Tronair 01-0400-0000 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: 01-0400-0000
Dash 8-400
Multi-Head
10/2012 - Rev. 03
When ordering Replacement Parts/Kits, please specify Model, Color and Serial Number of your Unit.

REVISION DATE TEXT AFFECTED
OR 04/1998 Original Release
01 02/2007 Major revision
02 05/2009 Modified Parts List
03 10/2012 Modified 1.1 Specifications

Model: 01-0400-0000
Dash 8-400 Multi-Head
10/2012 | Rev. 03
TABLE OF CONTENTS PAGE
1.0 DESCRIPTION ..............................................................................................................................................................1
1.1 SPECIFICATIONS .....................................................................................................................................................1
2.0 SAFETY INFORMATION...............................................................................................................................................1
2.1 GENERAL..................................................................................................................................................................1
3.0 OPERATION..................................................................................................................................................................1
3.1 PRELIMINARY CHECKLIST......................................................................................................................................1
3.1.1 Head Attachment Weldment ......................................................................................................................................1
3.1.2 Sliding Pin..................................................................................................................................................................1
3.2 USAGE PROCEDURE...............................................................................................................................................1
3.2.1 Multi-Head Attachment...............................................................................................................................................1
4.0 TRAINING......................................................................................................................................................................2
4.1 TRAINING REQUIREMENTS ....................................................................................................................................2
4.2 TRAINING PROGRAM...............................................................................................................................................2
4.3 OPERATOR TRAINING.............................................................................................................................................2
5.0 PROVISION OF SPARES .............................................................................................................................................2
5.1 SPARE PARTS..........................................................................................................................................................2
5.2 PARTS LISTS & ILLUSTRATIONS............................................................................................................................2
6.0 IN-SERVICE SUPPORT................................................................................................................................................2
7.0 GUARANTEES/LIMITATION OF LIABILITY ................................................................................................................2

Model: 01-0400-0000
Dash 8-400 Multi-Head
10/2012 | Rev. 03 Page | 1
Tronair towbars/heads must only be used with matching Tronair heads/towbars, and Tronair shear pins.
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 DESCRIPTION
The Tronair Model 01-0400-0000 Multi-Head Towbar is a towbar head attachment for the Dash 8-400 Aircraft manufactured by
DeHavilland.
The towbar head attachment is designed for use with Tronair Multi-Head Towbar Model 01-1202-0000 for towing the
previously stated aircraft. The towbar head attachment uses a sliding pin/stationary pin arrangement to interface with the
aircraft tow point.
1.1 SPECIFICATIONS
Aircraft Application: Dash 8-400 manufactured by DeHavilland
Maximum Aircraft Gross Weight: 65,400 lbs (29.7 Metric tons)
Dimensions: Length: 20.9 in (53 cm)
Width: 9.4 in (24 cm)
Height: 5 in (12.7 cm)
Weight: 35 lbs (15.9 kg)
Finish: Blue Powder Coat
2.0 SAFETY INFORMATION
2.1 GENERAL
The Tronair Model 01-0400-0000 Towbar Head Attachment is used for towing the Dash 8-400 Aircraft only.
To ensure safe operation, please read the following statements and understand their meaning. This manual contains safety
precautions, which are explained as follows. Please read carefully.
WARNING!
Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, and/or
substantial property damage if the Warning Notice is ignored.
CAUTION!
Caution is used to indicate the presence of a hazard, which will or can cause minor personal injury or property
damage is the Caution Notice is ignored.
WARNING!
A damaged or bent towbar should not be used. Towbar should be repaired or replaced.
3.0 OPERATION
3.1 PRELIMINARY CHECKLIST
3.1.1 Head Attachment Weldment
Check weld between connector tube and head plate for cracks.
Check weld between side rails and head plate for cracks.
Check weld between side rail and stationary pin for cracks.
Check weld between side rail and sliding pin sleeve for cracks.
3.1.2 Sliding Pin
Check sliding pin for bending or excessive wear. Ensure sliding pin slides freely.
Check sliding pin ball lok-T pin. Ensure ball lok-T pin is securely attached to the head attachment via its lanyard.
Ensure ball lok-T pin is not loose or missing.
3.2 USAGE PROCEDURE
3.2.1 Multi-Head Attachment
Secure the towbar head attachment using the ball lok-T pin (supplied with the multi-head towbar) onto the 01-1202-0000
Tronair Multi-Head Towbar
Ensure the sliding pin is locked in place using the ball lok-T pin.
CAUTION!
It is recommended that your towbar be attached to the aircraft first, and then connected to the tug to avoid
possible aircraft damage.

