Tronair K-3864 Installation and operating instructions

1740 Eber Rd
Tronair, Inc. Phone: [phone]
Holland, OH 43528-9794 www.tronair.com 800-426-6301
USA Email: [email protected] Fax: [phone]
Operation & Service Manual
Model: K-3864
2 ¼ " Load Alarm Kit
06/2004 −Rev. OR
Includes Illustrated Parts Lists

Model: K-3864
2 ¼" Load Alarm Kit
06/2004 −Rev. OR
TABLE OF CONTENTS PAGE
1.0 Product Information............................................................................................................................................................1
2.0 Safety Information..............................................................................................................................................................1
2.1 Alarm And Warning Systems..................................................................................................................................1
2.2 Warning And Danger Signs ....................................................................................................................................1
2.3 Component Safety Features...................................................................................................................................1
2.4 Functional Safety Features.....................................................................................................................................1
2.5 Features For Operator Safety.................................................................................................................................1
2.6 Environmental Safety Features...............................................................................................................................1
2.7 Protection Systems.................................................................................................................................................1
2.8 Closed Circuits........................................................................................................................................................1
2.9 Interlocking .............................................................................................................................................................1
2.10 Necessary Personal Protective Equipment.............................................................................................................1
2.11 Safety Guidelines....................................................................................................................................................1
2.12 Conditions For Safe Use.........................................................................................................................................2
2.13 Operator Qualifications...........................................................................................................................................2
2.14 Additional Safety Measures....................................................................................................................................2
3.0 Packaging And Storage......................................................................................................................................................2
3.1 Packaging Requirements........................................................................................................................................2
3.2 Handling..................................................................................................................................................................2
3.3 Strapping ................................................................................................................................................................2
3.4 Packaging Protection..............................................................................................................................................2
3.5 Labeling Of Packaging............................................................................................................................................2
3.6 Storage Compatibility..............................................................................................................................................2
3.7 Storage Environment..............................................................................................................................................2
3.8 Storage Space And Handling Facilities:..................................................................................................................2
4.0 Transporting Requirements................................................................................................................................................2
5.0 Assembly............................................................................................................................................................................3
5.1 General Instructions................................................................................................................................................3
5.2 Pre-Use Checks......................................................................................................................................................3
5.3 Personnel Requirements ........................................................................................................................................3
5.4 Assembly Steps......................................................................................................................................................3
5.5 Inspection And Test Procedures.............................................................................................................................3
6.0 Installation..........................................................................................................................................................................3
7.0 Operation ...........................................................................................................................................................................4
7.1 Operating Parameters.............................................................................................................................................4
7.2 Numerical Values....................................................................................................................................................4
7.3 Operator Controls ...................................................................................................................................................4
7.4 Operating Instructions.............................................................................................................................................4
7.4.1 Rules For Operating.................................................................................................................................4
7.4.2 Alarm Operation And Test........................................................................................................................4
8.0 Training..............................................................................................................................................................................4
9.0 Maintenance.......................................................................................................................................................................5
General ..............................................................................................................................................................................5
9.1 Maintenance Schedule ...........................................................................................................................................5
9.2 Cleaning Alarm.......................................................................................................................................................5
10.0 Troubleshooting .................................................................................................................................................................5
11.0 Provision Of Spares ...........................................................................................................................................................5
11.1 Recommended Spares To Be Kept On Hand.........................................................................................................5
11.2 Parts List.................................................................................................................................................................5
12.0 In-Service Support..............................................................................................................................................................7
13.0 Guarantees/Limitation Of Liability ......................................................................................................................................7

