Operation & Service Manual

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1 Operation & Service Manual Technical Manual Model: C Ton (10.8 Metric Ton) Two Stage Hydraulic Axle Jack 06/2006 Rev. OR Includes Illustrated Parts List Tronair, Inc Eber Road Holland, Ohio USA Telephone: (419) Fax: (419) Web Site:

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3 Model: C Ton Two Stage Hydraulic Axle Jack TABLE OF CONTENTS PAGE 1.0 Description Usage Specifications Assembly Instructions General Information Pre-Use Checks Operating Instructions Jack Instructions Maintenance...2 General Servicing Jack Removing And Servicing Pump Jack Function Load Test Trouble Shooting Parts List...3 APPENDIX I Hydraulic Schematic APPENDIX II HC Hand Pump (5,250 psi +300/-000) Parts List APPENDIX III MSDS Hydraulic Fluid (MIL-5606) APPENDIX IV Declaration of Conformity 06/ Rev. OR

4 Model: C Ton Two Stage Hydraulic Axle Jack Revision Date Text Affected OR 06/2006 Original Release 06/ Rev. OR

5 Model: Ton Two Stage Hydraulic Axle Jack 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. 1.0 DESCRIPTION The Tronair Model C0100 Hydraulic Axle Jack incorporates the following quality features: Steel construction Two-stage hydraulic extension Two stage mechanical extension Single speed, manually operated pump Uses standard MIL-H-5606 hydraulic fluid Preset relief/release valve Two sizes of base spacer blocks 2.0 USAGE The purpose of this jack is to lift aircraft for maintenance. It has a maximum capacity of 12 tons ( kn). Optional Kit K-1945 is offered which includes one each of the two different base spacer blocks. These may be required on some aircraft in order to raise the jack closer to the jack pad. 3.0 SPECIFICATIONS Vertical capacity 24,000 lbs ( kn) Minimum closed height 4.63 in (11.76 cm) Mechanical extension 4.50 in (11.43 cm) Hydraulic extension 6.00 in (15.24 cm) Maximum height obtainable in (38.43 cm) Weight 40 lbs ( N) BUNA 'N' Seals NOTE: These numbers increase accordingly when base spacer blocks are used. 4.0 ASSEMBLY INSTRUCTIONS 4.1 GENERAL INFORMATION This product should be assembled and/or repaired using good workmanship practices and proper tools. All replacement parts must be the same as or equal to the original parts supplied. 4.2 PRE-USE CHECKS Refer to the Illustrated Parts List to identify and ensure that all parts are present. Generally check over unit to assure the tightness of all nuts, bolts and screws. With rams completely collapsed, check hydraulic fluid level is between one- half (1/2) and three-quarter (3/4) inches from top of reservoir fitting. Replenish with MIL-H-5606 fluid as required. 5.0 OPERATING INSTRUCTIONS The user should be familiar with the following statements prior to using the jack(s). CAUTION! Never put hands between aircraft and jack pad. Always open reservoir vent screw before operating. 5.0 Operating instructions continued on following page 06/ Rev. OR - 1 -

6 Model: Ton Two Stage Hydraulic Axle Jack 5.0 OPERATING INSTRUCTIONS (continued) 5.1 JACK INSTRUCTIONS To Raise Aircraft: 1. Place jack on a hard level surface. 2. Raise jack as close to aircraft jack pad as possible, with appropriate base spacer blocks. Screw out the center mechanical extension for final adjustment. 3. Open reservoir vent screw. 4. Close pump release valve and operate pump. To Lower Aircraft: 1. Loosen pump release valve slightly to slowly lower aircraft. 6.0 MAINTENANCE GENERAL All maintenance and/or repair work should be done using good workmanship practices and proper tools. The work area should be clean and free of dirt. When O-rings and backup rings are removed, every effort should be made to avoid the contact of tools with the critical surfaces of parts. Surface deformities could cause degradation of seals and failure. It is good practice to replace all O-rings and backup rings once removed. Cut and damaged rings normally result in fluid leakage. At this time flush old hydraulic fluid and dirt from overall system and replenish with new, clean hydraulic fluid. No modifications shall be carried out which adversely affect the compliance of the jack with draft standard 98/37/EC. 6.1 SERVICING JACK To Disassemble Jack 1. Collapse jack rams. 2. Remove vent screw and drain all fluid from reservoir. 3. Remove cap screws (Item 25) surrounding jack cylinder, then remove flange, (Item 23). 4. Lift cylinder from jack base (Item 16). Operate jack hand pump to help remove cylinder. 5. Remove retaining ring (Item 12) and unscrew retaining plug, (Item 15). 6. Separate rams and replace all seals including retaining ring. To Reassemble Jack 1. Reassemble in reverse order of above. 2. Torque each cap screw (Item 25) to ft-lbs. 6.2 REMOVING AND SERVICING PUMP NOTE: If pump is found faulty, call the factory for replacement or replace seals as follows: Review Appendix I - HC Hand Pump Parts List during the following procedure: 1. Drain all fluid from reservoir. 2. Remove pump from jack. 3. Remove cotter pin (Item 16) from clevis pin. 4. Remove four (4) socket head cap screws. 5. Remove flanges. 6. Remove tube assembly (Item 14). 7. Replace O-rings and backup ring. See Pump Parts List for kits available. 8. Re-assemble in reverse order. 9. Torque each 3 /8 socket head cap screw to ft-lbs. Torque each ¼ socket head cap screw 10 to 12 ft-lbs. 06/ Rev. OR - 2 -

