ATR-42/72 Towbar Head

Operations and Maintenance Manual

AERO Product ID: 2000412
AERO Document ID: 2012521
Applies to: ATR 42 & 72
Address: 11175 West Emerald
Boise, Idaho, 83713 USA
Phone: +1 (208) 378-9888
Fax: +1 (208) 378-9889
Email: sales@aerospecialties.com
staff@aerospecialties.com
Website: www.aerospecialties.com

Please take a moment and fill in the following

information for convenience in parts ordering
or service for the AERO Specialties equipment
pertaining to this manual. The model and serial
number are located on a placard on your equipment.

Model:

Serial No:

Date Received:
Table of Contents
Introduction ................................................................................................................................................. 1
Agreement of Confidentiality ........................................................................................................................ 1
Warranty ...................................................................................................................................................... 2
Safety .......................................................................................................................................................... 3
DANGER! .................................................................................................................................................. 3
WARNING! ................................................................................................................................................ 3
CAUTION! .................................................................................................................................................. 3
Note .......................................................................................................................................................... 3
Training ........................................................................................................................................................ 3
Training Requirements ............................................................................................................................... 3
Training Program........................................................................................................................................ 3
General Information and Operating Instructions............................................................................................ 4
Preliminary Checklist ................................................................................................................................. 4
Aircraft Attachment .................................................................................................................................... 4
Pushback and Towing Operations .............................................................................................................. 4
Use of Proper Tug ...................................................................................................................................... 5
Hitches...................................................................................................................................................... 5
Towing Operation ....................................................................................................................................... 5
Linear Shear Forces ..................................................................................................................................... 6
Recommended Service Life........................................................................................................................... 7
Maintenance, Service, & Support ................................................................................................................. 7
Inspection Schedules: Heads........................................................................................................................ 8
AERO Head Preventative Maintenance Inspection Checklist ....................................................................... 8
Daily Head Inspection Items...................................................................................................................... 8
Torque Value Table ..................................................................................................................................... 8
Monthly Preventative Maintenance Head Inspection Items ....................................................................... 9
90-Day Preventative Maintenance Head Inspection Items: Heads with Shear Protection ............................ 9
Disclaimer.................................................................................................................................................. 10
Illustrated Parts ......................................................................................................................................... 11
ATR-42/72 Towbar Head Parts Break-Down ............................................................................................. 12
CE-Mark Information .................................................................................................................................. 15
Revisions
 1

Introduction
Thank you for purchasing an AERO Specialties towing product. When used properly, this piece of equipment will
provide years of servicing satisfaction.
AERO Specialties fabricates all of its aircraft equipment with high-quality materials, and assembles them with
durable and efficient components. As with any piece of ground support equipment, parts will need to be replaced
occasionally due to normal wear-and-tear.
AERO Specialties towbars and heads are covered under warranty for one year (see Warranty section on page 2 for
more information), and we are dedicated to helping keep equipment in operation for many years. AERO stocks all
replaceable parts for its towbars, and manufactures its own towbar and head components. All parts are available
for order through AERO’s secure online store (www.aerospecialties.com), which accepts both credit cards and PO#s
of registered members. Of course, parts can still be ordered the old-fashioned way by giving us a call at +1 (208)
378-9888.

Agreement of Confidentiality
This manual is, and shall remain, the property of AERO Specialties, Inc. This manual is provided for the use of
AERO Specialties, Inc.’s customers to aid in the operation and maintenance of equipment purchased from AERO
Specialties, Inc. The material contained within this manual is strictly confidential and the distribution of this
manual or revealing of its contents is expressly prohibited. The user’s acceptance of this manual constitutes
acknowledgment of these conditions and agreement to conform to them.
Any disclosure of the confidential material contained within this manual may result in the immediate repossession
of this manual by AERO Specialties, Inc., and termination of all warranty coverage and technical support.

