Operation & Service Manual Models: 01-1297-0100
Contents
1. Z 2 S S 7 4 TRONAR AN FIGURE 4 CORRECT INCORRECT 01 1950 5000 Standard Telecoupler FIGURE 5 Damage to the towbar and 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 Reference Figure 5 5 ensure proper towing and pushing check to make sure the pintle pin diameter is not too long for the eyebolt s inside diameter An approximate 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 AVOID CONTACT 3 2 4 Towing Operation Damage to the towbar or aircraft can result from pushing an aircraft while maintaining too sharp of an angle between the tug and the aircraft Contact between the towbar weldment and the tug must be avoided It is recommended that the angle between the tug and towbar not exceed 90 Reference2. 4 0 uillccme 3 4 1 TRAINING REQUIREMENTS x 32 5 3 etin Rated han 3 4 2 TRAINING PROGRAM zz circus foi ayanta m uy ee DR I 3 4 3 OPERATOR TRAINING er tr e Rte tre a RAE UG D LR 3 5 0 IN SERVICE SUPPORT L ccL 3 6 0 GUARANTEES LIMITATION OF LIABILITY norte ea Ionen ote rna les nino rauhen era 4 Appendix I Declaration of Conformity Appendix II Maintenance Schedules 04 2009 Rev 01 TRON IR Models 01 1297 0100 01A1297 0100 01B1297 0100 Embraer 170 175 190 195 Custom Towbars 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 1297 0100 01A1297 0100 and 01B1297 0100 Custom Towbars are designed for towing the Embraer 170 175 190 195 Aircraft manufactured by Embraer The custom towbar includes a hydraulic operated landing gear to raise a
3. Figure 6 TUG 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 FIGURE 6 4 2 TRAINING PROGRAM The employer provided operator training program should cover safety procedures concerning use of the towbar in and around the Embraer 170 175 190 195 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 IN SERVICE SUPPORT Contact Tronair for technical services and information 04 2009 Rev 01 Page 3 TRON IR Models 01 1297 0100 01 1297 0100 01B1297 0100 Embraer 170 175 190 195 Custom Towbars 6 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 contact
4. Inspect the pump fluid level Before adding MIL PRF 5606 hydraulic fluid ensure that the undercarriage is collapsed Inspect hydraulic fittings and hose for leaks If any hydraulic leaks exist contact Tronair or your Tronair distributor for replacement Inspect cylinder for hydraulic leaks If any hydraulic leaks exist contact Tronair or your Tronair distributor for replacement seals Check extension springs Extend cylinder to full stroke and open relief valve on pump The extension springs should retract the cylinder completely If not contact Tronair or your Tronair distributor for replacement Inspect cylinder mounting pins for bending or damage Ensure the springs are engaged on them If pins are bent or damaged contact Tronair or your Tronair distributor for replacement The undercarriage allows towing by a tow vehicle of speeds up to 6 mph 10 km h Check the towbar undercarriage for unusual wear or damage Inflate the pneumatic tires to the proper pressure repair any air leaks or replace if needed Ensure the wheels can rotate freely and wheel rims and tire axle are not bent Ensure mounting fasteners are tight and not missing Tighten or replace as required Grease tire axle every 90 days Inspect towbar undercarriage side plates for bending or damage If any exist contact Tronair or your Tronair distributor for replacement Inspect head adapter if applicable for Tronair 500 series towing heads Ensure it is not damaged or missing Con
