8

22 P216484A RISER PAN 1





Platform, Sliding Guardrail Assembly

P00137

1

2

3

4

567

8

9

11

15

14

13

9

8

7

10

5

12

16




Platform, Sliding Guardrail Assembly (Cont’d)

ITEM NO.


1 H004910 SPRING, EXTENSION 2

2 H001251 CAPSCREW,.375 NC X 1.25, GR 5 2

3 P065991A FLAT, LATCH 2

4 H001010 NUT, NYLOK,.38 NC 2

5 H001001 NUT, NYLOK,.50 NC, ZP 2

6 P066121A WASHER 2

7 A005078A WHEEL ASSY, HANDRAIL 4

8 P065843A BUSHING, WHEEL 6

9 H001053 CAPSCREW,.50 NC X 2.00, GR 5 4

10 H001066 WASHER, FLAT,.50, ZP 4

11 W227279A SLIDING GUARDRAIL WELDMENT 1

12 W227298A SLIDING GUARDRAIL WELDMENT 1

13 H006971 SCREW, TEK,.25 X 1.50, ZP 12

14 P227457A BOLT STRIP 2

15 P227455A HANDRAIL BUMPER 2

16 W006761C PLATFORM WELDMENT 1



Platform Bumper Swivel Assembly

P00138

1

4

2

8

9

10

11

12

13

14

15

3

5

6

7




Platform, Bumper Assembly (Cont’d)

ITEM NO.


1 A227330B TREAD GRIP SHEET 1

2 H001001 NUT, NYLOCK,.50 NC, ZP 4

3 H001042 BEARING, FIBERGLIDE JOURNAL 2

4 P222303A SPACER, 0.125 IN. 1

5 P227342A STRIP, RUB 1

6 H012685 RIVET, BLIND,.19 X .25 GRIP 9

7 H003130 CAPSCREW, FLATHEAD, .25 NC X 1.00 5

8 W227302B BACK PLATE WELDMENT 1

9 W227314B BUMPER MOUNT WELDMENT 1

10 P066491A STAIR BUMPER 1

11 W227302B BACK PLATE WELDMENT 1

12 H001139 CAPSCREW,.50 X 2.25 ZP 5

13 H004942 NUT, NYLOK JAM,.75 NC, ZP 3

14 H001311 1/4” X 1.00" TEK SCREW 2

15 W227554A LIGHT MOUNT WELDMENT 1



Front Caster Assembly (A004839A)

P00129

712

9

1

8

87

3

5

2

4

56

9A

9C

9F9C

9E

9B

9G

9D

12

11

10

13

14

9B




Front Caster Assembly (A004839A) (Cont’d)

ITEM NO.


1 W006531A CASTER WELDMENT 1

2 W006532A HUB WELDMENT 1

3 H001004 FLAT WASHER 1

4 H001040 BEARING CONE #13685 1

5 H001039 BEARING CUP #13621 2

6 H001038 BEARING CONE #13600LA 1

7 H001018 NUT, SLOTTED, HEX, 1.00 IN. N.F. 2

8 H001148 COTTER PIN, 0.188 IN. X 1.50 IN. 2

9 H001035 HUB ASSEMBLY, PAINTED BLACK 1

9A H002216 GREASE SEAL #15233VHY 1

9B H001762 BEARING CONE #LM67048 2

9C H001763 BEARING CUP #LM67010 2

9D H001764 GREASE SEAL #15234VB 1

9E H001982 LUG NUT, 0.50 IN. NF, ZP 5

9F H001741 GREASE ZERK, 0.188 IN. X 45° 1

9G H001981 BUSHING, 1.25 IN. X 1.88 IN. X 14 G. 1

10 P065854A TIRE & RIM ASSEMBLY 1

11 P064906A CAPSCREW, MOD. CASTER 1

12 P064907A SPACER BUSHING 2

13 H001041 DUST CAP 1

14 H001076 GREASE FITTING, 1/4 IN.-28 N.F. 90° 1



X-Frame Assembly (A227273B)

P00130

1

2

3

36

11

11

14

14

21

18

24

23




X-Frame Assembly (A227273B) (Cont’d)

ITEM NO.


