Tronair 04-6152-0120 Installation and operating instructions

OPERATION & SERVICE MANUAL
Tronair, Inc. Phone: [phone] | 800-426-6301
1 Air Cargo Pkwy East Web: www.tronair.com
Swanton, OH 43558 Email: [email protected]
Model: 04-6152-0120
Utility Crane
09/2017 Rev. 02

REVISION DATE TEXT AFFECTED
01 08/2008 Original Release
02 09/2017 Modified Parts List

04-6152-0120
Utility Crane
09/2017 | Rev. 02
TABLE OF CONTENTS PAGE
1.0 PRODUCT INFORMATION ..............................................................................................................................................1
1.1 DESCRIPTION....................................................................................................................................................1
1.2 MODEL & SERIAL NUMBER..............................................................................................................................1
1.3 MANUFACTURER..............................................................................................................................................1
2.0 SAFETY INFORMATION..................................................................................................................................................1
2.1 USAGE AND SAFETY INFORMATION..............................................................................................................1
3.0 TRAINING.........................................................................................................................................................................1
3.1 TRAINING REQUIREMENTS.............................................................................................................................1
3.2 TRAINING PROGRAM .......................................................................................................................................1
3.3 OPERATOR TRAINING......................................................................................................................................1
4.0 SPECIFICATIONS ............................................................................................................................................................2
5.0 FEATURES.......................................................................................................................................................................3
5.1 OPERATOR CONTROLS AND PARTS..............................................................................................................3
5.2 OPTIONAL FIELD INSTALLED KITS .................................................................................................................4
6.0 PREPARATION FOR USE ...............................................................................................................................................4
6.1 CRANE ASSEMBLY...........................................................................................................................................4
6.1.1 Crane Base Assembly.........................................................................................................................................4
6.1.2 Column and Boom Assembly..............................................................................................................................5
6.2 CRANE OPERATION .........................................................................................................................................5
7.0 WINCH KIT (K-2953 OPTION)..........................................................................................................................................6
7.1 TECHNICAL SPECIFICATIONS.........................................................................................................................6
7.2 INSTALLATION...................................................................................................................................................7
7.3 OPERATION.......................................................................................................................................................7
7.3.1 To Pull the Cable In or Raise the Load ...............................................................................................................7
7.3.2 To Let Cable Out or Lower the Load...................................................................................................................7
8.0 PNEUMATIC PUMP KIT (K-2013 OPTION).....................................................................................................................8
8.1 INSTALLATION...................................................................................................................................................8
8.2 OPERATION.......................................................................................................................................................8
9.0 GOOSENECK KIT (K-2012 OPTION)...............................................................................................................................9
9.1 INSTALLATION...................................................................................................................................................9
10.0 INSPECTION/MAINTENANCE.......................................................................................................................................10
10.1 INITIALINSPECTION .......................................................................................................................................10
10.2 BEFORE EACH USE........................................................................................................................................10
10.3 PERIODIC INSPECTION..................................................................................................................................11
10.4 ANNUAL INSPECTION.....................................................................................................................................11
10.4.1 CRANE INSPECTION & TESTING REQUIREMENTS.....................................................................................11
11.0 PROVISION OF SPARES...............................................................................................................................................12
11.1 SOURCE OF SPARE PARTS...........................................................................................................................12
11.2 RECOMMENDED SPARE PARTS LISTS ........................................................................................................12
12.0 IN SERVICE SUPPORT..................................................................................................................................................12
13.0 GUARANTEES/LIMITATION OF LIABILITY..................................................................................................................12
14.0 APPENDICES.................................................................................................................................................................12

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Utility Crane
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This product can not be modified without the written approval of Tronair, Inc. Any modifications done without written approval
voids all warranties and releases Tronair, Inc., it suppliers, distributors, employees, or financial institutions from any liability
from consequences that may occur. Only Tronair OEM replacement parts shall be used.
1.0 PRODUCT INFORMATION
1.1 DESCRIPTION
The Tronair heavy duty utility crane is designed to handle many lifting tasks required in aviation maintenance facilities, such as
engine changes, stabilizer removal, etc.
1.2 MODEL & SERIAL NUMBER
Reference nameplate on unit
1.3 MANUFACTURER
TRONAIR, Inc. Telephone: [phone] or 800-426-6301
1 Air Cargo Pkwy East Fax: [phone]
Swanton, Ohio 43558 USA E-mail: [email protected]
Website: www.tronair.com
2.0 SAFETY INFORMATION
2.1 USAGE AND SAFETY INFORMATION
To insure safe operations please read the following statements and understand their meaning. Also refer to your equipment
manufacturer’s manual for other important safety information. This manual contains safety precautions which are explained
below. Please read carefully.
WARNING! —Warning is used to indicate the presence of a hazard that can cause severe personal injury,
death, or substantial property damage if the warning notice is ignored.
CAUTION! —Caution is used to indicate the presence of a hazard that will or can cause minor personal injury
or property damage if the caution notice is ignored.
3.0 TRAINING
3.1 TRAINING REQUIREMENTS
The employer of the operator is responsible for providing a training program sufficient for the safe operation of the unit.
3.2 TRAINING PROGRAM
The employer provided operator training program should cover safety procedures concerning use of the unit in and around the
intended aircraft at the intended aircraft servicing location.
3.3 OPERATOR TRAINING
The operator training should provide the required training for safe operation of the unit.
NOTE: Maintenance and Trouble Shooting are to be performed by a skilled and trained technician.