5. TOWBAR UNDERCARRIAGE AND HOSE TOWING EYE RUBBER SKID OR CASTERS Tronair recommends towbar inspections at least once a week L Check towing eye for bending excessive wear and deformity If any are located remove towbar from service and contact Tronair for repair Check towing eye mounting bolts Ensure the fasteners are tight and not missing Tighten to 25 ft lbs or replace as required Ensure the towing eye does not move or turn by hand if the towing eye can turn this may indicate that the centering pin within the shock assembly may be broken and repairs are needed Contact Tronair for repairs Check the shock assembly for preload on the spring by pulling on the towing eye If the shock can be moved by hand this may indicate the spring is worn out contact Tronair for repairs Check the rubber skid or casters at the towing eye end Ensure that all fasteners are tight and not missing Tighten or replace as required If the bumper is split or excessively worn contact Tronair or your Tronair distributor for replacement Inspect the lifting handle for damage Contact Tronair or your Tronair distributor for repair or replacement if required Inspect the towbar tube for cracks gouges greater than 1 16 and bends or deformities If any are located remove towbar from service and contact Tronair for repair Inspect the pump for hydraulic leaks Replace seals if any leaks exist Contact Tronair or your Tronair distributor for replacement
6. chipped contact Tronair or your Tronair distributor for replacement use only Tronair specified shear pin bushings Inspect all steel components for signs of rust Touch up with paint as required D UD OO INS 2223 www tronair com Tronair Email sales tronair com Phone 419 866 6301 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
7. 24 Screw Cap 5 16 18 x 2 1 2 long 1 49 G 1152 106216 Screw Cap 5 16 18 x 1 3 4 long 1 50 H 2667 16 Plunger Ball 2 51 G 1202 1065 Elastic Stopnut 5 16 24 4 52 J 3557 01 Rail Side 1 53 G 1151 109710 Screw Cap 12 20 x 1 long 4 54 G 1315 06 1 50 Pin Dowel 4 04 2009 Rev 01 Page 6 TRONAIR APPENDIX I Declaration of Conformity TRONAIR DECLARATION of CONFORMITY The design development and manufacture is in accordance with European Community guidelines Multi Head Towbars 01 1297 0100 01A1297 0100 01B1297 0100 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 NU 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 laintenance Schedule Heavy Duty Universal Multi Head Towbars TOWING HEAD ATTACHMENT Models 01 1290 0100 01 1297 0100 01A1314 0100 01A1326 0100 BALL LOK PIN OR BOLT 01 1336 0100 01A1341 0100 01 1354 0100 CYLINDER 500 SERIES EXTENSION MOUNTING PIN HEAD ADAPTER CYLINDER SPRING if applicable me LIFTING HANDLE TOWBAR TUBE TOWING EYE MOUNTING BOLTS PNEUMATIC 2 s CYLINDER SIDE PLATE TIRES MOUNTING PIN HYDRAULIC FITTING
8. TRONAIR Operation amp Service Manual Models 01 1297 0100 01A1297 0100 01B1297 0100 Custom Towbars Embraer 170 175 190 195 Aircraft C 04 2009 Rev 01 Includes Illustrated Parts Lists 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 01 04 2009 Original release TRON IR Models 01 1297 0100 01A1297 0100 01B1297 0100 Embraer 170 175 190 195 Custom Towbars TABLE OF CONTENTS PAGE 1 0 DESCRIPTION m E M POR 1 1 1 SBEGIFIGATIONS Saitek a oto dei ide f ce de tete Sedo ated ae 1 2 0 SAFETY INFORMATION m 1 2 1 GENERAL nun rente iii 1 3 0 E R 2 3 1 PRELIMINARY CHECKLIST 2a ee tidad 2 3 1 1 TOWD ARS ro eo etri iones 2 3 1 2 Towing u To 2 3 2 USAGE PROCEDURE sieves 2 a a a sb ree ate ra ee Y evan NER 2 3 2 1 2 3 2 2 TUG Attachment astaun engen 2 3 2 3 A A e dte detiene madent eite 2 3 2 4 Towing Operation ES 3
9. air for repair Inspect the side rails head rail and head plate for bending If found remove the towbar multi head from service and contact Tronair for repair 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 sliding locking plate and the toggle mechanism for bending cracks and excessive wear If found remove the towbar multi head from service and contact Tronair or your Tronair distributor for replacement Ensure the sliding locking plate can move freely within its housing If any binding occurs inspect the sliding locking plate for bending and the housing for flatness If either condition exists contact Tronair for repair options 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 For towbar 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