1 W227272B X-FRAME WELDMENT 1

2 W217256A LATCH WELDMENT 1

3 P060973A INNER TUBE 2

4 P215530A INNER STRUT TUBE 2

5 P005431A BUSHING, SPANNER 2

6 W007051A CHANNEL WELDMENT 1

7 P005430A BUSHING, SPANNER 2

8 H001121 CAPSCREW, 3/8 IN. NC X 2 1/2 IN. GR. 5 4

9 H001008 WASHER, 3/8 IN. FLAT 2

10 H001010 NUT, 3/8 IN. NC NYLOK 6

11 H001855 PIN, ROLL, 3/16 IN. X 1 1/4 IN. 2

12 H004977 WASHER, 3/8 IN. LOCK 2

13 H001015 CAPSCREW, 3/8 IN. NC X 1 IN. 2

14 H006169 SPRING, EXTENSION 2

15 H001307 YOKE, BRAKE, 3/8 IN. PIN DIAMETER 2

16 H001308 NUT, JAM, 3/8 IN. NF 2

17 H001073 CAPSCREW, 3/8 IN. NC X 1/2 IN. 2

18 W217335A HANDLE WELDMENT, “AUTO LATCH" 1

19 H205856 BOLT, SHOULDER, 1/2 IN. X 1 1/4 IN. 1

20 H002712 NUT, JAM, 3/8 IN. NC NYLOK 1

21 H005899 HANDLE GRIP 1

22 P061252A DECAL, TO UNLATCH X-BRACE…. 1

23 P215536A LINKAGE ROD 1

24 A227318A INDICATOR ASSEMBLY 1



Towbar Assembly

ITEM NO. PART NO. DESCRIPTION QTY.

1 W227892A TOWBAR WELDMENT 1

2 H005627 DECAL, WARNING, TOW SPEED 1

3 P227463A DECAL, TOWBAR UP 2

4 P211804A DECAL, DANGER, PINCH POINT 2

5 H003066 CAPSCREW, 0.75 IN. NC X 10 IN. GR 5 1

6 P059837A BUSHING, POLE SPANNER 1

7 A227870A TOWBAR HOLD-UP ASSEMBLY 1

8 H011735 COLLAR, SETSCREW, 1.50 IN. ID 1

9 H001051 NUT, NYLOK, 0.75 IN. NC 1

P00132

1

2

3

4

5

4

3

8

7

6

9




Running Gear Assembly

ITEM NO.


1 W229343D FRONT RUNNING GEAR WELDMENT 1

2 A005137A STABILIZER JACK ASSEMBLY 2

3 W228103A SUPPORT TUBE WELDMENT 2

4 W228222A TROUGH WELDMENT 1

P00147

12

3

4



Decals

P00127P00127

5

18

19

20

21

7

2324

2228

26

26

9

910

3

515

141311

12

17

163

12

27

2

453

5

6

P0015030

29

28

3125




Decals (Cont’d)

ITEM NO.


1 P202111A REFLECTOR, RED / WHITE 1 IN. X 12 IN. 4

2 H004506 REFLECTOR, DOT, AMBER RECT 12

3 P211804A DECAL, PINCH POINT 6

4 P056211A DECAL, WARNING TO AVOID INJURY 1

5 P202110A REFLECTOR, RED / WHITE 2 IN. X 12 IN. 13

6 P227391A WIND DECAL 1

7 P061252A DECAL, LATCH HANDLE 1

8 P227661A TAPE, REFLECTIVE 1

9 P053867A DECAL, WARNING, MAX CAPACITY 4

10 P065750A DECAL, RETRCT GATE FULLY 2

11 P068065A DECAL, WARNING 1

12 P068066A DECAL, MAX. CAPACITY 1

13 P068067A DECAL, 500 LBS. 1

14 P227991A DECAL, STAIR OPERATION 1

15 P227479A DECAL, WARNING DO NOT OPERATE WITH OCCUPANTS 1

16 P005627A DECAL, WARNING TOW SPEED 1

17 P227463A DECAL, TOWBAR / STABILIZER REQUIREMENTS 2

18 P054070A DECAL, RECOMMENDED FLUID 1

19 P227484A DECAL, FLUID LEVEL 1

20 P227474A DECAL, OPEN / CLOSE 1

21 P050603A DECAL, RELEASE VALVE MAXIMUM OPEN 1




25 P051126A DECAL, PRIORITY VALVE 1

26 H004507 REFLECTOR, RECT, RED 5

27 H006067 DECAL, DANGER, PINCH POINT 2

28 P064306A DECAL, TIMER CONTROLLED 1

29 P065637A DECAL, TIMER 1

30 P064304A DECAL, LIGHTS 1

31 P063779A DECAL, 110 BOLT 1



Electrical Schematic (A227550B)

P00103

7

5 7

12 13

1615

21

16

5 7

12 13

1615

21

8

LO

AD

LIN

E

TIM

ER

18 19 2219 22

4

11

17 232 6

1

9

15

23

20

23

20

17

10

3

15

25

14

25

15

16 2414

29

28

26

14

27




Electrical Schematic (A227550B) (Cont’d)

ITEM NO.


