OPERATION & SERVICE MANUAL

Models: 01-1189-0012
01A1189-0012
Custom Towbar
CASA CN-235

08/2009 – Rev. 01

Tronair, Inc. Phone: (419) 866-6301 | 800-426-6301

1 Air Cargo Pkwy East Web: www.tronair.com
Swanton, OH 43558 Email: [email protected]
REVISION DATE TEXT AFFECTED
01 08/2009 Original release
 Models: 01-1189-0012, 01A1189-0012
Custom Towbar: CASA CN-235

TABLE OF CONTENTS

PAGE
1.0 DESCRIPTION .................................................................................................................................................................. 1
1.1 SPECIFICATIONS .............................................................................................................................................. 1
2.0 SAFETY INFORMATION .................................................................................................................................................. 1
2.1 GENERAL ........................................................................................................................................................... 1
3.0 OPERATION ..................................................................................................................................................................... 2
3.1 LANDING GEAR ASSEMBLY ............................................................................................................................. 2
3.2 PRELIMINARY CHECKLIST ............................................................................................................................... 2
3.2.1 Towbar ................................................................................................................................................................ 2
3.2.2 Towing Head ....................................................................................................................................................... 2
3.3 USAGE PROCEDURE ........................................................................................................................................ 2
3.3.1 Aircraft Attachment.............................................................................................................................................. 2
3.3.2 Tug Attachment ................................................................................................................................................... 2
4.0 TRAINING ......................................................................................................................................................................... 4
4.1 TRAINING REQUIREMENTS ............................................................................................................................. 4
4.2 TRAINING PROGRAM ....................................................................................................................................... 4
4.3 OPERATOR TRAINING ...................................................................................................................................... 4
5.0 PROVISION OF SPARES ................................................................................................................................................. 4
5.1 SPARE PARTS ................................................................................................................................................... 4
5.2 PARTS LIST AND ILLUSTRATIONS .................................................................................................................. 4
6.0 IN-SERVICE SUPPORT .................................................................................................................................................... 4
7.0 GUARANTEES/LIMITATION OF LIABILITY .................................................................................................................... 4
8.0 APPENDICES ................................................................................................................................................................... 4

08/2009 | Rev. 01
 Models: 01-1189-0012, 01A1189-0012
Custom Towbar: CASA CN-235

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 01-1189-0012 and 01A1189-0012custom Towbar is designed for towing CN-235 Aircraft manufactured by
Airtech Technology Industry (CASA/IPTN).

The custom towbar has an aircraft attachment by machined pins on the towing head to the nose landing gear tow point. There
is a handle and an eyebolt at the end of the towbar for towing.

1.1 SPECIFICATIONS
Aircraft Application .............................. CN-235 Aircraft manufactured by Airtech Technology Industry (CASA/IPTN)
Maximum Aircraft Gross Weight ......... 36,376 lbs (16.5 Metric tons)
Length
01-1189-0012 .................................. 146 7/16 in (372 cm) eyebolt centerline to aircraft attachment centerline
01A1189-0012................................. 147 9/16 in (375 cm) (eyebolt centerline to aircraft attachment centerline
Width ..................................................... 22-7/8 in (58.1 cm)
Height .................................................... 16 11/16 in (42.7 cm) From ground to aircraft attachment centerline
Weight ................................................... 128 lbs (58.1 kg)
Finish..................................................... Blue Powder Coat

2.0 SAFETY INFORMATION

2.1 GENERAL
The Tronair Model 01-1189-0012 and 01A1189-0012 Custom Towbar is to be used for moving the CN-235 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.

WARNING!
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.

08/2009 | Rev. 01 Page | 1

 Models: 01-1189-0012, 01A1189-0012
Custom Towbar: CASA CN-235

3.0 OPERATION
3.1 LANDING GEAR ASSEMBLY
Place landing gear assembly in desired location. Torque clamp nuts to 35 ft-lbs (47.5 N-m).

3.2 PRELIMINARY CHECKLIST

3.2.1 Towbar
 Check towing eye mounting bolts. Ensure fasteners are not loose or missing.
 Check towing eye for bending, excessive wear and/or deformity.
 Check shear pin. Ensure shear pin is not broken or missing; replace as required.

WARNING!
Towing an aircraft using a towbar with a broken or missing shear pin may cause damage to the aircraft.

3.2.2 Towing Head

 Check welds between side rails and head rail for cracks:
 Check welds between side rails and sliding pin wear sleeve for cracks.
 Check fastener connection of towing head to towbar. Ensure the connection is not loose or missing.
 Check sliding pin ball lok-T pin. Ensure ball lok-T pin is securely attached to the side rail via its lanyard. Ensure ball lok-T
pin is not missing.
 Check sliding pin for bending or excessive wear. Ensure sliding pin slides freely.
 Check sliding pin roll pin. Ensure roll pin is not loose or missing.

