Tronair 02-0517C0140 Installation and operating instructions

OPERATION & SERVICE MANUAL
Tronair, Inc. Phone: [phone] | 800-426-6301
1 Air Cargo Pkwy East Web: www.tronair.com
Swanton, OH 43558 Email: [email protected]
Models:
02-0517C0140 02A0517C0140
02B0517C0140 02C0517C0140
5 Ton (4.5 Metric Ton)
Two Stage Jack
10/2017 - Rev. 04

REVISION DATE TEXT AFFECTED
01 07/2007 Original Release
02 03/2012 Major revision
03 04/2014 7.4.2 Jack Instructions, Parts List
04 10/2017 Major revision

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04
TABLE OF CONTENTS PAGE
1.0 PRODUCT INFORMATION ..............................................................................................................................................1
1.1 DESCRIPTION....................................................................................................................................................1
1.2 MODEL & SERIAL NUMBER..............................................................................................................................1
1.3 MANUFACTURED..............................................................................................................................................1
1.4 USAGE ...............................................................................................................................................................1
2.0 SAFETY INFORMATION..................................................................................................................................................1
2.1 USAGE AND SAFETY INFORMATION..............................................................................................................1
2.2 WARNING AND DANGER SIGNS......................................................................................................................1
2.3 COMPONENT SAFETY FEATURES..................................................................................................................1
2.4 FUNCTIONAL SAFETY FEATURES ..................................................................................................................1
2.5 FEATURES FOR OPERATOR SAFETY ............................................................................................................1
2.6 PERSONAL PROTECTION EQUIPMENT..........................................................................................................1
2.7 ENVIRONMENTAL SAFETY FEATURES ..........................................................................................................2
2.8 SAFETY GUIDELINES .......................................................................................................................................2
2.9 CONDITIONS FOR SAFE USE ..........................................................................................................................2
2.10 OPERATOR QUALIFICATIONS.........................................................................................................................2
2.11 ADDITIONAL SAFETY MEASURES...................................................................................................................2
3.0 ASSEMBLY ......................................................................................................................................................................2
3.1 GENERAL INSTRUCTIONS...............................................................................................................................2
3.2 PRE-USE CHECKS............................................................................................................................................2
3.3 PERSONNEL REQUIREMENTS........................................................................................................................3
3.4 INSPECTION AND TEST PROCEDURES .........................................................................................................3
4.0 INSTALLATION................................................................................................................................................................3
4.1 AIR SUPPLY REQUIREMENTS.........................................................................................................................3
5.0 TRAINING.........................................................................................................................................................................3
5.1 TRAINING REQUIREMENTS.............................................................................................................................3
5.2 TRAINING PROGRAM .......................................................................................................................................3
5.3 OPERATOR TRAINING......................................................................................................................................3
6.0 OPERATION.....................................................................................................................................................................3
6.1 OPERATING PARAMETERS .............................................................................................................................3
6.2 NUMERICAL VALUES........................................................................................................................................3
6.3 OPERATOR CONTROLS...................................................................................................................................4
6.4 OPERATING INSTRUCTIONS...........................................................................................................................4
6.4.1 Rules For Operating............................................................................................................................................4
6.4.2 Jack Instructions .................................................................................................................................................5
7.0 PACKAGING AND STORAGE.........................................................................................................................................7
7.1 PACKAGING REQUIREMENTS.........................................................................................................................7
7.2 HANDLING .........................................................................................................................................................7
7.3 STRAPPING .......................................................................................................................................................7
7.4 LABELING OF PACKAGING ..............................................................................................................................7
7.5 STORAGE ENVIRONMENT...............................................................................................................................7
7.6 STORAGE SPACE AND HANDLING FACILITIES .............................................................................................7
8.0 TRANSPORTATION.........................................................................................................................................................7
9.0 TROUBLE SHOOTING.....................................................................................................................................................8
10.0 MAINTENANCE................................................................................................................................................................8
10.1 GENERAL...........................................................................................................................................................8
10.2 MAINTENANCE SCHEDULE..............................................................................................................................8
10.2.1 Storage/Low Usage.............................................................................................................................................8
10.3 SERVICING JACK..............................................................................................................................................9
10.4 REMOVING AND SERVICING PUMP................................................................................................................9
10.5 JACK FUNCTION LOAD TEST...........................................................................................................................9
10.6 PNEUMATIC PUMP............................................................................................................................................9
11.0 PROVISION OF SPARES.................................................................................................................................................9
11.1 SOURCE OF SPARE PARTS.............................................................................................................................9
11.2 RECOMMENDED SPARE PARTS LISTS ..........................................................................................................9
12.0 IN SERVICE SUPPORT..................................................................................................................................................10
13.0 GUARANTEES/LIMITATION OF LIABILITY..................................................................................................................10
14.0 APPENDICES.................................................................................................................................................................10