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4.0 SPECIFICATIONS
Minimum Length: 117 in (297.2 cm)
Width: 78 in (198.2 cm)
Minimum Height: 156 in (396.2 cm)
Weight: 2,399 lbs (1,088 kg)
Standard Boom
Position
Maximum
Load
lbs (kg)
Maximum
Height
in (cm)
Extension
“BL”
in (cm)
1
1350 (612)
231 (541)
115.25 (293)
2
1850 (839)
227 (577)
108.25 (275)
3
2200 (998)
223 (566)
101.25 (257)
4
2500 (1134)
219 (556)
94.25 (239)
5
2750 (1247)
215 (546)
87.25 (222)
6
2750 (1247)
211 (536)
80.25 (204)
7
2750 (1247)
207 (526)
73.25 (186)
Gooseneck Boom
Position
Maximum
Load
lbs. (kg)
Maximum
Height
in (cm)
Extension
“BL”
in (cm)
1
500 (227)
292 (741)
197 (500)
2
560 (254)
288 (731)
190 (482)
3
600 (272)
284 (721)
183 (464)
4
640 (290)
280 (711)
176 (447)
5
700 (317)
276 (701)
169 (429)
6
750 (340)
272 (690)
162 (411)
7
800 (363)
268 (680)
155 (393)
WARNING!
Load ratings listed above are valid for non-winch applications ONLY.
Reference section 5.1 Technical Specifications of 5.0 Winch Kit Operation for the appropriate safe load
conditions listed above.

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5.0 FEATURES
Heavy duty base provides required counter-weight for safe lifting
Clean design allows maximum workroom
Conveniently located controls
Positive holding hand break
Heavy duty bearing swivel casters and wheels
Built in handle for easy movement
Safety fuse prevents load dropping in case of hydraulic failure
Safety locking pin allows eight (8) locking positions on cylinder rod
Blue powder coated
5.1 OPERATOR CONTROLS AND PARTS
See illustration

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5.0 FEATURES (continued)
5.2 OPTIONAL FIELD INSTALLED KITS
K-2012 Kit, Gooseneck:
The Gooseneck is an extension to the main boom. The Gooseneck increases the overall maximum height of the crane to 275
inches (698 cm). (Reference Parts List page 15)
K-2013 Kit, Pneumatic Pump:
The pneumatic pump uses shop air to raise the main boom. (Reference Parts List page 14)
K-2953 Kit, Winch:
This hand winch kit allows loads to be lifted & lowered vertically, independently of boom, through use of an easy-to-operate
hand winch. The winch can be used with or without the Gooseneck kit. (Reference Parts List page 13)
6.0 PREPARATION FOR USE
The unit is shipped complete with the base partially assembled, and only the following steps are required to make the crane
operational:
6.1 CRANE ASSEMBLY
6.1.1 Crane Base Assembly
Step 1 Unpack all components and inspect parts.
Step 2 Using lift truck, crane or equivalent, place crane base on flat ground with front end of base supported by two 4” x 4”
pieces of lumber (supplied, part number W006-01*012.0) under front base tube.
Step 3 Position legs under both sides of base and align holes. There are six (6), 7/16 x 2 ½” long, bolts used to secure each
leg to the base.
NOTE: There are eight (8) holes in the leg, only six (6) will be used per side.
Starting from the rear of each leg, install bolt with washer through base and leg assembly, secure with washer and
elastic stopnut. C-clamps or equivalent may be necessary to help draw leg assembly to bottom of base. After all six
nuts and bolts are installed and hand-wrench tight, start from back of base, working to the front, torque bolts to 54 ft-
lbs. (73.2 nm). Repeat for other leg. Remove lumber supports and let base rest on ground.
Step 4 Install tow handle using one inch (1") bar and cotter pins.
Step 5 Install hand brake screw rod into base and install pad onto screw drive.
6.1 Crane assembly continued on following page.