3.3 USAGE PROCEDURE

3.3.1 Aircraft Attachment
 Ensure the sliding pin is locked in place using the ball lok-T pin.
CAUTION!
It is recommended that your towbar to attached to the aircraft first, and then connected to the tug to avoid
possible aircraft damage.

3.3.2 Tug Attachment

 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.

CAUTION!
Damage to the towbar or aircraft can result from an excessive towbar angle during towing operations.
Reference Figure 1.

Incorrect Correct
Excessive Towbar Angle FIGURE 1

08/2009 | Rev. 01 Page | 2

 Models: 01-1189-0012, 01A1189-0012
Custom Towbar: CASA CN-235

3.3 USAGE PROCEDURE (continued)

3.3.3 Couplers
CAUTION!
Damage to the towbar or aircraft can result while towing with the following types of couplers:
 Lift Head  Vertical Side Swing Latch
 Standard Duty Latch  Swivel Hook

The couplers listed above are known to cause binding and failure in
the eyebolt. Indicators of binding are wear on outside diameter of the
eyebolt and indentation on the inside diameter of the eyebolt.
Reference Figure 2.

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.
Reference Figure 3.

FIGURE 2

FIGURE 3
01-1950-5000 Standard Telecoupler
FIGURE 4
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 4.

To 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 (½")
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.

3.3.4 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 90º.
Reference Figure 5

FIGURE 5

08/2009 | Rev. 01 Page | 3

 Models: 01-1189-0012, 01A1189-0012
Custom Towbar: CASA CN-235

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 aircraft 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
1 Air Cargo Pkwy East Fax: (419) 867-0634
Swanton, Ohio 43558 USA E-mail: [email protected]
Website: www.tronair.com

5.2 PARTS LIST AND ILLUSTRATIONS

Reference following pages for ordering information of Replacement Parts and Kits.

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.

8.0 APPENDICES
APPENDIX I Declaration of Conformity

08/2009 | Rev. 01 Page | 4

 Models: 01-1189-0012, 01A1189-0012
Custom Towbar: CASA CN-235

Parts List
When ordering Replacement Parts/Kits, please specify Model & Serial Number of your product.

Item Part Number Description Qty

Z-1259-01 Assembly, Shock/Shear (01-1189-0012) 1
1
Z-1259-10 Assembly, Shock/Shear (01A1189-0012) 1

Item 1 consists of items 36 thru 44 (not shown) which are not sold separately.
Due to the high compression used in assembly, it is suggested this Shock Assembly be returned to Tronair for repair.
Discuss with your salesperson.

2 TR-1857-01 Tube, Handle 1

3 G-1100-105520 Bolt, Hex Head, Grade 5, ¼ - 28 x 2” long 1
4 G-1250-1050N Flatwasher, ¼ Narrow 1
5 G-1202-1055 Stopnut, ¼ - 28 Elastic 1
6 G-1420-106006 Bolt, Hex Head, Grade 8, 5/16 – 18 x ¾” long 8
7 G-1251-1060R Lockwasher, 5/16 Regular 8
8 Z-5758-01 Machining, Towbar 1
9 H-3258 Assembly, Shear Pin 3
10 H-3178*07.0 Assembly, Modified Lanyard 1
11 G-1250-1100N Flatwasher, 5/8 Narrow 1
12 G-1203-1105 Jamnut, 5/8 – 18 Elastic 1
13 TR-1583 Spacer, Wheel 2
14 U-1024 Wheel 1
15 Z-3697-01 Weldment, Landing Gear 1

08/2009 | Rev. 01 Page | 5

 Models: 01-1189-0012, 01A1189-0012
Custom Towbar: CASA CN-235

Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.