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04 Page | 1
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 PRODUCT INFORMATION
1.1 DESCRIPTION
5 Ton Two Stage Jack
1.2 MODEL & SERIAL NUMBER
Reference nameplate on unit
1.3 MANUFACTURED
TRONAIR, Inc. Telephone: [phone] or 800-426-6301
1 Air Cargo Pkwy East Fax: [phone]
Swanton, Ohio 43558 USA E-mail: [email protected]
Website: www.tronair.com
1.4 USAGE
The device is intended to lift an aircraft by its fuselage and/or main wing with other hydraulic jacks arranged by position and
quantity to provide proper balance, and in conjunction with the correct jack pad, whose maximum load on any one jack does
not exceed the rated capacity of the jack.
The jacks are not intended for metal forming, metal working, or any purpose other than that stated above.
2.0 SAFETY INFORMATION
2.1 USAGE AND SAFETY INFORMATION
To insure safe operations please read the following statements and understand their meaning. Also refer to your equipment
manufacturer’s manual for other important safety information. This manual contains safety precautions which are explained
below. Please read carefully.
WARNING! —Warning is used to indicate the presence of a hazard that can cause severe personal injury,
death, or substantial property damage if the warning notice is ignored.
CAUTION! —Caution is used to indicate the presence of a hazard that will or can cause minor personal injury
or property damage if the caution notice is ignored.
2.2 WARNING AND DANGER SIGNS
See labels on unit. WARNING!
The ram locknuts are user operated safety devices. Failure to utilize these locknuts may result in personal
injury or death.
2.3 COMPONENT SAFETY FEATURES
Ram Locknut prevents lowering of the ram. The Ram Locknut must be lowered as the aircraft is being lifted.
Hold to Run Air Valve requires the operator to hold the air valve lever to raise the ram using the air pump. Releasing the
air valve lever stops upward movement of the ram.
CE Hand Pump With Check Valve prevents unintentional decent of aircraft if relief valve fails.
Locknut Retention Ring prevents locknut from being unscrewed from 2nd stage ram
2.4 FUNCTIONAL SAFETY FEATURES
Pressure Relief Valve prevents overload during raising operations.
2.5 FEATURES FOR OPERATOR SAFETY
Always wear safCautions and Instruction Labels located on jack
Ram Locknut
Air Shut-Off Valve
2.6 PERSONAL PROTECTION EQUIPMENT
Safety glasses must be worn when operating the jack

