AVRO PCT600OC User manual

Cargo Dolly
Issue 1, December 2023
PCT600OC
UNIVERSAL PALLET
CONTAINER DOLLY
USER, MAINTENANCE AND
PARTS MANUAL

PCT600OC Cargo Dolly
Page 2 Issue 1, December 2023
Published in Canada by Avro GSE TM Limited.
All possible care has been taken in the preparation of this manual, but Avro GSE, its agents and distributors accept no
liability for any inaccuracies that may be found. This manual reflects the state of the product at its date of issue, but
further enhancements while in service may mean that the manual does not precisely reflect your system.
Avro GSE reserves the right to make changes without notice both to this manual and the products which it describes.
Avro GSE shall not be liable for errors contained herein or for incidental or consequential damages in connection with the
furnishing, performance or use of this manual.
Copyright: © Avro GSE TM 2023
All rights reserved.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means
electronic, mechanical, photocopying, recording or otherwise without the express prior written permission of the
copyright holder.
Avro GSE TM is a registered Trademark of Avro GSE TM.
All trademarks used within this document are the property of their respective owners.
CONTACT DETAILS.
If you require technical assistance with this product that is not covered within this manual, then help can be requested
from Avro GSE using the contact details given below, or from our distribution partners.



Address:
Avro GSE
4 Great Plains Industrial Drive
Emerald Park, SK, S4L 1B6
CANADA
Phone: [phone]
Parts: [email protected]
Service: [email protected]
Website: www.avrogse.com

PCT600OC Cargo Dolly
Issue 1, December 2023 Page 3
TABLE OF CONTENTS
Table of Contents ...................................................................................................................................................3
List of Abbreviations...............................................................................................................................................4
SAFETY....................................................................................................................................................................5
LETHAL DANGER –CARGO USE ONLY.....................................................................................................................5
LETHAL DANGER –DO NOT USE ON PUBLIC ROADS..............................................................................................5
WARNING –MAXIMUM SPEED ..............................................................................................................................5
WARNING –SIZE AND WEIGHT OF CARGO DOLLY.................................................................................................5
WARNING –HEAVY ITEMS .....................................................................................................................................6
WARNING –LUBRICANTS.......................................................................................................................................6
PRECAUTION –PERSONAL PROTECTIVE EQUIPMENT............................................................................................6
PRECAUTION - READ THIS MANUAL.......................................................................................................................6
Description .............................................................................................................................................................7
Cargo Dolly Loading Diagrams................................................................................................................................9
Troubleshooting and Failure Diagnosis................................................................................................................14
Scheduled maintenance.......................................................................................................................................14
Repair ...................................................................................................................................................................15
Exploded Parts View.............................................................................................................................................16
Parts Breakdown List............................................................................................................................................18
Warranty...............................................................................................................................................................20
Disposal ................................................................................................................................................................20

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Page 4 Issue 1, December 2023
LIST OF ABBREVIATIONS
C Centigrade mm millimetres
Deg degree (temperature) mph miles per hour
F Fahrenheit Nm Newton Metre
ft/lbs foot-pounds force P/N Part Number
kg kilograms PPE Personal Protective Equipment
IATA International Air Transport Association SAE Society of Automotive Engineers (specification)
in. Inches SWL Safe Working Load
kph kilometres per hour ULD Unit Load Device
lbs pounds