10. ball plungers 3 2 2 Tug Attachment CAUTION Damage to the towbar or aircraft can result from an excessive towbar angle during towing operations Reference Figure 1 Use a pintle height so that the towbar is as level as possible during towing Also the pintle hook height should prevent contact of the towbar with the ground during towing Z ES Al lt 6 NN ER Sc A FIGURE 1 Incorrect FIGURE 2 Correct 3 2 3 Couplers EYEBOLT CAUTION Damage to the towbar or aircraft can result while towing with the following types of couplers amp e Lift Head Standard Duty Latch e Vertical Side Swing Latch Swivel Hook The couplers listed above are known to cause binding and failure in 8 the towing eye Indicators of binding are wear on outside diameter of the eyebolt and indentation on the inside diameter of the eyebolt Reference Figure 3 INDENTATIONS WEAR FIGURE 3 3 2 3 Couplers continued on following page 04 2009 Rev 01 Page 2 TRON IR Models 01 1297 0100 0141297 0100 01B1297 0100 Embraer 170 175 190 195 Custom Towbars 3 2 3 Couplers continued Tronair recommends a telecoupler pintle hook arrangement This arrangement is known to eliminate binding Tronair offers a Standard Telecoupler Model Number 01 1950 5000 for use on tugs Heference Figure 4 LEN A e
11. ing 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 expre
12. nd lower the towing head The aircraft attachment is by machined hooks on the towing head to the nose landing gear tow pin There is a handle and an eyebolt at the end of the towbar for towing The eyebolt incorporates a compression spring to dampen shock loads during towing 1 1 SPECIFICATIONS Aircraft Application Embraer 170 175 190 195 manufactured by Embraer Eyebolt 01 1297 0010 23 16 in 5 6 cm Standard 01A1297 0010 2 in 7 3 cm 01B1297 0010 7 62 cm Dimensions Length 206 31 in 524 cm From eyebolt centerline to aircraft attachment centerline Width 24 2 in 61 5 cm Height 22 125 in 56 2 cm Weight 250 Ibs 113 4 kg Finish Towbar Blue Powder Coat Towing Head Zinc Plating 2 0 SAFETY INFORMATION 2 1 GENERAL The Tronair Model 01 1297 0100 01A1297 0100 and 01B1297 0100 Custom Towbars are used for moving the Embraer 170 175 190 195 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 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 CAUTION Caution is used to indicate the p
13. resence of a hazard which will or can cause minor personal 04 2009 Rev 01 Page 1 TRON IR Models 01 1297 0100 01 1297 0100 01B1297 0100 Embraer 170 175 190 195 Custom Towbars 3 0 OPERATION 3 1 PRELIMINARY CHECKLIST 3 1 1 Towbar Check weld between towbar and pump mount for cracks Check weld between towbar and cylinder mount for cracks Check weld between towbar and handles for cracks Check hydraulic connections for leaks Check air pressure in tires inflate deflate as required Check all fastener connections to ensure they are not loose or missing 3 1 2 Towing Head Check welds between head plate connector tube and shear plates for cracks Check shear pin to ensure it has not broken replace if necessary Check fastener connection of towing head to towbar Ensure the connection is not loose or missing Check shear pin bushings Ensure they are not cracked or chipped Check hooks on towing head for bending or excessive wear Check pivot bolt Ensure connection is secure Check slide assembly ensure ball detents plungers properly lock Check all fastener connections to ensure they are not loose or missing 3 2 USAGE PROCEDURE 3 2 1 Aircraft Attachment CAUTION It is recommended that your towbar be attached to the aircraft first and then connected to the tug to avoid possible aircraft damage Ensure the slide block is locked in place using the detent