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04 Page | 2
2.0 SAFETY INFORMATION (continued)
2.7 ENVIRONMENTAL SAFETY FEATURES
The jack is non-polluting. See Appendix for Material Safety Data concerning the recommended hydraulic fluid (MIL-PRF-
5606).
2.8 SAFETY GUIDELINES CAUTION!
Do not place hands on top of jack near ram locknuts while lowering jack. Pinch points exist between top of
jack and threads on ram.
1. NEVER put hands between the aircraft and the jack pad; as after aircraft has been lowered, struts may
have hung up.
2. NEVER align jack under aircraft by pounding on jack legs. Dented legs may lead to jack collapse.
3. ALWAYS lower ram locking nut(s) after jack is under load. Be sure ram nut(s) is seated fully after
jacking.
4. ALWAYS raise and lower jacks simultaneously so that aircraft remains level.
5. ALWAYS use a tail or nose stand, as applicable, for additional stability.
WARNING!
The ram locknuts are user operated safety devices. Failure to utilize these locknuts may result in personal
injury or death.
2.9 CONDITIONS FOR SAFE USE
Use in a clean dry environment on a level surface.
Operate between -20C and 50C (-4F and 122F).
2.10 OPERATOR QUALIFICATIONS
This jack is intended to be used by the skilled and trained aircraft technician. The operator must be familiar with the jacking
procedures for the aircraft to be raised, and the operation of the jack.
Installation/Maintenance/Dismantling Qualifications: This jack is to be installed, maintained, and dismantled by qualified
technicians familiar with hydraulic systems.
2.11 ADDITIONAL SAFETY MEASURES
This jack must be used in accordance with this technical manual, and in accordance with the aircraft manufacturer’s jacking
procedures.
3.0 ASSEMBLY
This product is shipped completely assembled and tested and requires no further assembly before operation. The following
sections apply when servicing the unit.
3.1 GENERAL INSTRUCTIONS
1. This product should be assembled and/or repaired using good workmanship practices and proper tools. Bolts and elastic
stopnuts should be tightened to a torque not to exceed industry standards for Grade '5' bolts.
2. All replacement parts must be the same as or better than the original parts supplied.
3. Dispose of waste per federal and local laws and regulations.
4. No modifications are allowed that will adversely affect the jacks safety performance.
5. The pressure relief valve is not serviceable. It must be replaced as a unit.
3.2 PRE-USE CHECKS
1. Refer to the Illustrated Parts List to identify and ensure that all parts are present.
2. Generally check over unit to assure the tightness of all nuts, bolts and fittings.
3. With rams completely collapsed, check hydraulic fluid level.
Replenish with MIL-PRF-5606 fluid as required.
Fluid Level: 1.5 in (3.8 cm) below vent.
NOTE: Refer to fluid manufacturer’s (Appendix) Material Safety Data Sheet, and advisory for handling and disposal
of fluid.
3.0 Assembly continued on following page.

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04 Page | 3
3.0 ASSEMBLY (continued)
3.3 PERSONNEL REQUIREMENTS
This jack is to be assembled by qualified technicians familiar with hydraulic systems.
3.4 INSPECTION AND TEST PROCEDURES
1. Ensure fluid level is within 1.5 inches (3.8 cm) from reservoir vent cap.
2. Raise ram to full stroke, and check for leaks.
4.0 INSTALLATION
Installation and commissioning requires connection of the air valve to an adequate air supply (Air Pump equipped Models
only).
4.1 AIR SUPPLY REQUIREMENTS
25 psi (1.72 bar) Minimum
40 psi (2.75 bar) Recommended
125 psi (8.60 bar) Maximum
5.0 TRAINING
5.1 TRAINING REQUIREMENTS
The employer of the operator is responsible for providing a training program sufficient for the safe operation of the unit.
5.2 TRAINING PROGRAM
The employer provided operator training program should cover safety procedures concerning use of the unit in and around the
intended aircraft at the intended aircraft servicing location. This jack must be used in accordance with aircraft manufacturer’s
instructions.
5.3 OPERATOR TRAINING
The operator training should provide the required training for safe operation of the unit.
NOTE: Maintenance and Trouble Shooting are to be performed by a skilled and trained technician.
6.0 OPERATION
6.1 OPERATING PARAMETERS
1. The user shall work in accordance with the Operator Manual.
2. At no time shall personnel work under the raised load until it is secured by suitable means, i.e. ram locknut.
3. The employer of the operator shall provide for all necessary training and give information about pumping and translating
forces.
4. Operate between -20C and 50C (-4F and 122F).
6.2 NUMERICAL VALUES
Rated Capacity: 10,000 lbs (4,536 kg)
Minimum Closed Height: 17 5/8 in (44.77 cm)
Mechanical Extension: 7 in (17.78 cm)
Hydraulic Extension: 22 in (55.88 cm)
Maximum Height Obtainable: 46 5/8 in (118.43 cm)
Weight: 105 lbs (47.63 kg)
Pressure Relief Setting: 2,500 +250/-0 psig (172.4+17.2/-0 bar)
Noise level is 64 dB(A) at a distance of 120 in (304.8 cm) at an inlet pressure of 100 psi (6.9 bar)