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Issue 1, December 2023 Page 5
SAFETY
Observe the following safety precautions.
LETHAL DANGER –CARGO USE ONLY
The Cargo Dolly is designed to move cargo pallets and Unit Load Device (ULD)
Containers, only. Do not overload the Cargo Dolly. Make sure that ULD Containers
are correctly positioned on the Cargo Dolly and secured with the spring-loaded
pallet stops. Refer to the list of approved ULD Containers on page 7, and the
loading diagrams (Figures 2 to 6).
DO NOT use the Cargo Dolly to transport people or other items. It is unsafe to do so, and lethal
injury may result.
LETHAL DANGER –DO NOT USE ON PUBLIC ROADS
The Cargo Dolly is designed for use in airports. It is NOT suitable, or legal, for use
on public roads. Attempting to use the Cargo Dolly on a public road may result in
a lethal accident.
DO NOT misuse or fool around with, or on, a Cargo Dolly. Lethal injury may result.
WARNING –MAXIMUM SPEED
Do not exceed the maximum speed of 13 kph (8 mph) recommended by the IATA
for Cargo Dollies with un-sprung wheels. It unsafe to exceed the recommended
speed.
WARNING –SIZE AND WEIGHT OF CARGO DOLLY
The Cargo Dolly weighs 1089.5 kg. When lifting the Cargo Dolly, always use suitable
lifting equipment (e.g. a crane with lifting slings or chains, or a forklift truck) with a
Safe Working Load (SWL) rated above the weight of the equipment to be lifted.
The Cargo Dolly must always be towed or moved using a suitable vehicle.

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WARNING –HEAVY ITEMS
The weight of all components exceeding 1 kg (2.2 lbs) is given in the Parts
Breakdown List. Always use correct manual handling techniques. For items
positioned below mid-lower leg height, safe lifting capacity is 10 kg (5 kg if not
close to your feet) for an able-bodied man and 7kg (3 kg if not close to your feet)
for an able-bodied woman.
WARNING –LUBRICANTS
Do not eat, drink or smoke when applying lubricant. Do not allow the lubricant to
come into contact with your eyes, mouth or nose. Wear Personal Protective
Equipment (PPE), for example suitable gloves, eye shields, and overalls. If
lubricant is ingested, or comes into contact with your eyes, seek medical
assistance immediately.
Lubricant is a slip hazard. Always clean up any spillages, or excess lubricant.
PRECAUTION –PERSONAL PROTECTIVE EQUIPMENT
When using, unpacking, moving, lifting, servicing, repairing, or transporting the
Cargo Dolly, always wear suitable Personal Protective Equipment (PPE) to prevent
crushing of hands, feet, or other body parts. For example, wear protective
footwear, safety glasses, hard hat, protective gloves, and high-visibility clothing.
When preparing the Cargo Dolly for transport by air, road, or rail, make sure it is
securely packed. Safeguard the Cargo Dolly against movement or break-away during transport
by securely strapping it in place.
If stacking the Cargo Dolly for storage, secure it in position by strapping it in place.
PRECAUTION - READ THIS MANUAL
Read this manual before operating, cleaning, repairing, or servicing this equipment.

PCT600OC Cargo Dolly
Issue 1, December 2023 Page 7
DESCRIPTION
The function of the PCT600OC Universal Pallet Container Dolly (Cargo Dolly) is to transport aircraft compatible cargo
pallets within the confines of airports. The Cargo Dolly is NOT suitable for use on public roads. The Cargo Dolly is
designed to be towed by a Baggage Tractor, and multiple Cargo Dolly’s can be linked together, up to the towing limit of
the Baggage Tractor and the regulations of the relevant airport/transport authorities.
Figure 1 –Cargo Dolly
The Cargo Dolly can carry the following combinations of Unit Load Device (ULD) containers:
➢One LD2 ULD.
➢Two LD2 ULD.
➢Four LD2 ULD.
➢One LD3 ULD.
➢Two LD3 ULD.
➢One LD7 ULD.
➢One LB8 ULD.
➢Two LD8 ULD.