Model: 01-0400-0000
Dash 8-400 Multi-Head
10/2012 | Rev. 03 Page | 2
4.0 TRAINING
4.1 TRAINING REQUIREMENTS
The employer of the operator is responsible for providing a training program sufficient for the safe operation of the towbar.
4.2 TRAINING PROGRAM
The employer provided operator training program should cover safety procedures concerning use of the towbar in and around
the Dash 8-400 at the servicing location.
4.3 OPERATOR TRAINING
The operator training should provide the required training for safe operation of the towbar.
NOTE: Maintenance and Trouble Shooting are to be performed by the skilled and trained technician.
5.0 PROVISION OF SPARES
5.1 SPARE PARTS
Spare parts may be obtained from the 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
5.2 PARTS LISTS & ILLUSTRATIONS
Reference the following page for Replacement Parts and Kits available.
6.0 IN-SERVICE SUPPORT
Contact Tronair for technical services and information.
7.0 GUARANTEES/LIMITATION OF LIABILITY
Tronair products are warranted to be free of manufacturing or material defects for a period of one year after shipment to the
original customer. This is solely limited to the repair or replacement of defective components. This warranty does not cover the
following items:
a) Parts required for normal maintenance
b) Parts covered by a component manufacturers warranty
c) Replacement parts have a 90-day warranty from date of shipment
If you have a problem that may require service, contact Tronair immediately. Do not attempt to repair or disassemble a product
without first contacting Tronair, any action may affect warranty coverage. When you contact Tronair be prepared to provide the
following information:
a) Product Model Number
b) Product Serial Number
c) Description of the problem
If warranty coverage is approved, either replacement parts will be sent or the product will have to be returned to Tronair for
repairs. If the product is to be returned, a Return Material Authorization (RMA) number will be issued for reference purposes
on any shipping documents. Failure to obtain a RMA in advance of returning an item will result in a service fee. A decision on
the extent of warranty coverage on returned products is reserved pending inspection at Tronair. Any shipments to Tronair must
be shipped freight prepaid. Freight costs on shipments to customers will be paid by Tronair on any warranty claims only. Any
unauthorized modification of the Tronair products or use of the Tronair products in violation of cautions and warnings in any
manual (including updates) or safety bulletins published or delivered by Tronair will immediately void any warranty, express or
implied.
The obligations of Tronair expressly stated herein are in lieu of all other warranties or conditions expressed or implied. Any
unauthorized modification of the Tronair products or use of the Tronair products in violations of cautions and
warnings in any manual (including updates) or safety bulletins published or delivered by Tronair will immediately
void any warranty, express or implied and Tronair disclaims any and all liability for injury (WITHOUT LIMITATION and
including DEATH), loss or damage arising from or relating to such misuse.

Model: 01-0400-0000
Dash 8-400 Multi-Head
10/2012 | Rev. 03 Page | 3
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Item
Part Number
Description
Qty
1
Not Sold Separately
Head Weldment
REF
K-1443
Kit, Sliding Bar Replacement; consists of:
11
J-1314
Sliding Bar
2
K-1452
Kit, Spring Replacement; consists of:
8
G-1302-11
Spring
1
9
H-1263
Pin
1
K-2802
Kit, Adapter Replacement; consists of:
2
J-2639
Adapter, Axle
1
3
G-1100-107520
Bolt, Hex Head, Grade 5, 3/8-24 x 2" long
6
4
G-1250-1070N
Flatwasher, 3/8 Narrow
12
5
G-1202-1075
Stopnut, 3/8-24 Elastic
6
13
J-2640
Adapter, Axle
1
K-2803
Kit, Actuator Linkage Replacement; consists of:
6
G-1300-25340
Roll Pin, 1/4" diameter x 3-1/2" long
1
7
H-1205
Handle Cover
2
8
H-1263
Spring
1
10
Z-3675
Weldment, Actuator
1
11
J-1314
Sliding Bar
2
12
R-1756
Rod
1

