Tronair 02-7813-0100-A5 Installation and operating instructions

Operation & Service Manual
Model: 02-7813-0100-A5
12 Ton (10.8 Metric Ton) Two Stage
Hydraulic Axle Jack
04/2003 – AB −Rev. 02
Includes Illustrated Parts List
Tronair, Inc.
1740 Eber Road
Holland, Ohio 43528-9794
USA
Telephone: [phone] • 800-426-6301
Fax: [phone]
Web Site: www.tronair.com E-mail: [e-mail]

Model: 02-7813-0100-A5
12 Ton (10.8 Metric Ton) Two Stage
Hydraulic Axle Jack
04/2003 – AB −Rev. 02
TABLE OF CONTENTS PAGE
1.0 Description.....................................................................................................................................................1
2.0 Usage ............................................................................................................................................................1
3.0 Specifications.................................................................................................................................................1
4.0 Assembly Instructions....................................................................................................................................1
4.1 General Information..........................................................................................................................1
4.2 Pre-Use Checks ...............................................................................................................................1
5.0 Operating Instructions ...................................................................................................................................1
5.1 Jack Instructions...............................................................................................................................2
6.0 Maintenance..................................................................................................................................................2
General..........................................................................................................................................................2
6.1 Servicing Jack...................................................................................................................................2
6.2 Removing And Servicing Pump........................................................................................................2
6.3 Jack Function Load Test ..................................................................................................................3
7.0 Trouble Shooting ...........................................................................................................................................3
8.0 Parts List........................................................................................................................................................3
APPENDIX I HC-1533-01 Hand Pump (4,700 psi) Parts List
APPENDIX II MSDS Hydraulic Fluid

Model: 02-7813-0100-A5
12 Ton (10.8 Metric Ton) Two Stage
Hydraulic Axle Jack
04/2003 – AB −Rev. 02
- 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.
1.0 DESCRIPTION
The Tronair Model 02-7813-0100-A5 Hydraulic Axle Jack incorporates the following quality features:
• Steel construction
• Two-stage telescoping rams
• Quick action mechanical extension
• Single speed, manually operated pump
• Uses standard MIL-H-5606 hydraulic fluid
• Preset relief/release valve
2.0 USAGE
The purpose of this jack is to lift aircraft for maintenance. It has a maximum capacity of 12 tons (106.75 kN).
3.0 SPECIFICATIONS
• Vertical capacity: 24,000 lbs (106.75 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: 15.13 in (38.43 cm)
• Weight: 40 lbs (177.93 N)
• BUNA 'N' Seals
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 Jack Illustrated Parts List to identify and assure 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 inch (½") and
three-quarters inch (¾") 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

Model: 02-7813-0100-A5
12 Ton (10.8 Metric Ton) Two Stage
Hydraulic Axle Jack
04/2003 – AB −Rev. 02
- 2 -
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. 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/or 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.
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 6). 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 50-55 ft-lbs.
6.2 REMOVING AND SERVICING PUMP
NOTE: If pump is found faulty, call the factory for replacement or replace seals as follows:
1. Reference Appendix I: HC-1533-01 Hand Pump Parts List during the following process.
2. Drain all fluid from reservoir.
3. Remove pump from jack.
4. Remove cotter pin (Item 16) from clevis pin.
5. Remove four (4) socket head cap screws.
6. Remove flanges.
7. Remove tube assembly (Item 14).
8. Replace O-rings and backup ring. See Appendix I for kits available.
9. Re-assemble in reverse order.
10. Torque each
3/8inch socket head cap screw to 20-25 ft-lbs. Torque each ¼ inch socket head cap
screw to 10-12 ft-lbs.

Model: 02-7813-0100-A5
12 Ton (10.8 Metric Ton) Two Stage
Hydraulic Axle Jack
04/2003 – AB −Rev. 02
- 3 -
6.0 MAINTENANCE
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 CORRECTIVE ACTION
High pressure leaks (at joint, plugs or tubing) Re-tighten or repair
Leaky discharge check valve Open release valve. Pump rapidly to dislodge;
Or repair pump
Leaky ram O-ring packing Replace packing
(Replacement Part Number K-1934)
Leaky release valve Tighten release valve
Leaky pump O-ring packing Repair pump
(Ref. Appendix I: K-1939 Kit)
Lack of oil Refill reservoir check system for leaks
Sticking inlet check valve Open release valve.
Pump rapidly to dislodge;
Or repair pump
Closed air vent Open air vent
Air under ram Bleed system
Plugged inlet diffuser inside reservoir tank Replace inlet diffuser
(Replacement Part Number H-2679)
JACK WILL NOT LOWER
PROBABLE CAUSE CORRECTIVE ACTION
Closed air vent or release valve Open air vent or release valve
Broken pump release valve Repair release valve
Bent ram Replace suspected ram assembly
Plugged inlet diffuser inside reservoir tank Replace inlet diffuser
(Replacement Part Number 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.