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The Cargo Dolly can carry both 88 in. x 125 in. and 96 in. x 125 in. pallets.
The Cargo Dolly comprises a steel frame assembly to which the other parts are attached. The Cargo Dolly incorporates 70
enclosed castors, and eight rollers, to enable easy positioning of the cargo. Spring-loaded tip-up pallet stops secure the
cargo in position. The two front dual wheels are mounted on swivel castors, whereas the two sets of dual rear wheels are
fixed. The tires are solid rubber.
The Cargo Dolly has a tow bar activated braking system, which applies the brake to the rear wheels when the tow bar is
raised. A spring-loaded E-Type hitch at the rear allows multiple units to be linked together.
Cargo Dollies can be stacked for shipping and storage.
SPECIFICATION
The specification of the Cargo Dolly is given in the following Table.
Table 1 Cargo Dolly specification
Cargo Dolly
Value
Units
Notes
Dimensions
Length (towing position)
4661
183 1/2
mm
in.
Length (tow bar raised)
3514
138 5/16
mm
in.
Width
2592
102 1/16
mm
in.
Height
521
20 1/2
mm
in.
Weight
1089.5
kg
2401.9
lbs
Maximum permitted load
7000
kg
15432
lbs
Operating temperature range
-50 to +70
deg C
Ambient temperature
-58 to 158
deg F
Storage temperature range
-50 to +70
deg C
Ambient temperature
-58 to 158
deg F
Humidity range
0 to 100
%
Relative humidity
Maximum towing speed
13
8
kph
mph
Max. speed recommended by the IATA for a
Cargo Dolly with un-sprung wheels.
(AHM 427, ULD Transportation, refers)

PCT600OC Cargo Dolly
Issue 1, December 2023 Page 9
CARGO DOLLY LOADING DIAGRAMS
Figure 2 through Figure 6 show how to position LD2, LD3, LD7, and LD8 ULD Containers on the Cargo Dolly. Note the
positions of the spring-loaded pallet stops which secure the ULD Containers in place.
Figure 2 –Four LD2 Containers on Cargo Dolly

PCT600OC Cargo Dolly
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Figure 3 –Two LD3 Containers on Cargo Dolly

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Issue 1, December 2023 Page 11
Figure 4 –LD7 Container on Cargo Dolly

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Figure 5 –A single LD8 Container on Cargo Dolly

PCT600OC Cargo Dolly
Issue 1, December 2023 Page 13
Figure 6 –Two LD8 Containers on Cargo Dolly

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TROUBLESHOOTING AND FAILURE DIAGNOSIS
Troubleshooting and failure diagnosis of the Cargo Dolly is limited to performing the visual inspection procedure
described in the Scheduled Maintenance table.
SCHEDULED MAINTENANCE
Scheduled maintenance is limited to the activities specified in the Table below. The maintenance intervals given are
approximate, assume heavy use of the Cargo Dolly, and may be varied by ±10% without adverse effects. Every Cargo
Dolly should be inspected and serviced based on its own requirements, for example variation in the hours of use and the
environment in which it is used.
When fitting fasteners, DO NOT apply thread-locking adhesive. The wheel nuts have a minimum torque setting, specified
in the Table below, to which they must be tightened using a Torque Wrench. For all other fasteners, it is sufficient to
tighten them hand-tool tight: - there is no requirement to use a Torque Wrench or apply a specific torque.
Task
Monthly
6 Monthly
1
Cleaning
a.
Use water and degreaser, or a domestic detergent and water solution. Do not
use industrial cleaning agents, or caustic agents, or aircraft de-icing and
cleaning agents. Use of a spray washer is permitted.
X
X
2
Visual and Mechanical Inspection
Examine the Cargo Dolly for the following. During the inspection tighten any
fasteners that are loose.
a.
Main Frame undamaged. Minor damage or corrosion is acceptable. Damage to
the Main Frame that affects the operation of the Cargo Dolly requires the
replacement of the Cargo Dolly.
X
X
b.
Check the Swivel Castors. Replace any that are damaged or missing.
X
X
c.
Check the Rollers. Replace any that are damaged or missing.
X
X
d.
Check that the e-hitch is undamaged, secure, and functions correctly. Replace
if required.
X
X
e.
Check Tow Bar is undamaged, secure, and functions correctly. Replace Tow
Bar and/or Tow Bar Mounting Assembly, if required.
X
X
f.
Check that the Towbar Adjustable Stops are present and undamaged. Replace
if missing or damaged.
X
X
g.
Check that all Hood Spring Stops and Handle Stops are present, secure,
undamaged and function correctly. Replace any that are missing or
unserviceable.
X
X
h.
Check Qty. four Wheel Axel Assemblies and Qty. two Front Swivel Axle
Assemblies for wear, damage, security of attachment, trapped debris, and
X
X