AERO Specialties ATR-42/72 Towbar Head Operation and Maintenance Manual v.01/19
Questions? Contact AERO Specialties at +1 (208) 378-9888
2

Warranty
AERO Specialties products are warrantied to be free of manufacturing or material defects for a period of one
year after shipment date 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 that have a 90-day warranty from date of shipment
If you have a problem that may require service, contact AERO Specialties immediately. DO NOT attempt to repair or
disassemble a product without first contacting AERO Specialties, as any action will affect warranty coverage. When you
contact AERO, 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 AERO Specialties for repairs. A decision on the extent of warranty coverage on returned products is reserved
pending inspection at AERO Specialties. Any shipments to AERO must be shipped by insured, prepaid freight.
Freight costs on shipments to customers will be paid by AERO on warranty claims only.

AERO Specialties ATR-42/72 Towbar Head Operation and Maintenance Manual v.01/19
Questions? Contact AERO Specialties at +1 (208) 378-9888
 3

Safety
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.

DANGER!
“Danger” is used to indicate the presence of an immediate hazard which, if not avoided, will result in serious
personal injury or death, and could include property damage. Danger notices in this manual are indicated with
the following label:
!
WARNING!
“Warning” is used to indicate the presence of a hazard which, if not avoided, could result in serious personal
injury or death, and could include property damage. Warning notices in this manual are indicated with the
following label:
!
CAUTION!
“Caution” is used to indicate the presence of a hazard which, if not avoided, could result in minor or moderate
personal injury or property damage. Caution notices in this manual are indicated with the following label:

!
Note
“Note” is used to indicate important information that could relate to warranty coverage, damage prevention, a
hazard, etc. Notices in this manual are indicated with the following label: NOTE.

Training
Training Requirements
The employer of the operator is responsible for providing a training program sufficient for the safe operation of the
towbar.

Training Program
The employer-provided operator training program should cover safety procedures concerning use of the towbar in
and around all aircraft types expected to be serviced at the particular facility.

AERO Specialties ATR-42/72 Towbar Head Operation and Maintenance Manual v.01/19
Questions? Contact AERO Specialties at +1 (208) 378-9888
4

General Information and Operating Instructions

Preliminary Checklist
• Check all welds on towbar and head for cracks.
• Check running gear (wheels, axles, nuts, and bolts) for proper torque.
• Check lunette assembly for proper tightness and free play (lunette torque specifications are listed on towbar
diagrams).
• Check flange bolts (if applicable) for proper tightness.
• Check shear pins for cracks. Replace if cracked, broken, or bent. Replace spare shear pins if missing.

!
A damaged or bent towbar should not be used. The towbar should be repaired or replaced.
BENT TOWBARS CANNOT BE REPAIRED AND MUST BE REPLACED.

Aircraft Attachment
It is recommended that the towbar is attached to the aircraft first, and then connected to the tug to avoid potential
aircraft damage.

Pushback and Towing Operations

Damage to the towbar or aircraft can result from an incorrect towbar angle during pushback operations. For
maximum capacity pushbacks, the aircraft attachment should ideally be about 2” (5 cm) higher than the tug
attachment. (See Figures 1 and 2) This is especially relevant for 2-wheel drive tugs, as only 30% of the tug weight
is at the front end.

!
Incorrect towbar angle
can cause damage to both
towbar and aircraft.

Fig. 1: Incorrect attachment

Fig. 2: Correct attachment

AERO Specialties ATR-42/72 Towbar Head Operation and Maintenance Manual v.01/19
Questions? Contact AERO Specialties at +1 (208) 378-9888
 5

Use of Proper Tug

Using the proper class of tug for the pushing or towing application is perhaps the most important consideration
for safe and secure aircraft movements. Using a tug that is too large or too small for a particular aircraft greatly
increases the potential for damage to equipment and injury to personnel. The table above provides a guideline
for matching the proper tug to the particular aircraft. Using a Category 2, 3 or 4 tractor - which generates 3 to 10
times the required force - to push Category 1 aircraft can increase pushback problems caused by excessive power.
Aircraft pushback incidents increase because the towbar and nose gear are not rated to absorb the excessive
power of these larger tugs.