Item Part Number Description Qty

16 G-1009-33 U-bolt 2
17 G-1250-1090N Flatwasher, ½ Narrow 4
18 G-1203-1095 Jamnut, ½ - 20 Elastic 4
19 G-1100-107554 Bolt, Hex Head, Grade 5, 3/8 – 24 x 5 – ½” long 1
20 G-1250-1070N Flatwasher, 3/8 Narrow 2
21 G-1202-1075 Stopnut, 3/8 – 24 Elastic 2
22 G-1100-105526 Bolt, Hex Head, Grade 5, ¼ - 28 x 2 ¾” long 4
23 G-1250-1050N Flatwasher, ¼ Narrow 8
24 G-1202-1055 Stopnut, ¼ - 28 Elastic 4
25 Z-1777-02-01 Weldment, Landing Gear Bracket 1
26 Z-1790-01 Weldment, Axle Mounting Bracket 1
27 G-1100-109554 Bolt, Hex Head, Grade 5, ½ - 20 x 5 – ½” long 1
28 G-1250-1090N Flatwasher, ½ Narrow 2
29 G-1203-1095 Jamnut, ½ - 20 Elastic 1
30 Z-5956-01 Weldment, Head (includes labels) 1
31 G-1310-0415 Pin, Ball Lok-T, ¼” diameter x 1.5 Grip 1
32 G-1351-04 Rivet, Pop 1
33 H-1026*07.0 Assembly, Lanyard 1
34 R-2158 Pin, Sliding 1
35 G-1150-103503 Screw, Hex Head Machine, # 10 – 32 x 3/8” long 1
K-1115 Kit, Shock Bolt Replacement; consist of:
6 G-1420-106006 Bolt, Hex Head, Grade 8, 5/16 – 18 x ¾” long 8
7 G-1251-1060R Lockwasher, 5/16 Regular 8
K-1112 Kit, Wheel (Single) Replacement; consist of:
11 G-1250-1100N Flatwasher, 5/8 Narrow 1
12 G-1203-1105 Jamnut, 5/8 – 18 Elastic 1
14 U-1024 Wheel 1
K-1308 Kit, Ball Lok-T Pin Replacement; consist of:
31 G-1310-0415 Pin,, Ball Lok-T, ¼” diameter x .15” Grip 1
32 G-1351-04 Rivet, Pop 1
33 H-1026*07.0 Assembly, Lanyard 1
K-1560 Kit, Axle Replacement; consist of:
11 G-1250-1100N Flatwasher, 5/8 Narrow 2
12 G-1203-1105 Jamnut, 5/8 – 18 Elastic 2
13 TR-1583 Spacer, Wheel 2
22 G-1100-105526 Bolt, Hex Head, Grade 5, ¼ - 28 x 2 – ¾” long 4
23 G-1250-1050N Flatwasher, ¼ Narrow 8
24 G-1202-1055 Stopnut, ¼ - 28 Elastic 4
26 Z-1790-01 Weldment, Axle Mounting Bracket 1

08/2009 | Rev. 01 Page | 6

 Models: 01-1189-0012, 01A1189-0012
Custom Towbar: CASA CN-235

Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.

K-2545 Kit, Head Assembly Replacement; consist of:

27 G-1100-109554 Bolt, Hex Head, Grade 5, ½ - 20 x 5 – ½” long 1
28 G-1250-1090N Flatwasher, ½ Narrow 2
29 G-1203-1095 Jamnut, ½ - 20 Elastic 1
30 Z-5956-01 Weldment, Head (includes labels) 1
31 G-1310-0415 Pin, Ball Lok-T, ¼” diameter x 1.5 Grip 1
32 G-1351-04 Rivet, Pop 1
33 H-1026*07.0 Assembly, Lanyard 1
34 R-2158 Pin, Sliding 1
35 G-1150-103503 Screw, Hex Head Machine, # 10 – 32 x 3/8” long 1
K-2718 Wheel Bracket Replacement; consist of:
11 G-1250-1100N Flatwasher, 5/8 Narrow 2
12 G-1203-1105 Jamnut, 5/8 – 18 2
15 Z-3697-01 Weldment, Landing Gear 1
16 G-1009-33 U-bolt 2
17 G-1250-1090N Flatwasher, ½ Narrow 4
18 G-1203-1095 Jamnut, ½ - 20 Elastic 4
19 G-1100-107554 Bolt, Hex Head, Grade 5, 3/8 – 24 x 5 – ½” long 1
20 G-1250-1070N Flatwasher, 3/8 Narrow 2
21 G-1202-1075 Stopnut, 3/8 – 24 Elastic 2
22 G-1100-105526 Bolt, Hex Head, Grade 5, ¼ - 28 x 2 ¾” long 4
23 G-1250-1050N Flatwasher, ¼ Narrow 8
24 G-1202-1055 Stopnut, ¼ - 28 Elastic 4
25 Z-1777-02-01 Weldment, Landing Gear Bracket 1
26 Z-1790-01 Weldment, Axle Mounting Bracket 1

08/2009 | Rev. 01 Page | 7

 APPENDIX II

Declaration of Conformity
 DECLARATION of CONFORMITY
The design, development and manufacture is in accordance with European Community guidelines

Custom Towbar
01-1189-0012
01A1189-0012

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

Tronair, Inc. Phone: (419) 866-6301 | 800-426-6301

1 Air Cargo Pkwy East Web: www.tronair.com
Swanton, OH 43558 Email: [email protected]