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04 Page | 4
6.0 OPERATION (continued)
6.3 OPERATOR CONTROLS
6.4 OPERATING INSTRUCTIONS
The user should be familiar with the following statements prior to using the jack(s):
CAUTION!
1. NEVER put hands between the aircraft and the jack pad; as after aircraft has been lowered, struts may
have hung up.
2. NEVER align jack under aircraft by pounding on jack legs. Dented legs may lead to jack collapse.
3. ALWAYS lower ram locking nut(s) after jack is under load. Be sure ram nut(s) is seated fully after
jacking.
4. ALWAYS raise and lower jacks simultaneously so that aircraft remains level.
5. ALWAYS use a tail or nose stand, as applicable, for additional stability.
WARNING!
When collapsing rams by hand miss-staging may occur and cause pinch points. To collapse ram, add a
minimum 50 lb load to the mechanical extension. Keep hands and fingers clear of locking nuts. Failure to
adhere to this safety instruction can cause injury.
6.4.1 Rules For Operating
1. The user shall work in accordance with the Operator and/or Technical Manuals.
2. At no time shall personnel work under the raised load until it is secured by suitable means, i.e. ram locknut.
3. The employer of the operator shall provide for all necessary training and give information about pumping and translating
forces.
4. Operate between -20C and 50C/-4F and 122F.
6.4 Operating instructions continued on following page.

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04 Page | 5
6.4 OPERATING INSTRUCTIONS (continued)
6.4.2 Jack Instructions
To Raise Aircraft:
1. Place jack on a hard, level surface.
2. Hydraulic rams must be completely retracted before operating jack.
3. Raise mechanical extension as close to aircraft jack pad as possible.
WARNING!
The locking pin MUST be placed in the ram protection ring groove and fully through the mechanical
extension.
The locking pin washer and ball lock MUST be placed outside the ram protection ring.
Visually inspect the jack prior to every use.
Do not place extra locking pins in any other hole on
the mechanical extension.
Insure mating surfaces to jack point are free of
debris and damage.
Under no conditions should the locking pin washer
or washer groove be inside the ram protection ring
groove.
Under no conditions should the locking pin’s ball
lock be inside the ram protection ring groove.
Never use the jack if the ram protection ring is not
installed.
Never use the locking pin without a locking pin
washer.
Never use a locking pin that has been damaged.
Never use a ram protection ring that has been
damaged or deformed.
Replace ram protection ring if it does not have a
radius groove for the locking pin.
Load test jacks annually.
Only order replacement parts from Tronair.
Failure to comply could result in premature failure
below certified weight and could cause serious injury including death.
Correct Pin Placement

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04 Page | 6
6.4.2 Jack Instructions (continued) Incorrect Pin Placements
Results Of Locking Pin In Incorrect Location
Ram Protection Ring
6.4.2 Jack instructions continued on following page.
Washer In
Ram Protection Ring
Ball Lock In
Ram Protection Ring
Washer On Top Of
Ram Protection Ring
Locking Pin Not In
Ram Protection Ring
and top Locking Pin
in Mechanical Extension
(use only one pin)
Unacceptable Condition
Acceptable Condition
Damage
and
Deformation
No
Deformation

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04 Page | 7
6.4.2 Jack Instructions (continued)
4. Close pump release valve by turning clockwise.
Note: Turning the pump release valve counter-clockwise lowers the jack. Turning the pump release valve
clockwise stops the jack’s descent, and allows it to be raised.
5. Hydraulic rams must extend in order form largest to smallest diameter.
6. Lower ram locknut(s) as aircraft is raised. Keep locknuts within 1 inch from bottom of extending ram.
7. Largest diameter hydraulic ram must fully extend before the next stage ram begins to rise.
8. Do not continue to operate hand pump after all rams have fully extended.
WARNING!
The ram locknuts are user operated safety devices. Failure to utilize these locknuts may result in
personal injury or death.
Do not place hands on top of jack near ram locknuts while lowering jack. Pinch points exist between
top of jack and threads on ram.
Always wear safety glasses.
To Lower Aircraft:
1. Lower all jacks simultaneously.
2. If ram locknut(s) is tight, raise jack slightly to release nut(s) ¼ inch from tripod.
3. Ensure proper staging as aircraft is being lowered: loosen ram locknut beginning with smallest ram (1” max) until stage is
completely lowered. Repeat for next largest stage.
4. Loosen pump release valve slightly to slowly lower aircraft.
NOTE: When using jack during washing operations, completely cover top of jack near ram seal.
7.0 PACKAGING AND STORAGE
7.1 PACKAGING REQUIREMENTS
Jacks are to be packaged as required to prevent damage to legs or hydraulic equipment during shipment.
7.2 HANDLING
Jacks can be rolled by hand on its casters.
7.3 STRAPPING
Jacks can be strapped down by suitable means to prevent unwanted movement during shipment.
7.4 LABELING OF PACKAGING
Packaging should be labeled DO NOT DROP.
7.5 STORAGE ENVIRONMENT
Store jacks between -20C and +50C/-4F and 122F.
Always store jack with ram all the way down.
Suitable for outdoor storage by using a full coverage waterproof tarp or canvas.
7.6 STORAGE SPACE AND HANDLING FACILITIES
Minimum Closed Height: 17 5/8 in (44.77 cm)
Weight: 105 lbs (47.63 kg)
8.0 TRANSPORTATION
Lifting can be accomplished by crane and strap thru top of tripod, or by fork truck under lower tripod support. Approximate
weight is 105 lbs (47.63 kg).