7 Model: Ton Two Stage Hydraulic Axle Jack 6.0 MAINTENANCE (continued) 6.3 JACK FUNCTION LOAD TEST 1. Take all necessary precautions to prevent injury. 2. Always jack against a load and never against the jack itself. 3. Do not exceed a test load equal to the jack rated capacity plus 10%. 7.0 TROUBLE SHOOTING Ram will not rise or rises erratically PROBABLE CAUSE High pressure leaks (at joint, plugs or tubing) Leaky discharge check valve Leaky ram O-ring seal Leaky release valve Leaky pump O-ring seal Lack of oil Sticking inlet check valve Closed air vent Air under ram Plugged inlet diffuser inside reservoir tank CORRECTIVE ACTION Re-tighten or repair Open release valve. Pump rapidly to dislodge; Or repair pump Replace seals (Order: K-1934 Kit) Tighten release valve Repair pump (Ref. Appendix I: K-1939 Kit) Refill reservoir check system for leaks Open release valve. Pump rapidly to dislodge; Or repair pump Open air vent Bleed system Replace inlet diffuser (Order: H-2679) Jack will not lower or lowers slowly PROBABLE CAUSE Closed air vent or release valve Broken pump release valve Bent ram Plugged inlet diffuser inside reservoir tank CORRECTIVE ACTION Open air vent Replace release valve Replace suspected ram assembly Replace inlet diffuser (Order: H-2679) 8.0 PARTS LIST Reference Pages 4 8 for ordering information of Replacement Parts and Kits. When ordering Replacement Parts/Kits, please specify Model & Serial Number of your product. 06/ Rev. OR - 3 -

8 Model: Ton Two Stage Hydraulic Axle Jack Parts List This Axle Jack uses MIL-H-5606/MIL-H Fluid Only. When ordering Replacement Parts/Kits, please specify Model & Serial Number of your product. ITEM PART NUMBER DESCRIPTION QTY 2... H Screw, Vent J Assembly, Base Plate N Plug, 1 /16 NPT Pipe HC O-ring, Pump/Base HC O-ring, Pump/Reservoir N S... Plug, 3 /8" Pipe...1 K-4026 Kit, Pump Replacement; consists of: 1... HC Hydraulic Hand Pump (Assembled) G Socket Head Cap Screw, ¼-20 x 2 ½" long G Socket Head Cap Screw, 3 /8-16 x 1" long HC Pump/Base O-ring HC Pump/Reservoir O-ring...1 K-1931 Kit, Reservoir Replacement; consists of: 2... H Vent Screw HC Reservoir G Socket Head Cap Screw, ¼-20 x 2 ½" long HC Pump/Reservoir O-ring / Rev. OR - 4 -

9 Model: Ton Two Stage Hydraulic Axle Jack This page left blank intentionally 06/ Rev. OR - 5 -

10 Model: Ton Two Stage Hydraulic Axle Jack Parts List When ordering Replacement Parts/Kits, please specify Model & Serial Number of your product. 06/ Rev. OR - 6 -