PCT600OC Cargo Dolly
Issue 1, December 2023 Page 15
Task
Monthly
6 Monthly
wheel rotation. Remove debris. Check Front Swivel Axle Assemblies for swivel
function. Replace any that are badly worn, damaged or not fully functional.
i.
On all wheels, check that the wheel nuts are present. Make sure that all wheel
nuts are tightened to a MINIMUM torque of 156 Nm (115 ft/lbs).
X
X
j.
Check Brake Line Linkage and associated threaded rods, spring, threaded
yoke, and fasteners, are all present, secure, serviceable, and function
correctly. Replace any that are missing or unserviceable.
X
X
k.
Check Brake Bar is present, undamaged, secure, and functioning. Check
associated Brake Shoes are present and not so worn that brake function is
degraded. Replace if missing or unserviceable item.
X
X
l.
Check side bumpers are present and secure. Replace if required.
X
X
m.
Check red and yellow reflective stickers are present. Replace if required.
X
X
3
Lubrication
Use a heavy-duty, marine grade, agricultural grade, or military grade, bearing
grease suitable for long term use outside in severe environments. For
example: Plews & Edelmann LubriMatic type 11404 Marine Trailer Wheel
Bearing and Corrosion Control Grease.
Or an equivalent. For example: MIL-PRF-10924 (NATO Code No G-403) Grease
Automotive and Artillery.
a.
Lubricate the Qty. four Wheel Axel Assemblies.
X
b.
Lubricate the Qty. two Front Swivel Axle Assemblies.
X
REPAIR
Repair of the Cargo Dolly is by direct replacement of the faulty or damaged component. The Exploded Parts View
illustrations show all the components and how the Cargo Dolly is dismantled and re-assembled. All the components are
listed in the Parts Breakdown List and the numbers on the Exploded Parts View illustrations are keyed to the Parts
Breakdown List.
Replacement parts should be sourced from Avro GSE. The use of major components not obtained from Avro GSE will
invalidate the Warranty.
NOTE
It is expected that replacement fasteners may be sourced locally. If sourcing fasteners locally, make sure
that the replacement fasteners are the same type and grade of material, and have the same protective
coating, as the original. The Parts Breakdown List specifies the required material and finish.
The Main Frame Assembly is not available as a spare. Any significant damage to the Main Frame Assembly will almost
certainly be part of catastrophic damage to the Cargo Dolly. Also, the time and effort required to strip down the Cargo
Dolly, replace the Main Frame Assembly, and then rebuild, is such that significant damage to the Main Frame Assembly
renders the Cargo Dolly “Beyond Economic Repair”.

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EXPLODED PARTS VIEW
Figure 7 –Exploded Parts View (from above)

PCT600OC Cargo Dolly
Issue 1, December 2023 Page 17
Figure 8 –Exploded Parts View (from below)

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PARTS BREAKDOWN LIST
NOTE
Weights are only given in the table below for items that have a weight of 1 kg or more.
Item
Part No.
Description
Qty
Weight per
item (kg)
1
PRNP00032
Main Frame Assembly
1
654.0
2
PRNP00026
Tow Bar Mounting Assembly
2
2.0
3
PRNP00023
Front LD8 Stop Support
1
9.0
4
PRNP00021
LD1,2,3 Stop Support
2
11.0
5
PRNP00018
Hood Stop Support
2
4.0
6
PRNP00022
LD8 Stop Support
1
5.0
7
PRNP00020
Middle Stop Support
1
3.0
8
PRNP00007
Front Swivel Axle Assembly
2
10.0
9
PRNP00024
Wheel Axle Assembly
4
35.0
10
PRNP00003
Solid Tire with Rim
8
11.4
11
PRNP00005
Brake Shoe Assembly
2
4.0
12
PRNP00008
Tow Bar
1
34.8
13
PRNP00006
Brake Line Linkage
1
5.1
14
PRNP00033
Brake Bar Assembly
1
28.0
15
Side Bumper
2
7.1
16
PRNP00004
Towbar Latch
1
-
17
Right Rear Roller Bracket
2
3.1
18
Left Rear Roller Bracket
2
3.1
19
Brake Bar Bracket
2
1.0
20
Front Splash Guard
2
-
21
Rear Over Wheel Splash Guard
2
-
22
Rear Splash Guard
2
-
23
Front Over Wheel Splash Guard
2
-
24
PRNP00035
Towbar Adjustable Stop
2
-
25
PRNP00002
Swivel Castor
70
-
26
PRNP00029
Left-Hand Threaded Rod
1
-
27
PRNP00034
Threaded Rod
1
1.2
28
PRNP00016
Roller - Rear
2
4.5
29
PRNP00018
Hood Spring Stop
8
2.0