APPENDIX I
INS-1582
Towbar Usage Instructions

Tronair, Inc. Phone: [phone] | 800-426-6301
1 Air Cargo Pkwy East Web: www.tronair.com
Swanton, OH 43558 Email: [email protected]
INS-1582
Towbar Usage
Instructions
11/2003 –Rev. 03

REVISION DATE TEXT AFFECTED
03 11/25/03 pg 1 Warning added

INS-1582
Towbar Usage Instructions
11/2003 | Rev. 03 Page | 1
Your Tronair towbar is engineered and built to the highest standards of quality and workmanship. Under normal usage and
with minimal maintenance this towbar will provide exceptional service.
WARNING! A damaged or bent towbar should not be used, but should be repaired or replaced.
Using a damaged or bent towbar can result in aircraft or equipment damage and possible
personal injury.
WARNING! Towbars With Hydraulic Lifting Mechanism:
The hydraulic lift mechanism (on those towbars so equipped) should only be used to raise the
towbar to facilitate connection to the aircraft or tug.
Release any hydraulic pressure when towing aircraft or moving towbar.
WARNING! Towbars Should be Used with Category 1 Tugs:
Tronair recommends the use of a towbar with a category 1 or category 2 tug and aircraft not exceeding
75,000 lbs gross weight. Using the towbar with aircraft weighing in excess of this specific limitation may
result in excessive loads and stresses being applied to the towbar and/or the aircraft. These excessive
loads may cause failure of the towbar which could cause damage (INCLUDING WITHOUT LIMITATION to
the aircraft) and/or personal injury OR DEATH. TRONAIR MAKES NO REPRESENTATION, WARRANTY OR
GUARANTEE AS TO SUCH MISUSE AND DISCLAIMS ANY AND ALL LIABILITY FOR INJURY, LOSS OR
DAMAGE ARISING FROM OR RELATING TO SUCH MISUSE.

INS-1582
Towbar Usage Instructions
11/2003 | Rev. 03 Page | 2
(If Applicable)
FIGURE 2
NOTE: Typical towbar. Your towbar and/or head may not have all of the features shown
NOTE: Typical towbar. Your towbar and/or head may not have all of the features shown
FIGURE 1

INS-1582
Towbar Usage Instructions
11/2003 | Rev. 03 Page | 3
BEFORE USING TOWBAR, COMPLETE THE FOLLOWING CHECKLISTS:
Reference Figures 1 & 2 on Page 2.
TOWBAR:
Area of Towbar: Check:
Shock Assembly: 1. Weld between eye and tube (Are there cracks?)
2. Bolts attaching shock to towbar (Loose, missing, stripped, etc.)
3. Eyebolt (Is it bent, worn down, or deformed?
Towbar Weldment: 1. Tube (Is it bent, dented, bowed, and/or have cracks?)
2. Weld at head end (Are there any cracks in the welds?)
3. Head hole (Is it elongated? Is the ball lok pin attached to the towbar?)
Caster/Skid Plate: 1. Casters (Are they missing or bent?)
2. Handles (Are they broken, bent, or missing?)
3. Bolts (Are they missing or loose?)
Wheel Assembly: 1. Wheels (Are they flat? Is the rim bent?)
2. Axle (Is it bent?)
HEAD:
Area of Head: Check:
Bolts & Lanyards: 1. Are they loose, missing, or stripped? Are they attached to the head?
Weldment: 1. Welds holding side rails to head rail (Are there any cracks?)
2. Shear Plates (Are there cracks in welds? Are the plates bent?)
Shear Pin Mechanism: 1. Shear Pin (Is it bent or deformed? Are there spares?)
2. Bushings (Are they cracked, chipped, secure?)
3. Pivot Bolt (Are the nuts tight? Are there washers present?)
Area of Head: Check:
Aircraft Attach Point: 1. Sliding Pin(s) (Are they bent, cracked? Do they slide freely?)
2. Locking Pin (Are they loose? Do they hold the sliding pins securely?)
3. Wear sleeves (Are the welds cracked?)
4. Roll Pins(s) (Are they rusted? Are they missing? Are they loose?)
5. Ball Lok Pin (Is it attached to head? Is it rusted? Is it bent?)
6. Axle Adapter (Is it bent? Is the slot deformed? Are bolts tight?)
SNAP-BAK AND UNIVERSAL TOWBARS:
Area of Towbar: Check:
Towbar: 1. Spring (Has it taken a set? Loose in the assembly?)
2. Eyebolt (Is it bent, worn down, or deformed?)
3. Tube (Is it bent, dented, bowed, or cracked? Is it rusted badly?)
4. Welds (Are there any cracks in the welds?)
5. Head Hole (Is it elongated? Is the bolt attached correctly?)
Function: 1. Does it snap back?
Head: 1. Pivot Bolt (Is it present along with washers? Is the nut tight? Is it rusted?)
2. Roll Pin(s) (Are they rusted? Are they missing? Are they loose?)
3. Weldment (Is it deformed, bent, or rusted beyond reasonable use?)
4. Lanyard (Is it attached to weldment?)
5. Sliding Pin(s) (Are they bent, cracked or rusted? Does it slide?)