Hitches
!
The use of pintle hitches can cause damage to both towbar, other
equipment, and aircraft, which could cause personal injury.
AERO Specialties strongly discourages the use of pintle hitches
(see Fig. 3) for towing aircraft as they do not provide the security
of a secondary lock or a platform on which the tow ring can be Fig. 4:
Fig. 3:
placed.
Pintle Hitch E-Hitch
NOTE: TOWBAR DAMAGE CAUSED BY PINTLE HITCH USE WILL NOT (Not Recommended) (Recommended)
BE COVERED UNDER WARRANTY.
AERO Specialties recommends E-hitch style hitches (see Fig. 4) available for purchase from AERO via phone or
on-line store. All AERO Specialties towbars feature limited rotation of the towbar eye-bolt, which prevents binding of
towbar on the tug hitch.

Towing Operation
Damage to the towbar or aircraft can result from pushing an aircraft at too sharp
an angle between the tug and the aircraft. Contact between the tug and the
towbar tube must be avoided.

!
DO NOT EXCEED a 90-degree angle between the tug and towbar. (See Fig. 5)
Fig. 5

AERO Specialties ATR-42/72 Towbar Head Operation and Maintenance Manual v.01/19
Questions? Contact AERO Specialties at +1 (208) 378-9888
6

Linear Shear Forces

The following table shows the linear (push-pull) force required to break the active shear bolt in towbar heads
equipped with shear protection (such towbar heads have one active and two spare shear bolts).

!
Using shear bolts other than the types that are initially provided (see Illustrated Parts Section for list of parts provided)
can cause damage to aircraft. It is not recommended that shear bolts of different types be substituted for one another.
NOTE: DAMAGE CAUSED BY THE USAGE OF SHEAR BOLT TYPES OTHER THAN THOSE INITIALLY PROVIDED FOR THE
EQUIPMENT IS NOT COVERED UNDER WARRANTY.

4086 lbf
2003204 Shear Pin, SP0
18175 N
6013 lbf
2002060 Shear Pin, SP2
26747 N
8751 lbf
2003199 Shear Pin, SP3
38926 N
3270 lbf
2012466 Shear Pin, 1/4-3270
14546 N
2000 lbf
2012468 Shear Pin, 3/16-2000
8896 N
11496 lbf
2000604 Shear Bolt, AN5
51137 N
15904 lbf
2009188 Shear Bolt, C130
70615 N

Fig. 6

AERO Specialties ATR-42/72 Towbar Head Operation and Maintenance Manual v.01/19
Questions? Contact AERO Specialties at +1 (208) 378-9888
 7

Recommended Service Life

The use of old towbars and heads results in multimillion dollar accidents each year. Like any product, towbars and
heads have a limited life span. AERO Specialties recommends a usable service life of 10 years for towbars and
15 years for towheads. Once this lifetime is achieved, the equipment should be retired to avoid any unnecessary
damages caused by aging.
Refer to the table below to determine the age of your AERO Specialties product

Maintenance, Service, & Support

Maintenance and troubleshooting are to be performed by trained mechanics only. This product cannot be modified
without the written approval of AERO Specialties. Any modifications done without written approval voids all warranties
and releases AERO Specialties, its suppliers, distributors, or financial institutions from any liability from consequences
that might occur.
Any questions about operation, maintenance, and/or functionality of AERO Specialties towbar equipment not
answered by this manual should be directed to AERO Specialties either by phone at +1 (208) 378-9888, or by
email to staff@aerospecialties.com.

AERO Specialties ATR-42/72 Towbar Head Operation and Maintenance Manual v.01/19
Questions? Contact AERO Specialties at +1 (208) 378-9888
8

Inspection Schedules: Heads

AERO Head Preventative Maintenance Inspection Checklist

MODEL NUMBER
SERIAL NUMBER
EQUIPMENT NUMBER
LOCATION

Daily Head Inspection Items

Visually inspect towbar heads for any damage to include the following:
NOTE: REPORT ANY DAMAGE IMMEDIATELY AND REMOVE FROM SERVICE!
1. Check for damage on head including dings, dents, heavy scratches, gouged paint or stress cracking of frame.
2. Check if head is equipped with shear bolts; check that the lock nut is in place and that spare shear bolts are
present.
3. Check that engagement pins slide freely and ball lock pins (including lunette, if equipped) are secure and
undamaged.
4. On gear mounted heads, check that spring loaded lever pulls freely and spring returns latches to closed
position automatically.