14. ss 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 04 2009 Rev 01 Page 4 TRON IR Models 01 1297 0100 01 1297 0100 01B1297 0100 Embraer 170 175 190 195 Custom Towbars Parts Lists When ordering replacement parts kits please specify model serial number and color of your unit Item Part Number Description Qty e Z 4753 Assembly Shock for 01 1297 0100 1 1 Z 4752 Assembly Shock for 01A1297 0100 1 Z 6355 Assembly Shock for 01B1297 0100 1 2 G 1420 106012 Bolt Hex Head Grade 8 5 16 18 x 1 1 4 long 12 3 G 1251 1060R Lock Washer 5 16 Regular 12 4 TR 1857 01 Tube Handle 1 5 G 1100 105520 Bolt Hex Head Grade 5 4 28 X 2 long 1 6 G 1250 1050N Flatwasher 1 4 narrow 1 04 2009 Rev 01 Page 5 When ordering replacement parts kits please specify model serial number and color of your unit Models 01 1297 0100 01A1297 0100 01B1297 0100 Embraer 170 175 190 195 Custom Towbars Parts Lists Part Number Description Qty 7 G 1202 1055 Elastic Stopnut 1 4 28 3 8 Z 5593 01 Machining Towbar 1 9 H 2945 Pump Hydraulic 1 10 TF 1043 18 22 0 A
15. ssembly Hose 1 11 H 2664 Spring Extension 2 12 HC 2119 Cylinder Hydraulic 1 18 J 3435 01 Plate Landing Gear 2 14 G 1420 111554 Bolt Hex Head Grade 8 34 16 x 5 12 long 1 15 G 1250 1110N Flatwasher 3 4 narrow 2 16 G 1208 1115 Elastic Jamnut 34 16 1 17 Z 5837 01 Machining Shear Plate 1 18 G 1155 109226 Screw Shoulder 5 8 diameter 3 19 G 1255 10 Washer 5 8 AN 3 20 G 1202 1090 Elastic Stopnut Ye 13 3 21 H 1724 09 Bushing 2 22 G 1444 32 Shear Pin 3 23 U 1096 Wheel Pneumatic 2 24 G 1250 1110N Flatwasher 34 narrow 2 25 G 1203 1115 Elastic Jamnut 34 16 2 26 G 1250 1100N Flatwasher 5 8 narrow 4 27 G 1202 1105 Elastic Stopnut 5 8 18 4 28 G 1100 105006 Bolt Hex Head Grade 5 1 4 20 x 34 long 4 29 G 1251 1050R Lockwasher 1 4 regular 4 30 G 1000 105006 Bolt Hex Head Grade 5 4 20 x 34 long 4 31 G 1251 1050R Lockwasher 1 4 regular 4 32 Z 5611 Assembly Skid 1 33 J 3558 Machining Head 1 34 H 1725 16 Bushing 1 35 J 3544 Spacer 1 36 H 2717 Clamp Toggle 1 37 G 1100 106520 Bolt Hex Head Grade 5 5 16 24 x 2 long 4 38 G 1250 1060N Flatwasher 5 16 narrow 8 39 G 1207 1070 Jamnut 3 8 16 1 40 H 2722 Rod End 1 41 G 1155 106206 Screw Shoulder 3 8 diameter 1 42 G 1152 106210 Screw Cap 5 16 18 x 1 long 2 43 J 3542 Block Slide 1 44 J 3543 Plate Slide 1 45 J 3557 02 Rail Slide 1 46 J 3551 Block Slide 1 47 J 3552 Plate Slide 1 48 G 1152 1062
16. tact Tronair or your Tronair distributor for replacement if required Inspect towing head attachment ball lok pin or bolt for bending or unusual wear Verify the factory supplied pin or bolt is used Contact Tronair for replacement if required Use only Tronair specified ball lok pins fasteners Ensure the towing head attachment ball lok pin is connected to the towbar via its lanyard Replace lanyard if missing Inspect all steel components for signs of rust Touch up with paint as required OO OOF DD D O OO OO D D O INS 1792 www tronair com Tronair Email sales tronair com Phone 419 866 6301 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 Maintenance Schedule Heavy Duty Clamp Style Attachment Heads SPARE SHEAR PINS Models 01 1297 0100 01A1326 0100 01A1332 0100 01 1336 0100 SHEAR PINS SHOULDER BOLT CONNECTION TOGGLE MECHANISM SLIDING LOCKING PLATE SHEAR PIN BUSHING OUTER SHEAR PLATE INNER SHEAR PLATE AIRCRAFT ATTACHMENT Tronair recommends towbar inspections at least once a week Inspect for weld cracks If found remove the towbar multi head from service and contact Tron
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