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04 Page | 8
9.0 TROUBLE SHOOTING
TROUBLE
PROBABLE CAUSE
ACTION
Fluid leakage at pump
piston or pump body
Damaged backup ring, o-ring, piston or pump
body
Remove piston and pump body. Inspect for
damage. Replace defective part(s). Replace
removed o-ring and backup ring
External fluid leakage at
rams
Damaged o-ring, backup ring or inner cylinder
wall
Remove rams as a unit from cylinder. Inspect
parts. Replace o-ring and defective part(s)
Jack fails to lift rated load
Release valve not closed properly
Fully tighten release valve
Low fluid level
Fill to correct fluid level
Pressure relief valve improperly adjusted
Adjust or replace release valve
Leakage at inlet or outlet check ball
Inspect valve body for wear or replace valve
body and check balls
Vent screw closed
Open vent screw
Rams will not support load
after manual or pneumatic
pump up
Leaking ram o-ring seals
Check for external leakage, if present replace
defective seal and back up ring
Leaking pressure check valve
Inspect valve body for wear or replace valve
body and check balls
Leaking pressure relief valve
Remove release valve, inspect ball and ball
seat in pump block. Replace effective part(s)
Rams raise and fall with
each manual pump stroke
Release valve open
Fully tighten release valve
Inlet check valve not seated or sticking
Pump rapidly to dislodge or replace valve
body
Pressure check valve not seated or sticking
Pump rapidly to dislodge or replace valve
body
Jack fails to lower
Ram locknut not loosened
Raise jack ¼ inch and release locknut
Vent screw closed
Open vent screw
O-Ring (pinched or rolled)
Replace o-ring and back-up ring, clean up
cylinder wall of debris
10.0 MAINTENANCE
10.1 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 both 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 over-all 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 2006/42/EC.
10.2 MAINTENANCE SCHEDULE
Check Fluid Level................................................................Each Use
Lubricate Casters................................................................3 Months
Cleaning..............................................................................Annually Or As Needed
Capacity Test (105%-110% of jack’s rated capacity) ..........Annually
NOTE: Wipe with soft cloth only, do no pressure wash or spray water directly at ram seal.
10.2.1 Storage/Low Usage
If jack is not being used on a regular basis, every 90 days the jack should be fully extended and retracted to exercise the seals
and to prevent rust build up on the cylinder I.D. While ram is extended, clean the threads and spray with DoALL RPM, LPS, or
equivalent that is water repellent and will not harm BUNA “N” O-rings.
10.0 Maintenance continued on following page.