Model: K-3864
2 ¼" Load Alarm Kit
06/2004 −Rev. OR
- 1 -
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., its 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
NAME OF EQUIPMENT: 2 ¼″Load Alarm Kit
MODEL NUMBER: K-3864 See nameplate for Serial Number.
MANUFACTURED BY: TRONAIR, Inc. 1740 Eber Rd., Holland, OH 43528-9794 USA
USAGE: This device is used in conjunction with Tronair stabilizing stands and is designed to alert the operator when
a load is being applied to the top of the stabilizing stand.
LIST OF DRAWINGS: Reference Illustrated Parts List, page 6.
2.0 SAFETY INFORMATION
2.1 ALARM and WARNING SYSTEMS
The alarm system alerts the operator that a force of 100 to 150 lbs (45.36 to 68.04 kg) is being applied to the top
of a stabilizing stand. The unit is attached to a stabilizing stand and sounds a loud 85 db pulsating alarm until the
force is reduced.
2.2 WARNING and DANGER SIGNS
None
2.3 COMPONENT SAFETY FEATURES
Extension Pin provides a visual check that the pin is fully inserted to meet the rated load capacity of the
tailstand.
2.4 FUNCTIONAL SAFETY FEATURES
None.
2.5 FEATURES FOR OPERATOR SAFETY
None
2.6 ENVIRONMENTAL SAFETY FEATURES
Load Alarm is non-polluting.
2.7 PROTECTION SYSTEMS
None.
2.8 CLOSED CIRCUITS
Reference Illustration 2.8.
2.9 INTERLOCKING
None.
2.10 NECESSARY PERSONAL PROTECTIVE EQUIPMENT
CAUTION!
Always wear safety glasses.
2.11 SAFETY GUIDELINES CAUTION!
1. DO NOT place hands near the die springs on the load alarm kit while the stabilization stand is in use.
Pinch point exists on the die springs and between the top plate and the base of the load alarm kit.
2. ALWAYS be sure the load alarm extension pin is fully locked and inserted through the tube.
3. DO NOT allow prolonged exposure to the sounding of the alarm. The alarm sound may cause
permanent hearing loss.
4. DO NOT place objects in the path of the alarm’s horn opening that may limit the audible range and
reduce the effectiveness of the alarm.
5. DO NOT turn setscrew located under the plunger switch. The distance between the setscrew and
plunger switch is pre-set by the factory.
2.0 Safety Information continued on following page.
2.8 −
−−
−Closed Circuits

Model: K-3864
2 ¼" Load Alarm Kit
06/2004 −Rev. OR
- 2 -
2.0 SAFETY INFORMATION (continued)
2.12 CONDITIONS FOR SAFE USE
•Use in a clean dry environment.
•Operate between +4°C and 38°C/+40°F and 100°F.
2.13 OPERATOR QUALIFICATIONS
This load alarm is intended to be used by a skilled and trained aircraft technician. The operator must be familiar
with the jacking procedures for the aircraft to be raised, and the operation of a stabilizing stand.
Installation/Maintenance/Dismantling Qualifications: This load alarm is to be installed, maintained, and
dismantled by qualified technicians familiar with aircraft maintenance systems.
2.14 ADDITIONAL SAFETY MEASURES
This load alarm must be used in accordance with this Technical manual, and in accordance with the aircraft
manufacturer’s jacking and stabilizing procedures.
3.0 PACKAGING AND STORAGE
3.1 PACKAGING REQUIREMENTS
Load alarm is to be packaged as required to prevent damage to the electronic circuits. Battery must be removed from
unit and shipped separately..
3.2 HANDLING
Load alarm can be carried by hand.
3.3 STRAPPING
None
3.4 PACKAGING PROTECTION
No special packaging material for cushioning or suspension is required.
3.5 LABELING OF PACKAGING
Packaging should be labeled DO NOT DROP.
3.6 STORAGE COMPATIBILITY
No special considerations.
3.7 STORAGE ENVIRONMENT
•Store load alarm between +4°C and +38°C/+40°F and 100°F.
•Load alarm must be stored in a clean and dry environment.
3.8 STORAGE SPACE AND HANDLING FACILITIES:
•Weight: 4 lbs (1.8 kg)
•Width: 5 ½ in (13.97 cm)
•Length: 7 ½ in (19.05 cm)
•Height: 5 3/16 in (13.18 cm)
4.0 TRANSPORTING REQUIREMENTS
No special considerations.