Torque Value Table

!
Failure to maintain heads according to the tables below may result in severe damage to aircraft and/or injury to
operators.

30 ft lbs
22 2005465 Nylock nut and washers 30 days
40.7 Nm
47 ft lbs
23 2005476 Medium strength thread locker 60 days
63.7 Nm

AERO Specialties ATR-42/72 Towbar Head Operation and Maintenance Manual v.01/19
Questions? Contact AERO Specialties at +1 (208) 378-9888
 9

Monthly Preventative Maintenance Head Inspection Items

(In addition to the above)
30 60 90 30 60 90 30 60 90 30 60 90
Ensure the engagement pin(s) can move freely
in and out within its housing. Pin should not
be able to rotate. If binding or rotation are
present, remove from service and contact
manufacturer.
Inspect ball lock pin. Ensure pin can be inserted
and removed easily. If it does not, replace ball
lock pin.
Verify all ball lock pins have lanyard. Replace
the lanyard if missing.

90-Day Preventative Maintenance Head Inspection Items: Heads with Shear Protection
(In addition to the above)

30 60 90 30 60 90 30 60 90 30 60 90
Inspect area where head and shank bolt
together for bending or signs of stress. If
found, remove from service for repair or
replacement.
Check main head 3/4” retainer bolts are
secure and nylock nuts are in place - torque
to 30 ft lbs/ 40.7 Nm.
Heads using shear bolts - 1 active and 2
spares should be present. Verify bolt is not
bent and has nylock nut in place. Active shear
bolt should be torqued to no more than 10 ft
lbs/13.6 Nm.
Heads using shear pins - 1 active and 2
spares should be present. Verify shear pin
retaining clip and lanyard are in place. Inspect
for bending or signs of stress; replace pin if
damaged.
Check and tighten all other fasteners.
Clean and touch up paint as required to
maintain appearance.

AERO Specialties ATR-42/72 Towbar Head Operation and Maintenance Manual v.01/19
Questions? Contact AERO Specialties at +1 (208) 378-9888
10

Any technical or performance related questions can be forwarded to AERO Specialties by phone at +1 (208) 378-
9888, by fax at +1 (208) 378-9889, or by email to sales@aerospecialties.com. Complete manuals are available
upon request. If you have a problem that may require service, contact AERO Specialties immediately. DO NOT
attempt to repair or disassemble a product without first contacting AERO Specialties, as any action will affect
warranty coverage. When you contact AERO, be prepared to provide the following information:
a. Product Model Number
b. Product Serial Number
c. Description of the Problem

Disclaimer
AERO SPECIALTIES SHALL NOT BE LIABLE FOR ANY PRODUCT FAILURES NOT MAINTAINED IN ACCORDANCE
WITH THIS NOTICE. AERO SPECIALTIES MAKES NO OTHER EXPRESSED OR IMPLIED WARRANTIES. AERO
SPECIALTIES HEREBY DISCLAIMS ALL EXPRESSED OR IMPLIED WARRANTIES, WHETHER IMPLIED BY
OPERATION OF LAW OR OTHERWISE, INCLUDING, WITHOUT LIMITATION, ALL IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS OR FITNESS FOR A PARTICULAR PURPOSE. UNDER NO CIRCUMSTANCES,
AND IN NO EVENT, WILL AERO SPECIALTIES BE LIABLE FOR PERSONAL INJURY OR PROPERTY DAMAGE OR
ANY OTHER LOSS, DAMAGE, COST OF REPAIRS OR INCIDENTAL, PUNITIVE, SPECIAL, CONSEQUENTIAL, OR
LIQUIDATED DAMAGES OF ANY KIND, WHETHER BASED UPON WARRANTY, CONTRACT, STRICT LIABILITY,
NEGLIGENCE OR ANY OTHER CAUSE OF ACTION ARISING IN CONNECTION WITH THE DESIGN, MANUFACTURE,
SALE, TRANSPORTATION, INSTALLATION, USE, REFURBISHMENT OR REPAIR OF THE PRODUCTS SOLD BY AERO
SPECIALTIES.