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04 Page | 9
10.0 MAINTENANCE (continued)
10.3 SERVICING JACK
To Disassemble Jack For Seal Replacement:
1. Raise first stage ram high enough to allow removal of the threaded tube stop.
2. Raise both first and second stage rams together to the point where this assembly can be lifted from the jack cylinder.
NOTE: If the second stage ram is allowed to precede the first stage ram, it will fill with oil causing an oil spill when
the assembly is removed from the cylinder.
To Re-assemble Jack:
1. Re-assemble in reverse order of above.
NOTE: Lubricate cylinder, ram(s) and o-ring(s) for assembly:
Lubricate inner cylinder wall(s) with MIL-PRF-5606 hydraulic fluid
Apply suitable o-ring lubricant grease to installed o-ring(s) and to o-ring lead-in chamfer at opening of cylinder
NOTE: To minimize air entrapment under the rams. Actuate cylinder with had pump several inches and release. This
will circulate oil and bleed out air.
2. Spray I.D. of cylinder and O.D. of rams with DoALL RPM, LPS or equivalent water repellent that will not harm the Buna
“N” O-rings to protect surfaces from rusting when not in use.
3. Ensure locknut retaining ring is present on second stage ram to prevent nut removal after seal kit installation.
10.4 REMOVING AND SERVICING PUMP
Note: If pump is found faulty, call the factory for replacement:
1. Clamp suction (push on) hose and remove hose from pump.
2. Uncouple fitting of hydraulic hoses from pump.
3. Remove pump from jack.
4. Re-assemble in reverse order.
10.5 JACK FUNCTION LOAD TEST
NOTE: If function load testing is required:
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 5% to 10%.
10.6 PNEUMATIC PUMP
See Appendix II Haskel Air Pump Manufacturer Data for complete parts list and repair information.
11.0 PROVISION OF SPARES
11.1 SOURCE OF SPARE PARTS
Spare parts may be obtained from the manufacturer:
TRONAIR, Inc. Telephone: [phone] or 800-426-6301
1 Air Cargo Pkwy East Fax: [phone]
Swanton, Ohio 43558 USA E-mail: [email protected]
Website: www.tronair.com
11.2 RECOMMENDED SPARE PARTS LISTS
Reference the following page(s) for Replacement Parts and Kits available.
Recommended Spares to be kept on hand:
K-4588 Kit, Ram Seal Replacement
K-3441 Kit, Seal Replacement
K-1685 Kit, Repair Fluid Seal (Air Option only)
K-1686 Kit, Repair Air Seal (Air Option only)

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04 Page | 10
12.0 IN SERVICE SUPPORT
Contact Tronair, Inc. for technical services and information. See Section 1.3 Manufacturer.
13.0 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.
14.0 APPENDICES
APPENDIX I Hydraulic Schematic
APPENDIX II Haskel Air Pump Manufacturer Data
APPENDIX III Safety Data Sheet –MIL-PRF-5606 Hydraulic Fluid
APPENDIX IV Declaration of Conformity
APPENDIX V Maintenance Schedule

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04 Page | 11
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Item
Part Number
Description
Qty
2
H-1009-01
Assembly, Pump Handle
1
3
V-1001
Label, Made in USA
1
4
V-1775
Label, Pump Force
1
5
V-1776
Label, Down
1
6
G-1100-109526
Bolt, Hex Head, Grade 5, ½-20 x 2 ¾" long
2
7
U-1002
Wheel
2
8
G-1203-1095
Jamnut, ½-20 Elastic
2
K-2037
Kit, Jack Weldment Replacement; consists of:
1
Z-4800-01
Weldment, Jack (includes labels)
1

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04 Page | 12
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Item
Part Number
Description
Qty
9
N2788-02-S-B
Elbow, 90° Male
1
11
N-2001-08-S-B
Elbow, 90° Male
1
12
HC-2764
Pump, Hydraulic Hand
1
10
TF-1043-03*21.0
Assembly, Hose
1
13
G-1154-107216
Screw, Hex Socket Head Cap, 3/8-16 x 1 ¾" long
3
14
Z-7678-01-01
Weldment, Tube
1
15
V-1779
Label, Serial Number
1
16
V-1198
Label, Tronair
1
17
G-1251-1070R
Lockwasher, 3/8Regular
2
18
G-1100-107010
Bolt, Hex Head, Grade 5, 3/8-16 x 1" long
2
19
N-2001-08-S-B
Elbow, 90Male
1
20
N-2706-02-S-B
Elbow, Extra Long 90Male
1
44
J-4982-01
Retaining Ring, Cylinder
2
45
G-1154-106212
Screw, SOC HD BUT CAP 5/16 –18 x 1 ¼” long
4
46
G-1202-1060
Stopnut, Elastic 5/16 –18
4
47
G-1250-1060N
Flatwasher, 5/16 Narrow
4
49
G-1202-1070
Stopnut, Elastic ⅜–16
3
50
G-1250-1070N
Flatwasher, ⅜Narrow
3
51
N-2066-06-S-B
Plug, Hollow Hex with O-Rings (w/out air only)
1
Not Shown
TF-1047-01*05.5
Hose, Push-on
1