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6.1 CRANE ASSEMBLY (continued)
6.1.2 Column and Boom Assembly
Step 1 Install column assembly onto base, using eight (8) ¾ inch bolts with flatwashers and lockwashers. Torque to 380 ft-
lbs (515 nm).
NOTE: If winch kit is included with crane review section 5.2 BEFORE proceeding.
Step 2 Install main boom onto column using 1¼ inch pin and lock rings.
Step 3 Connect cylinder to boom using one inch (1") pin and lock rings.
6.2 CRANE OPERATION
Step 1 Fill reservoir to within one inch (1") of top with mineral base hydraulic fluid.
Step 2 Position boom extension to desired position.
Step 3 See chart located on crane column for loading and height information.
Step 4 Close flow control valve and pump to raise the main boom.
Step 5 Open flow control valve to lower main boom.

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7.0 WINCH KIT (K-2953 OPTION) WARNING!
The winch is of general purpose design for manual operation only and the load rating is based on an
intermittent duty cycle. The winch is not designed to be a human hoist and should never be operated
when there are persons positioned on or under the load being lifted.
Obey crank rotation instructions. Disregarding these instructions could cause bodily harm or property
damage. When facing the crank handle side of the winch, crank clockwise to lift the load, counter-
clockwise to lower the load. Never release the crank handle unless the ratchet pawl is fully engaged
and supporting the load.
NEVER exceed the rated capacities shown on the winch frame.
Never exceed the boom rated capacities shown under section 2.0.
Maintain a minimum of four (4) wraps of cable on the drum at all times.
WARNING!
NEVER use worn, kinked or frayed cable. These conditions are unsafe. Replace the cable immediately
with Tronair certified cable only!
Always inspect the cable and hook before each use to make sure they are not damaged. If the cable or
hook breaks, the cable can act like a whip and inflict serious damage to anyone in its path.
NEVER stand along side the winch cable, or guide the cable with your hands.
NEVER permit anyone on or under the load that is being lifted.
NEVER operate with wet or oily hands and always use a firm grip on the handle.
NEVER leave a weight hanging by the winch while the winch is unattended, as unauthorized persons
may attempt to operate the winch, thereby creating an unsafe condition.
NEVER use crane if any damage or excessive wear is found.
NEVER make any alterations or modifications to crane.
CAUTION!
Tether load to keep the load from swinging.
ALWAYS stay clear of suspended loads.
NEVER use sling to lift personnel.
NEVER leave suspended loads unattended.
NEVER remove or obscure warning labels.
DO NOT use crane until you have read and understood this manual.
NEVER lift loads higher than necessary.
7.1 TECHNICAL SPECIFICATIONS
NOTE: Read Thern’s Owner’s Manual for complete technical specifications and instructions on winch use and its
operation (Thern winch model # M452B-A).
Maximum capacity 3000 lbs (1360.7 kg)
Cable: 5/16 inch diameter, 7x19 Aircraft (8 mm)
19.5:1 gear ratio, Maximum mechanical advantage 101:1
Automatic load holding break system.
When cranking counter-clockwise, this winch incorporates a mechanical brake bypass system that winds cable off the drum
when the load is very light. The brake will reset when the load is increased.
7.0 Winch Kit (K-2953 Option) continued on following page.

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7.0 WINCH KIT (K-2953 OPTION) (continued)
7.2 INSTALLATION
Step 1 Attach cable to winch per INS-1517 supplied with winch kit.
Step 2 Install pulley at end of beam extension, install pulley on column and beam intersection.
Step 3 Bolt winch plate to crane with 3/8 inch bolts. Torque to 49 ft-lbs (66 nm).
Step 4 Bolt winch to winch plate using ½ inch bolts. Torque to 120 ft-lbs (163 nm)
Step 5 Run 5/16 inch diameter cable into front end of main boom over pulleys.
Step 6 Secure cable on drum as shown in INS-1517.
Standard Boom Cable Routing
7.3 OPERATION
The brake is actuated by turning the handle. The load-lock brake is designed to hold the load whenever the handle is released.
7.3.1 To Pull the Cable In or Raise the Load
1. The cable must be securely fastened to the object being lifted and to the winch drum.
2. Always be sure that the cable and cable attachments are not damaged.
3. Crank handle clockwise to lift, making sure the clicking sound of the ratchet is heard.
7.3.2 To Let Cable Out or Lower the Load
1. Crank the handle counter-clockwise. No clicking sound will be heard because the load-lock braking system is now
activated.