AERO Specialties ATR-42/72 Towbar Head Operation and Maintenance Manual v.01/19
Questions? Contact AERO Specialties at +1 (208) 378-9888
 11

Illustrated Parts

AERO Specialties ATR-42/72 Towbar Head Operation and Maintenance Manual v.01/19
Questions? Contact AERO Specialties at +1 (208) 378-9888
12

ATR-42/72 Towbar Head Parts Break-Down

Part No. 2000412

6
22
28
19
15 12

24
10

17 27 8
11

29

5 7 21 25
14

16

TWO SPARE SHEAR PINS

13
26 18
30
31 23

20
3

30 ft lbs
22 2005465 Nylock nut and washers
40.7 Nm
47 ft lbs
23 2005476 Medium strength thread locker
63.7 Nm

AERO Specialties ATR-42/72 Towbar Head Operation and Maintenance Manual v.01/19
Questions? Contact AERO Specialties at +1 (208) 378-9888
 13

AERO Specialties ATR-42/72 Towbar Head Operation and Maintenance Manual v.01/19
Questions? Contact AERO Specialties at +1 (208) 378-9888
14

AERO Specialties ATR-42/72 Towbar Head Operation and Maintenance Manual v.01/19
Questions? Contact AERO Specialties at +1 (208) 378-9888
 15

CE-Mark Information

Towbars: Towbar Heads:

2000674: Hydraulic Lift Kit 2003218: AN-24 2000369: ERJ-170/190
2002171: JX Towbar 2000412: ATR-42/72 2000415: FAL1 (discontinued)
2001684: MH-60 2002866: AW109 2002860: FAL1
2001901: MQ-9 2000240: AW139 2001338: FAL2
2001048: Rx-ATR 2002899: AW139 (shear protection) 2001358: FAL7XR
2001049: Rx-BAE146 2000413: BAE146 2001601: F50
2001153: Rx-C130 2000443: BEC2 2002035: F70/100
2001050: Rx-CRJ 2000430: BEC3 2000347: G5
2001185: Rx-CRJ3 2002113: CESSNA PIPER 2000472: G100
2001184: Rx-CRJ7 2000353: CGE 2000468: G200
2001051: Rx-D8-300 2001463: CH-46 2000194: G200S
2001052: Rx-D8-400 2000414: CL1R 2002137: GLOBAL 7000/8000
2001053: Rx-EMB120 2000416: CL3R 2002025: HONDA JET
2001055: Rx-ERJ-145 2000483: CNA2 2000425: HS1
2001054: Rx-ERJ-170/190 2000393: CNA3 2000075: JET
2001627: Rx-F50 2000400: CNA4 2000440: JS31/32
2002036: Rx-F70/100 2000364: CRJ3 2000619: JS41
2008303: Rx-P3 Orion 2000359: CRJ7 2001552: KFIR
2000042: TB1 2001967: CRJ-COMBO 2000686: L85
2001535: TB1 Fly-Away 2001415: D8-300 2000448: MU2
2000067: TB2.5 2000861: D8-400 2000435: P180
2000052: TB3 2001429: D228 2000427: PC12
2000605: TB125-5 2001845: DC-3 2012623: PC24
2000099: TB125-10 2001334: E500 2000611: S76
2001561: TB125-10 Fly Away 2001333: EC155/AS365N 2000489: SBL
2000160: TB125-15 SP 2000180: EMB100 2000488: SMW1
2001995: TB125-15 2000454: EMB120 2001361: T38
2001998: TB125-20 2R 2000285: EMB300 2008640: T38 (with shear)
2000108: Reducer 2002662: EMB500 Dash 7
2000420: ERJ-145

January 1, 2019

AERO Specialties ATR-42/72 Towbar Head Operation and Maintenance Manual v.01/19
Questions? Contact AERO Specialties at +1 (208) 378-9888
11175 West Emerald
Boise, Idaho, 83713 USA

Phone: 208-378-9888
Fax: 208-378-9889

Email: sales@aerospecialties.com
Website: www.aerospecialties.com