Operation & Service Manual Model: 01-0505-0000 Falcon
Contents
1. FIGURE 7 CORRECT 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 90 See Figure 9 11 2003 Rev 03 FIGURE 8 AVOID CONTACT FIGURE 9 INCORRECT Page 5 TRONAIR APPENDIX Il Declaration of Conformity TRONAIR DECLARATION of CONFORMITY The design development and manu2. For towbar multi heads with shear inspect the shear plates for bending If found remove the towbar multi head from service and contact Tronair for repair Inspect the towing hooks for bending and excessive wear If found remove the towbar multi head from service and contact Tronair or your Tronair distributor for replacement Check the towing hook mounting bolts Ensure they are tight and not missing Tighten or replace as required Inspect the axle locking mechanism Ensure that it springs back to positively hold the towing hooks on the aircraft towing hook up If it does not contact Tronair or your Tronair distributor for replacement repair For towbar multi heads with shear check the shoulder bolt connections through the shear plates Verify they are not clamping the shear plates together There should not be any clamping force applied to the shear plates so the assembly functions properly If required back the stopnut off to remove any clamping force applied Fortowbar multi heads with shear inspect the shear pin If the shear pin is bent broken or missing contact Tronair or your Tronair distributor for replacement Tronair recommends purchasing spare shear pins for rapid replacement use only Tronair specified shear pins For towbar multi heads with shear inspect the shear pin bushings If the shear pin bushings are cracked or chipped contact Tronair or your Tronair distributor for replacement use only Tronair specified shear pin bus
3. BEFORE USING TOWBAR COMPLETE THE FOLLOWING CHECKLISTS Reference Figures 1 amp 2 on Page 2 TOWBAR Area of Towbar Shock Assembly Towbar Weldment 2 Caster Skid Plate Wheel Assembly HEAD Area of Head Bolts amp Lanyards Weldment Shear Pin Mechanism Area of Head Aircraft Attach Point Check 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 1 Tube Is it bent dented bowed and or have cracks 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 1 Casters Are they missing or bent 2 Handles Are they broken bent or missing 3 Bolts Are they missing or loose 1 Wheels Are they flat Is the rim bent 2 Awxle Is it bent Check 1 they loose missing or stripped Are they attached to the head 1 Welds holding side rails to head rail Are there any cracks 2 Shear Plates Are there cracks in welds Are the plates bent 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 Check 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
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 Towbar Function Head 11 2003 Rev 03 Check Spring Has it taken a set Loose in the assembly Eyebolt Is it bent worn down or deformed Tube Is it bent dented bowed or cracked Is it rusted badly Welds Are there any cracks in the welds Head Hole Is it elongated Is the bolt attached correctly DD Does it snap back Pivot Bolt Is it present along with washers Is the nut tight Is it rusted Roll Pin s Are they rusted Are they missing Are they loose Weldment Is it deformed bent or rusted beyond reasonable use Lanyard Is it attached to weldment Sliding Pin s Are they bent cracked or rusted Does it slide eO ort Page 3 TRON IR INS 1582 Towbar Usage Instructions 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 usi
5. TRONAIR Operation amp Service Manual Model 01 0505 0000 Falcon 10 20 100 200 Multi Head C 02 2007 Rev 02 When ordering replacement parts kits please specify model serial number and color of your unit 1740 Eber Rd Tronair Inc Phone 419 866 6301 Holland OH 43528 9794 www tronair com 800 426 6301 USA Email sales tronair com Fax 419 867 0634 REVISION DATE TEXT AFFECTED 02 02 2007 Major Revision TRONAIR Falcon 10 20 100 200 Multi Head TABLE OF CONTENTS PAGE 1 0 DESCRIPTION cuidada ETE 1 1 1 SPECIFICATIONS q tt es 1 2 0 SAFETY INFORMATION civic iio ui kin iic ik a a ci via 1 2 1 GENERAL 22 2 ee I ld u a 1 3 0 OPERATION E os aa au sg has 1 3 1 PRELIMINARY CHECK Z u to ana na 1 3 1 1 Head Attachment Weldment 1 3 1 2 Sliding 1 3 2 USAGE PROCEDURE x amie coe aaa 1 3 2 1 Multi Flead Attachment u su stereo a 1 4 0 puelle 2 4 1 TRAINING REQUIREMENTS 2 uui 2 4 2 TRAINING PROGRAM e ettet edd teste decd teet eee tete athe ve tete reo Q ep ceo ete a k 2 4 3 OPERATOR TRAINING O 2 5 0 PROVISION OF EJ izlimeeccee 2 5 1 SPARE PARTO iti suasana a allem edu
6. 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 Frei
7. cere Des Wo ate eoe etie eoa ns 2 5 2 PARTS LISTS 65 1 1 1 a hay a a i i ha m asa a a 412555 2 6 0 IN SERVICE SUPPORT Lugu EE 2 7 0 GUARANTEES LIMITATION OF LIABILITY rre 2 02 2007 Rev 02 TRON IR Model 01 0505 0000 Falcon 10 20 100 200 Multi Head 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 0505 0000 Multi Head Towbar is a towbar head attachment for the Falcon 10 20 100 200 Aircraft manufactured by Dassault 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 Falcon 10 20 100 200 manufactured by Dassault Maximum Aircraft Gross Weight 30 000 Ibs 13 608 kg Dimensions Length 4 937 in 37 9