1 H006570 RECEPTACLE 1

2 H006569 BATTERY, DEEP CYCLE, 12 VOLT 2

3 A005424A BATTERY CHARGER ASSEMBLY 1

4 H006815 SWITCH, INTERVAL TIMER 1

5 H003416 CHASSIS CLIP 2

6 H003423 BOX, BATTERY 2

7 H005731 SPLICE TAP #31572 30

8 H007319 RELAY #75251 1

9 H003822 BREAKER, CIRCUIT, 20 AMP. 1

10 P067328A HOLD DOWN, BATTERY CHARGER 1

11 A214603A LIGHT ASSEMBLY, LED 17

12 H006647 GROMMET, RUBBER 16

13 H001910 R-CLAMP, 3/8 IN. 10

14 H005680 CONNECTOR, WIRE, #31913 48

15 H005681 CONNECTOR, WIRE, #31903 5

16 H005709 CONNECTOR, WIRE, #31904 3

17 H005713 CONNECTOR, WIRE, #32902 3

18 H005714 CONNECTOR, WIRE, #32903 1

19 H006676 CONNECTOR, WIRE, #32904 3

20 H005715 CONNECTOR, WIRE, #32905 3

21 H005407 CORD, 912 IN.14-2 1

22 H005746 WIRE (WHITE), 32 IN.10 GA. 1

23 H005589 WIRE (RED), 30 IN.10 GA. 1

24 H005754 WIRE (WHITE), 12 IN.14 GA. 1

25 H005747 WIRE (RED), 60 IN. 14 GA. 1

26 NA WIRE, 14-2 CORD, 7 FT. (213.3 CM), BLACK AND WHITE REF.






Hydraulic Schematic (A229376B)

P00104

8

16

151413

10

5

12

18

1111

2

17

4

11

9

1

6

20 3 197




Hydraulic Schematic (A229376B) (Cont’d)

ITEM NO. PART NO. DESCRIPTION QTY.

1 H001435 HYD. SWIVEL, 3/8 IN. M. NPT X 3/8 IN. F. 90° 1

2 H002059 HYD. TEE, 3/8IN. F. NPT 1

3 H002101 HYD. PIPE NIPPLE 3/8 IN.NPT 1

4 A001817A HYD. HOSE ASSEMBLY, 3/8 IN. X 27 IN. LG. 1

5 H002230 BREATHER PLUG, 3/8 IN. 1

6 H004793 FLOW FUSE CARTRIDGE 1



9 H005176 HYDRAULIC CYLINDER, 1-1/2 IN. X 4 IN. STROKE (STABILIZER) 2

10 H206031 HYDRAULIC CYLINDER, 2 IN. X 52 IN. 1

11 H002103 SWIVEL, FEMALE STRAIGHT, 3/8 IN. NPT X 3/8 IN. 4

12 H002466 ELBOW, FEMALE 90°. ST., 3/8 IN. NPT X 3/8 IN. 1


14 H005178 VINYL COATED CLAMP, 5/8 IN. 1

15 H001022 SCREW, SELF DRILLING TEK, ZP, 1/4 IN. X 3/4 IN. 1

16 A227557B HYDRAULIC TANK ASSEMBLY REF.

17 P054552A SPACER FLAT 1

18 W007402A BREATHER CAP 1

19 H002466 HYDRAULIC ELBOW, STREET, 90°, 5502-6 1

20 H002489 HYDRAULIC PIPE ELBOW, MALE 90° 1



Hydraulic Tank Assembly (A227557B)

P00131

302928

27

1

31

7

22

21

20

7

13

144 1110

12

33

22

9

8 12

23

16

32

17

2

196 24

18

36

526

25

34




Hydraulic Tank Assembly (A227557B) (Cont’d)

ITEM NO.