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04 Page | 13
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Item
Part Number
Description
Qty
K-1061-04
Kit, Reservoir Replacement; consists of:
21
N-2653-01-S-B
Elbow, 90° Male
1
22
TF-1047-01*09.0
Hose, Push-on
1
23
H-1045
Breather
1
24
HC-2328
Reservoir, Translucent
1
25
V-1102-01
Label, "Use MIL-PRF-5606"
1
26
V-1016
Label, "Capacity 10,000 lbs"
1
27
V-1819
Label, Hydraulic Jack Caution
1
28
V-1820
Label, Hydraulic Jack Instruction
1
29
G-1250-1050N
Flatwasher, ¼ Narrow
3
30
G-1100-105006
Bolt, HH, Grade 5, ¼ - 20 x ¾ Long
3
Not Shown
H-1516-08
Clamp, 2 Ear Hose
1

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04 Page | 14
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Item
Part Number
Description
Qty
31
G-1318-0825
Pin, ½ x 2.5" Model D
1
32
TR-1026
Ring, Ram Protection
1
33
R-1013-02
Shaft, Extension
1
34
TR-2223
Stopnut, Second Stage Ram
1
35
H-3446
Stopnut, Second Stage Ram
1
36
G-1397-206
Ring, Retaining
1
37
TR-2222
Stop, Tube
1
38
Z-7683-01
Ram, Second Stage
1
39
Z-7681-01
Ram, First Stage
1
K-4588
Kit, Ram Seal Replacement; consists of:
40
HC-2020-329
Ring, Backup
1
41
HC-2000-329
O-ring
1
42
HC-2020-338
Ring, Backup
1
43
HC-2000-338
O-ring
1
K-2017
Kit, Jack Pad Replacement; consists of:
Not Shown
R-1239
Pad, Jack
1

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04 Page | 15
Parts List - Air Pump Option
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Item
Part Number
Description
Qty
4
N-2789-01-S-B
Connector, Straight Male, ¼ Hose x SAE #4
1
5
N-2740-04-S-B
Tee, Male Branch, SAE #4
1
6
TF-1047-01*05.0
Hose, ¼ Gray x 5" long
1
21
N-2791-01-S-B
Connector, 45º Male, ¼ Hose, SAE #4
1
Not Shown
H-1516-08
Clamp, 2 Ear Hose
2
Z-4621
Assembly, Air Pump; consists of:
1
G-1100-106512
Bolt, Hex Head, Grade 5, 5/16 -24 x 1 ¼ " long
2
2
G-1250-1060N
Flatwasher, 5/16 Narrow
4
3
G-1202-1065
Stopnut, 5/16 -24 Elastic
2
7
TF-1043-03*15.0
Assembly, Hose
1
8
G-1202-1055
Stopnut, ¼-28 Elastic
4
9
G-1250-1050N
Flatwasher, ¼ Narrow
8
10
H-1174
Pump, Air
1
11
N-2009-08-S
Connector, Male, 3/8-37JIC x ¼ NPT
1
12
G-1100-105510
Bolt, Hex Head, Grade 5, ¼-28 x 1" long
4
13
H-1173
Plug, Valve
1
14
TF-1047-01*06.5
Hose, ¼ Gray x 6 ½" long
1
15
J-3415-01
Bracket, Air Pump
1
16
N-2210-04-S
Reducer, 3/8NPT x 1/8NPT
1
17
N-2410-01
Elbow, 90Male, ¼ Hose x 1/8NPT
1
18
Included with Item 20
Hose
1
19
N-2250-03
Adapter, Expander Pipe
1
20
H-2961
Blowgun
1

5 Ton (4.5 Metric Ton) Two Stage Jack
Models: 02-0517C0140 (Standard)
02A0517C0140 (with Air Pump Option)
02B0517C0140 (with Air Pump Option and Spring Loaded Casters)
02C0517C0140 (with Spring Loaded Casters)
5 Ton (4.5 Metric Ton) Two Stage Jack
10/2017 | Rev. 04 Page | 16
Parts List - Spring Loaded Caster Option
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Item
Part Number
Description
Qty
1
G-1203-1105
Jamnut, 5/8-18 Elastic
1
2
G-1250-1100N
Flatwasher, 5/8Narrow
1
3
Z-3910-02-01
Weldment, Tube
1
4
H-1128-02
Spring, Compression
1
5
G-1250-1100W
Flatwasher, 5/8Wide
1
6
U-1053
Caster, Stem
1
7
G-1202-1060
Stopnut, 5/16 -18 Elastic
4
8
G-1250-1060N
Flatwasher, 5/16 Narrow
4
9
G-1009-18
U-bolt
2