Model: K-3864
2 ¼" Load Alarm Kit
06/2004 −Rev. OR
- 3 -
Figure 2
Figure 1
Figure 4
Figure 3
5.0 ASSEMBLY
5.1 GENERAL INSTRUCTIONS
1. This product should be assembled and/or repaired using good workmanship practices and proper tools.
Bolts and elastic stopnuts should be tightened to a torque not to exceed industry standards for Grade '5'
bolts.
2. All replacement parts must be the same as or better than the original parts supplied.
3. No modifications are allowed as they may adversely affect the load alarm’s safety performance.
5.2 PRE-USE CHECKS
1. Refer to the Illustrated Parts List to identify and ensure that all parts are present.
2. Generally check over unit and ensure the tightness of all nuts and bolts.
5.3 PERSONNEL REQUIREMENTS
This jack is to be assembled by qualified technicians familiar with aircraft maintenance systems.
5.4 ASSEMBLY STEPS
1. Assemble the load alarm kit over the outer extension tube. The base of the load alarm kit will rest on the
stabilizing stand’s top plate. (see Figure 1)
2. Assemble the center extension through the center of the load alarm kit. Pin the center extension to the
desired height with the extension pin (see figure 1)
3. Install a 9-volt battery in the alarm by removing two screws located in the back of the alarm. (see Figure 2)
5.5 INSPECTION AND TEST PROCEDURES
1. Depress test button on alarm to test battery is
installation. (see Figure 3)
2. Depress the plunger switch to check electronic circuit.
The alarm will sound when the switch is engaged. (see
Figure 4)
3. Test alarm by slowly applying an evenly distributed force
of 100 to 150 lbs across the top of the load alarm. The
top plate of the load alarm kit will lower and engage the
plunger switch, A loud pulsating alarm will then sound. If
alarm does not sound, refer to the Troubleshooting
section. (see Figure 4)
6.0 INSTALLATION
None

Model: K-3864
2 ¼" Load Alarm Kit
06/2004 −Rev. OR
- 4 -
FIGURE 5
7.0 OPERATION
7.1 OPERATING PARAMETERS
1. The user shall work in accordance with the Operator and/or Technical Manuals
2. The employer of the operator shall provide all necessary training
3. Operate between +4°C and 38°C/+40°F and 100°F
7.2 NUMERICAL VALUES
•Weight: 4 lbs (1.8 kg)
•Width: 5 ½ in (13.97 cm)
•Length: 7 ½ in (19.05 cm)
•Height: 5 3/16 in (13.18 cm)
•Alarm (Battery Powered): 9 vdc
•Alarm Horn: 85 db
7.3 OPERATOR CONTROLS
None
7.4 OPERATING INSTRUCTIONS
The user should be familiar with the following statements prior to using the load alarm kit:
CAUTION!
1. DO NOT place hands near the die springs on the load alarm kit while the stabilization stand is in use.
Pinch point exists on the die springs and between the top plate and the base of the load alarm kit.
2. ALWAYS be sure the load alarm extension pin is fully locked and inserted through the tube.
3. DO NOT allow prolonged exposure to the sounding of the alarm. The alarm sound may cause
permanent hearing loss.
4. DO NOT place objects in the path of the alarm’s horn opening that may limit the audible range and
reduce the effectiveness of the alarm.
5. DO NOT turn setscrew located under the plunger switch. The distance between the setscrew and
plunger switch is pre-set by the factory.
7.4.1 Rules For Operating
1. The user shall work in accordance with the Operator and/or Technical Manuals.
2. The employer of the operator shall provide all necessary training.
3. Operate between +4°C and 38°C/+40°F and 100°F
4. Load alarm is designed as an add-on kit for Tronair stabilizing stands only.
5. Extension pin included with the load alarm kit replaces the use of the existing extension pin on the
stabilizing stand.
WARNING!
Extension pin shall not be used in the center tube section of the
welded tripod stand. The load alarm kit will not operate if the
adjustable extension tube is pinned in this area of the stand. (see
Figure 5)
7.4.2 Alarm Operation and Test
1. When a force of 100 to 150 lbs (45.36 to 68.04 kg) is
applied to the top of the cradle, the alarm unit sounds a
loud 85 db pulsating alarm until the force is reduced.
2. Press test button on the alarm and hold for a minimum of
five 5 seconds. This will sound alarm if the electronic
circuitry, horn and battery are operating correctly.
3. Depress plunger switch under the load alarm’s top plate
and hold for a minimum of 2 seconds. This will sound the
alarm if the switch is operating correctly.
8.0 TRAINING
Training of operating personnel is the responsibility of the employer.
This load alarm must be used in accordance with aircraft manufacturer’s
instructions.