PCT600OC Cargo Dolly
Issue 1, December 2023 Page 19
Item
Part No.
Description
Qty
Weight per
item (kg)
30
PRNP00036
e-Hitch
1
11.0
31
PRNP00031
Reflective Sticker, Red, plastic, 3" Dia.
4
-
32
PRNP00030
Reflective Sticker, Yellow, plastic, 3" Dia.
4
-
33
PRNP00028
Forged Yoke, 3/4", Right-Hand Thread
1
3.4
34
PRNP00015
Brake Line Spring
1
1.3
35
PRNP00019
Bent Handle Stop
12
1.4
36
PRNP00020
Straight Handle Stop
1
1.4
37
PRNP00027
Forged Yoke, 3/4", Left-Hand Thread
1
3.4
38
PRNP00017
Roller - Side
6
3.1
39
Hex Bolt - 5/16-18 X 1" - Zinc Plated, SAE Grade 8
176
-
40
Hex Bolt - 5/16-18 X 2-3/4" –Zinc Plated, SAE Grade 8
4
-
41
Hex Bolt - 1/2-13 X 1-1/2" - Zinc Plated, SAE Grade 8
24
-
42
Hex Bolt - 1/2-13 X 2-1/2" - Zinc Plated, SAE Grade 8
4
-
43
Hex Bolt - 1/2-13 X 2-3/4" - Zinc Plated, SAE Grade 8
21
-
44
Hex Bolt - 9/16-12 X 2" - Zinc Plated, SAE Grade 8
24
-
45
Hex Bolt - 5/8-11 X 3" - Zinc Plated, SAE Grade 8
2
-
46
Hex Bolt - 3/4-10 X 2" - Zinc Plated, SAE Grade 8
4
-
47
Hex Bolt - 3/4-10 X 3" - Zinc Plated, SAE Grade 8
2
-
48
Hex Bolt - 5/16-18 X 1-1/2" - Zinc Plated, SAE Grade 8
9
-
49
Hex Nut - 3/4-10 - Zinc Plated, SAE Grade 8
4
-
50
Nut, NYLOCK, Self-Locking - 5/16-18 - Zinc Plated, SAE
Grade 8
189
-
51
Nut, NYLOCK, Self-Locking - 1/2-13 - Zinc Plated, SAE
Grade 8
85
-
52
NUT, NYLOCK, Self-Locking - 9/16-12 –Zinc Plated, SAE
Grade 8
24
-
53
Nut, NYLOCK, Self-Locking - 5/8-11 - Zinc Plated, SAE
Grade 8
2
-
54
Nut, NYLOCK, Self-Locking - 3/4-10 - Zinc Plated, SAE
Grade 8
1
-
55
Nut, NYLOCK, Self-Locking - 3/4-10 - Zinc Plated, SAE
Grade 8
5
-
56
Washer, Flat, Wide - 3/4" - Zinc Plated, Carbon Steel
2
-
57
Socket Head Cap Screw 0.5 –13x2x2-HX-N
36
-

PCT600OC Cargo Dolly
Page 20 Issue 1, December 2023
WARRANTY
All Avro GSE products are covered by our Warranty Policy. If you require a copy of our Warranty Policy, please contact us
using the contact details given on page 2 of this manual.
DISPOSAL
The Cargo Dolly contains no electrical components. A Cargo Dolly that is damaged beyond economic repair, or worn out,
should be recycled at a metal recycling facility.