8. cm Width 10 in 25 4cm Height 4 59 in 11 66 cm Weight 30 lbs 13 6 kg Finish Blue Powder Coat 2 0 SAFETY INFORMATION 2 1 GENERAL The Tronair Model 01 0505 0000 Towbar Head Attachment is used for towing the DassaultFalcon 10 20 100 200 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 N 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 N 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 Ensu
9. facture is in accordance with European Community guidelines Multi Head 01 0505 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 1740 Eber Rd Tronair Inc Phone 419 866 6301 Holland OH 43528 9794 www tronair com 800 426 6301 USA Email sales tronair com Fax 419 867 0634 TRON Standard Clamp Style Attachment Heads Models 01 0400 0000 01 0505 0000 01 0515 0000 01 0517 0000 01 0520 0000 SHEAR PIN 01 0520 0010 01 0535 0000 01 0544 0000 01 0549 0000 01 0550 0000 SHEAR BUSHING 01 0555 0000 01 0558 0000 01 0560 0000 01 0560 0010 01 0565 0000 01 0578 0000 01 0578 0010 01 0589 0000 01 0589 0010 01 0590 0000 01 0601 0000 01 0602 0000 01 0604 0000 01 0606 0000 01 0610 0000 01 0611 0000 01 0612 0000 WELDMENT TOWING HOOK ee REIN Y SHEAR Y TOWING HOOK MOUNTING BOLT AXLE LOCKING MECHANISM AXLE LOCKING MECHANISM TOWING HOOK MOUNTING BOLT TOWING HOOK Tronair recommends towbar inspections at least once a week Inspect for weld cracks If found remove the towbar multi head from service and contact Tronair for repair Inspect the weldment members for bending If found remove the towbar multi head from service and contact Tronair for repair
10. ght 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 02 2007 Rev 02 Page 2 TRONAIR Model 01 0505 0000 Falcon 10 20 100 200 Multi Head Parts List When ordering replacement parts kits please specify model serial number and color of your unit Ban A Puai Part Number Description Qty 1 Z 1383 01 Weldment Head Not Sold Separately 12 G 1300 16100 Roll Pin 5 32 diameter x 1 long 1 K 1124 Kit Adapter Set Replacement consists of 2 G 1202 1075 Stopnut 3 8 24 Elastic 6 4 J 2664 Adapter Axle 1 5 G 1250 1070N Flatwas
11. her 3 8 Narrow 12 6 G 1100 107516 Bolt Hex Head Grade 5 3 8 24 x 1 34 long 6 10 G 1300 19040 Roll Pin 3 16 diameter x 1 2 long 1 11 J 2663 Adapter Axle 1 K 1125 Kit Axle Locking Mechanism Replacement consists of 3 H 1205 Cover Handle 1 7 Z 0019 Weldment Axle Locking 1 8 G 1300 16050 Roll Pin 5 32 diameter x 5 8 long 1 9 G 1300 25340 Roll Pin 14 diameter x 1 2 long 1 02 2007 Rev 02 Page 3 TRONAIR APPENDIX I Ins 1582 Towbar Usage Instructions TRONAIR INS 1582 Towbar Usage Instructions 11 2003 Rev 03 1740 Eber Rd Tronair Inc Phone 419 866 6301 Holland OH 43528 9794 www tronair com 800 426 6301 USA Email sales tronair com Fax 419 867 0634 REVISION DATE TEXT AFFECTED 03 11 25 03 pg 1 Warning added IR INS 1582 Towbar Usage Instructions 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 A 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 T 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
12. hings Inspect all steel components for signs of rust Touch up with paint as required D OO D INS 1790 www tronair com Tronair Email sales tronair com Phone 419 866 8301 or 800 426 6301 Fax 419 867 0634 Asia Sales Offices China Email tronairchina tronair com Phone 86 592 5560735 Fax 86 592 5563132 Asia Australia Email tronairasia tronair com Phone 66 2665 6511 Fax 66 2204 1858 Europe Middle East amp Africa Sales Office Email saleseurope tronair com Phone 44 0 113 245 3300 Fax 44 0 113 322 0436
13. ng two pintle hooks as shown in Figures 4 amp 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 WEAR FAILURE POINT e INDENTAT ONS 7 FIGURE 6 FIGURE 5 CORRECT 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 11 2003 Rev 03 Page 4 TRONAIR USAGE PROCEDURE continued INS 1582 Towbar Usage Instructions 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
14. 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 Ibs 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 11 2003 Rev 03 Page 1 TRON IR INS 1582 Towbar Usage Instructions EYE TOW HANDLES TOWBAR LOCKING HANDLE PIVOT POINT If Applicable TYPICAL SNAP BAK TOWBAR SLIDING ARM SLIDING PIN PIPER TOW PIN FIGURE 2 NOTE Typical towbar Your towbar and or head may not have all of the features shown SHOCK ASSEMBLY CASTER SKID PLATE TOWBAR WELDMENT WHEEL ASSEMBLY SHEAR PIN MECHAN SM TYPICAL TRONAIR TOWBAR BOLT amp LANYARDS HEAD WELDMENT FIGURE 1 NOTE Typical towbar Your towbar and or head may not have all of the features shown 11 2003 Rev 03 Page 2 TRONAIR INS 1582 Towbar Usage Instructions
15. re 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 Tronair 01 1202 0000 Multi Head _ Ensure the sliding pin is locked in place using the ball lok T pin CAUTION AN It is recommended that your towbar be attached to the aircraft first and then connected to the tug to avoid possible aircraft damage 02 2007 Rev 02 Page 1 TRONAI R Falcon 1 SSO 100 200 MUlt is i 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 Falcon 10 20 100 200 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 419 866 6301 or 800 426 6301 1740 Eber Road Fax 419 867 0634 Holland Ohio 43528 9794 USA E mail sales tronair com Website www tronair com 5 2 PARTS LISTS amp ILLUSTRATIONS Reference the following page for Replacement Parts
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