Model: K-3864
2 ¼" Load Alarm Kit
06/2004 −Rev. OR
- 5 -
9.0 MAINTENANCE
GENERAL
•All maintenance and/or repair work should be done using good workmanship practices and proper tools.
•Load alarm shall be maintained and repaired in accordance with the manufacturer’s instructions. Such
maintenance and repair shall be carried out by qualified persons.
•No modifications shall be carried out as they may adversely affect the compliance of the load alarm with draft
standard prEN 1494:1994.
9.1 MAINTENANCE SCHEDULE
Cleaning................................................. Annually or as Needed
Lubricate Cradle Stem.................................................3 Months
Lubricate Casters.........................................................3 Months
NOTE: Wipe with soft cloth only, do not pressure wash or spray water directly at load alarm.
9.2 CLEANING ALARM
Remove alarm from mounting bracket. The openings around the alarm perimeter may be cleared of debris by
using compressed air or a vacuum cleaner hose to blow/suction openings. The outside surface of the alarm unit
may be wiped with a damp cloth.
10.0 TROUBLESHOOTING
Alarm will not sound:
Load was on the cradle for a short period of time..........Limit switch has to be engaged for a minimum of 2 seconds
Defective Alarm .............................................................Replace Alarm
Battery power depleted..................................................Replace Battery
Defective Limit Switch....................................................Replace Limit Switch
Broken wire connection .................................................Check wire connection between limit switch and alarm
Cradle head did not lower far enough to........................Adjust the set screw under the plunger switch and test per
contact limit switch section 5.5.3
Alarm “chirps”:
Indicates low Battery......................................................Replace battery (Alarm will “chirp” every 20 to 30 seconds for a
minimum of 7 days until battery is changed)
11.0 PROVISION OF SPARES
11.1 Recommended Spares to be kept on hand
EC-1854........................Battery, 9 volt
Spare parts may be obtained from the Manufacturer:
TRONAIR, Inc. Telephone: [phone] or 800-426-6301
1740 Eber Road Fax: [phone]
Holland, Ohio 43528-9794 USA E-mail: [email protected]
Website: www.tronair.com
11.2 PARTS LIST
When ordering replacement parts/kits, please specify model, serial number and color of your unit.

Model: K-3864
2 ¼" Load Alarm Kit
06/2004 −Rev. OR
- 6 -
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
ITEM PART NUMBER DESCRIPTION QTY
1............................G-1493 ............................................Pin, 3/8 diameter x 3 LG...........................................................1
2............................H-1026*07.0....................................Assembly, Cable ......................................................................1
3............................EC-1796..........................................Switch, Limit.............................................................................1
K-3887 Kit,Alarm Replacement; consists of:
4............................ ........................................................Alarm........................................................................................1
............................ ........................................................Terminal, Ring..........................................................................2
WARNING!
•Use only the batteries specified.
•Use of different batteries may have a detrimental effect on the alarm.
•Use only the following 9 volt replacement batteries for alarm:
BATTERY SPECIFICATIONS
Alkaline Type............EVEREADY 522; DURACELL MN1604, MX1604 GOLD PEAK 1604A, AL9 RAYOVAC

Model: K-3864
2 ¼" Load Alarm Kit
06/2004 −Rev. OR
- 7 -
12.0 IN-SERVICE SUPPORT
Contact Tronair for technical services and information.
13.0 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.