11 Model: Ton Two Stage Hydraulic Axle Jack Parts List This Axle Jack uses MIL-H-5606/MIL-H Fluid Only. ITEM PART NUMBER DESCRIPTION QTY G Socket Head Cap Screw, ¼-20 x ¾" long G Retaining Washer G Retaining Ring G Set Screw, Hex x 3 /8" long R Retaining Plug J Flange TR nd Stage Ram G Socket Head, Cap Screw, ½-20 x 1 ½" long TR st Stage Ram TR Outer Tube TR Outer Mechanical Extension TR Inner Mechanical Extension...1 K-1934 Kit, Seal Replacement; consists of: Retaining Ring Retaining Plug O-ring nd Stage Backup Ring nd Stage O-ring st Stage Backup Ring st Stage O-ring Outer Tube Backup Ring Outer Tube O-ring Socket Head Cap Screw st Stage Rod Wiper nd Stage Rod Wiper...1 K-3701 Kit, Cylinder Assembly Replacement; consists of: Screw, Socket Head Cap, ¼-20 x ¾" long Washer, Retaining Ring, Retaining O-ring, Retaining Plug Screw, Hex Set, x 3 /8" long Plug, Retaining Backup Ring, 2nd Stage O-ring, 2nd Stage Backup Ring, 1st Stage O-ring, 1st Stage Backup Ring, Outer Tube O-ring, Outer Tube Ram Tube, 2nd Stage Ram Tube, 1st Stage Tube, Outer Rod Wiper, 1st Stage Rod Wiper, 2nd Stage Tube, Outer Extension Tube, Inner Extension / Rev. OR - 7 -

12 Model: Ton Two Stage Hydraulic Axle Jack Parts List This Axle Jack uses MIL-H-5606/MIL-H Fluid Only. When ordering Replacement Parts/Kits, please specify Model & Serial Number of your product. ITEM PART NUMBER DESCRIPTION QTY Z " Base Spacer Block Z " Base Spacer Block H Inlet Diffuser...1 NOTE: Optional Kit Available for Axle Jack (K-1945); consists of: One (1) Extension Base Blocks (Z , 1 inch height) One (1) Extension Base Blocks (Z , 2 inches height) 06/ Rev. OR - 8 -

13 APPENDIX I Hydraulic Schematic

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15 Hydraulic Schematic

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17 APPENDIX II HC ,250 psi Hand Pump Parts List

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19 Model: HC psi Hand Pump *** Parts List With Illustrations 06/2006 Rev. OR ** When ordering Replacement Parts/Kits, please specify Model, Color and Serial Number of your Unit.** Tronair, Inc Eber Road Holland, Ohio USA Telephone: (419) Fax: (419) Web Site:

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21 Model: HC PSI Hand Pump 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. Parts List This pump is compatible with MIL-H-5606/MIL-H hydraulic fluid. Reference Parts List Illustration on Page 3. REPLACEMENT PARTS ITEM PART NUMBER DESCRIPTION QTY 1...CXD Pump Body Flange Half Handle Piston Tube Handle Grip Snap Ring Socket Head Cap Screw, 1/4-20 x 3/4" long Valve Body Pipe Plug CXD Screw Retainer...1 All other parts available in Replacement Kits only. REPLACEMENT KITS ITEM PART NUMBER DESCRIPTION QTY K-4027 Kit, Release Valve Replacement; consists of: Screw Retainer Release Valve...1 K-1068 Kit, Linkage Replacement; consists of: Pivot Pin Assembly Strap Pump Handle Bracket Clevis Pin Assembly...1 K-4028 Kit, Internal Parts Replacement; consists of: Outlet Check Spring Outlet Check Ball Inlet Check Spring Inlet Check Ball Ball Spring...1 Replacement Kits List continued on following page. 06/2006 Rev. OR - 1 -

22 Model: HC PSI Hand Pump Parts List This pump is compatible with MIL-H-5606/MIL-H hydraulic fluid. Reference Parts List Illustration on Page 3. REPLACEMENT KITS ITEM PART NUMBER DESCRIPTION QTY K-4029 Kit, Seal Replacement; consists of: Outlet Check O-Ring Tube Seal O-Ring Valve Body O-Ring Rod Wiper Backup Ring Piston Seal O-Ring Relief Valve O-Ring Relief Valve Back Up Ring Relief Valve O-Ring Release Valve O-Ring...1 Not Shown Pump / Reservoir O-Ring...1 Not Shown Pump / Base Plate O-Ring...1 Refer to your axle jack parts list for correct location. NOTE: Entire pump assembly can be purchased as a kit. See Hydraulic Jack Parts List pertaining to your model. 06/2006 Rev. OR - 2 -

23 Model: HC PSI Hand Pump Parts List Illustration WARNING! Item 26 (H-2934) is a preset relief valve. Do Not disassemble this valve. Replacement parts are available as a preset relief valve assembly 06/2006 Rev. OR - 3 -

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25 APPENDIX III MSDS Hydraulic Fluid (MIL-H-5606)

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35 APPENDIX - IV Declaration of Conformity

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37 DECLARATION of CONFORMITY Axle Jack C0100 Relevant provisions complied with by the machinery: 98/37/EC Relevant standards complied with by the machinery: DIN EN DIN EN Identification of person empowered to sign on behalf of the manufacturer: Quality Assurance Representative Tronair, Inc Eber Road Holland, Ohio USA Telephone: (419) Fax: (419) Web Site:

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