INS-1582
Towbar Usage Instructions
11/2003 | Rev. 03 Page | 4
USAGE PROCEDURE
Aircraft Attachment:
It is recommended that your towbar be attached to the aircraft first, and then connected to the tug to avoid possible aircraft
damage.
Ensure sliding pins are locked in place before towing aircraft.
Tug Attachment:
Damage to the towbar or aircraft can result from an excessive towbar angle during towing operations (Reference to Figure 3).
If aircraft with both high and low tow points are encountered, consider using two pintle hooks, as shown in Figures 4 & 5, so
that the towbar is as level as possible during towing. Also pintle hook height should prevent contact of towbar wheels with the
ground, during towing. (Reference Figure 5).
Type Of Coupler:
Damage to the towbar or aircraft can result while towing with the following type of couplers:
- Lift Head - Vertical Side Swing Latch
- Standard Duty Latch - Swivel Hook
These types of couplers are known to cause binding and failure in the eyebolt. Indicators of eyebolt binding are wear on the
outside diameter of the eye and indentations on the inside diameter. The failure will begin at the head of the eye. See Figure
6.
FIGURE 3 - INCORRECT
FIGURE 4 - CORRECT
FIGURE 5 - CORRECT
FIGURE 6

INS-1582
Towbar Usage Instructions
11/2003 | Rev. 03 Page | 5
USAGE PROCEDURE (continued)
Type Of Coupler:
Damage to the towbar or aircraft can result while towing with the following type of couplers:
- Lift Head - Vertical Side Swing Latch
- Standard Duty Latch - Swivel Hook
These types of couplers are known to cause binding and failure in the eyebolt. Indicators of eyebolt binding are wear on the
outside diameter of the eye and indentations on the inside diameter. The failure will begin at the head of the eye. See Figure
6.
Figure 7 illustrates a pintle hook arrangement that is known to eliminate eyebolt binding. Tronair recommends using this type
of hook on your tug.
Eyebolt and Pintle Pin Size:
Damage to the towbar or aircraft can result by towing or pushing an aircraft
with an incorrect size eyebolt or pintle pin. A correct size eyebolt will make
contact with the pintle pin. A gap between the eyebolt outside diameter
and the coupler face plate should be easily seen. An eyebolt which is too
large will cause the eyebolt to make contact with the face plate of the
coupler. When the eyebolt is too large for the coupler, a gap between the
inside diameter of the eyebolt and the coupler face plate will be seen. See
Figure 8.
To ensure proper towing and pushing, check to make sure that the pintle
pin diameter is not too large for the eyebolt's inside diameter.
Approximately a one-half inch (1/2") gap between the pin diameter and the
eyebolt should be seen. If any of these conditions are not met, please
contact Tronair for information to obtain a new coupler.
Towing Angle:
Damage to the towbar or aircraft can result from pushing an aircraft while
maintaining too sharp of an angle between the tug and the towbar. Contact
between the towbar weldment and tug must be avoided. It is
recommended that the angle between the tug and towbar not exceed 90º.
See Figure 9.
FIGURE 9
FIGURE 8
FIGURE 7

APPENDIX II
Declaration of Conformity

Tronair, Inc. Phone: [phone] | 800-426-6301
1 Air Cargo Pkwy East Web: www.tronair.com
Swanton, OH 43558 Email: [email protected]
DECLARATION of CONFORMITY
The design, development and manufacture is in accordance with European Community guidelines
Multi-Head
01-0400-0000
Relevant provisions complied with by the machinery:
2006/42/EC
Relevant standards complied with by the machinery:
EN ISO 12100-1
Identification of person empowered to sign on behalf of the Manufacturer:
Quality Assurance Representative