1 W215859A PUMP TANK ASSEMBLY 1

2 H001796 HAND PUMP 1

3 P205323A VALVE, BALL, 3-WAY, 3/8 IN. NPT 3-WAY 1

4 H001805 VALVE, GATE, 3/8 IN. REGO 1

5 H001959 CAPSCREW, 1/4 IN. NC X 2 3/4 IN., GR. 5 2

6 H001027 NUT, NYLOK, 1/4 IN. NC 3

7 H001435 ELBOW, HYDRAULIC SWIVEL, 90° 2

8 H002466 ELBOW, STREET, HYDRAULIC, 5502-6-6 3

9 A216566A FITTING ASSEMBLY, MODIFIED 1

10 H216090 FITTING, PIPE CROSS HYDRAULIC 1

11 H002101 NIPPLE, PIPE, MALE, HYDRAULIC, 5404-6 1

12 H002103 ADAPTER, MALE, HYDRAULIC SWIVEL 2

13 H001067 NUT, JAM, 3/4 IN. NF 1

14 H206161 RELIEF VALVE, 1600 PSI 1

15 H002208 5406-P-6 HYDRAULIC HEX HEAD PLUG (NOT SHOWN) 1

16 H002182 CAP, BREATHER, THREADED, 1 IN. 1

17 H002137 O-RING, 6900-6-6 HYDRAULIC SWIVEL 1

18 H002104 ELBOW, HYDRAULIC SWIVEL, 1503-6-6 1

19 H002271 O-RING, 90° HYDRAULIC SWIVEL 1

20 P051126A DECAL, PRIORITY VALVE 1

21 P050603A DECAL, RELEASE VALVE 1

22 P054070A DECAL, DEXRON III 1

23 A216099A HOSE ASSEMBLY, 13 IN. 2

24 H001176 CAPSCREW, 1/4 IN. NC X 1 1/2 IN. 1

25 H005645 WASHER, FENDER, 1/4 IN. 1

26 H005644 CAPSCREW, 6 MM X 1 X 12MM ZP 1

27 P227498A HANDLE, PUMP 1

28 H002994 CAPSCREW, 3/8 IN. NC X 6 IN., GR. 5 2

29 H001008 WASHER, FLAT, 3/8 IN. 2

30 H001010 NUT, NYLOK, 3/8 IN. 2

31 A002934A HOSE ASSEMBLY, 3/8 IN. X 29.00 1

32 A003529A HOSE ASSEMBLY, 3/8 IN. X 38.00 1

33 P227474A DECAL, CLOSE 1

34 P227484A DECAL, FLUID LEVEL 1


MANUFACTURER’S APPENDICES

MANUFACTURER’S APPENDICES

BATTERY CHARGER OPERATING INSTRUCTIONS (WESTWARD MODEL 1JYV1A) . . . .97Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103Battery Charger Troubleshooting (Model 1JYV1A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104Battery Charger Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106


MANUAFACTURER’S APPENDICES

BATTERY CHARGER OPERATING INSTRUCTIONS (WESTWARD MODEL 1JYV1A)

Description

P00088


BATTERY CHARGER OPERATING INSTRUCTIONS (WESTWARD MODEL 1JYV1A) (CONT’D)

Safety

P00090




Operation

P00091



Operation (Cont’d)

P00092





P00093




P00094




Maintenance

P00095



Battery Charger Troubleshooting (Model 1JYV1A)

P00096




Battery Charger Troubleshooting (Model 1JYV1A) (Cont’d)

P00097



Battery Charger Warranty

P00099


WARRANTY

WARRANTY

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109


WARRANTY

WARRANTY

WARRANTYWASP Inc. Equipment

WASP, Inc. warrants, to the original purchaser only, each of its new products to be free from defects inmaterial and workmanship under normal and recommended use and service, subject to the conditionsand qualifications herein set forth. The obligation of WASP, Inc. hereunder is limited to the repair orreplacement of those parts which WASP, Inc., at it's sole discretion, determines to have failed as aresult of defects in material or workmanship within a period of twelve (12) months after the date ofpurchase.

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

1. Second-hand parts or components.

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

3. Tires, batteries, motors, electrical controls, etc. except that WASP, Inc. agrees to make availableto the first user whatever Warranty benefits may be made available to WASP Inc. for thesepurchased components.

This warranty does not apply to failures resulting from the use of attachments not sold or approved byWASP, Inc.

WASP, Inc. will repair, or at it's option replace any part of its new products which under normal use andservice fail to conform to this Warranty, providing that such part shall be returned to WASP, Inc. or toan 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 Warrantyof merchantability or fitness for a particular purpose.

This Warranty shall immediately become void if any service other than normal maintenance, isperformed by anyone other than an authorized WASP Representative or Dealer; or if any alteration ormodification is made without the prior consent of WASP, or if, in the sole discretion of WASP, Inc., thefailure is due to abuse or neglect in the operation or maintenance of the product due to failure to followthe provisions set forth in the Operation & Maintenance Manual.

Printed in U.S.A.Warranty Department1 - 320 - 634 - 5126


ALPHABETICAL INDEX
ALPHABETICAL INDEX
BATTERY CHARGER OPERATING INSTRUCTIONS (WESTWARD MODEL 1JYV1A) . . . .97EQUIPMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25FEATURES AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23GENERAL INFORMATION AND OPERATING INSTRUCTION SAFETY PRECAUTIONS . .21GENERAL OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43ILLUSTRATED PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3MAINTENANCE AND REPAIR SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .43MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24NORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27PREPARE FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45PURPOSE OF EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23RECORD OF REVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6SAFETY IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4SHIPPING AND TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61STORAGE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64TECHNICAL ADVISORIES / BULLETINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16TITLE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109


Equipment shown is subject to change without notice.© 2013 WASP, Inc. Printed in U.S.A.

® Copyright March 2014

PO Box 249, 20631 State Highway 55Glenwood, MN 56334

Tel: (320) 634-5126 Fax: (320) 634-5881www.waspinc.com

operation & maintenance manualcustomers.waspinc.com/manuals/a227266d operations... · equipment...

Documents