Model: 02-7813-0100-A5
12 Ton (10.8 Metric Ton) Two Stage
Hydraulic Axle Jack
04/2003 – AB −Rev. 02
- 4 -
Parts List
This Axle Jack uses Mil-H-5606 Fluid Only.
When ordering Replacement Parts/Kits, please specify Model & Serial Number of your product.
ITEM PART NUMBER DESCRIPTION QTY
2...................H-1720 ............................................. Vent Screw......................................................................1
6...................J-3418-01......................................... Base Plate Assembly ......................................................1
7...................N-2248 ............................................. Pipe Plug,
1/16 NPT..........................................................1
8...................HC-2000-111.................................... Pump/Base O-ring...........................................................1
9...................HC-2000-210.................................... Pump/Reservoir O-ring....................................................1
33...................N-2205-04-S..................................... 3/8" Pipe Plug ...................................................................1
K-1929-01 Kit, Pump Replacement; consists of:
1...................HC-1533-01...................................... Hydraulic Hand Pump (Assembled)................................1
4...................G-1151-105224................................ Socket Head Cap Screw, ¼-20 x 2 ½" long....................2
5...................G-1151-107210................................ Socket Head Cap Screw, 3/8-16 x 1" long ......................4
8...................HC-2000-111.................................... Pump/Base O-ring...........................................................1
9...................HC-2000-210.................................... Pump/Reservoir O-ring....................................................1
K-1931 Kit, Reservoir Replacement; consists of:
2...................H-1720 ............................................. Vent Screw......................................................................1
3...................HC-1536-01...................................... Reservoir.........................................................................1
4...................G-1151-105224................................ Socket Head Cap Screw, ¼-20 x 2 ½" long....................2
9...................HC-2000-210.................................... Pump/Reservoir O-ring....................................................1

Model: 02-7813-0100-A5
12 Ton (10.8 Metric Ton) Two Stage
Hydraulic Axle Jack
04/2003 – AB −Rev. 02
- 5 -
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Model: 02-7813-0100-A5
12 Ton (10.8 Metric Ton) Two Stage
Hydraulic Axle Jack
04/2003 – AB −Rev. 02
- 6 -
Parts List
This Axle Jack uses Mil-H-5606 Fluid Only.
When ordering Replacement Parts/Kits, please specify Model & Serial Number of your product.

Model: 02-7813-0100-A5
12 Ton (10.8 Metric Ton) Two Stage
Hydraulic Axle Jack
04/2003 – AB −Rev. 02
- 7 -
Parts List
This Axle Jack uses Mil-H-5606 Fluid Only.
ITEM PART NUMBER DESCRIPTION QTY
10...................G-1151-105006................................ Socket Head Cap Screw, ¼-20 x ¾" long.......................1
11...................G-1475............................................. Retaining Washer............................................................1
12...................G-1394............................................. Retaining Ring.................................................................1
14...................G-1187-01........................................ Set Screw, Hex 10-32 x 3/8" long.....................................1
15...................R-1325 ............................................. Retaining Plug.................................................................1
23...................J-1845.............................................. Flange..............................................................................1
24...................TR-1299........................................... 2nd Stage Ram ...............................................................1
25...................G-1165............................................. Socket Head, Cap Screw, ½-20 x 1 ½" long...................4
26...................TR-1298........................................... 1st Stage Ram.................................................................1
27...................TR-1300 ........................................... Outer Tube ......................................................................1
30...................TR-1809........................................... Outer Mechanical Extension ...........................................1
31...................TR-1810........................................... Inner Mechanical Extension............................................1
K-1934 Kit, Seal Replacement; consists of:
12................... ......................................................... Retaining Ring.................................................................1
13................... ......................................................... Retaining Plug O-ring......................................................1
17................... ......................................................... 2nd Stage Backup Ring...................................................1
18................... ......................................................... 2nd Stage O-ring.............................................................1
19................... ......................................................... 1st Stage Backup Ring....................................................1
20................... ......................................................... 1st Stage O-ring ..............................................................1
21................... ......................................................... Outer Tube Backup Ring.................................................1
22................... ......................................................... Outer Tube O-ring ...........................................................1
25................... ......................................................... Socket Head Cap Screw.................................................4
28................... ......................................................... 1st Stage Rod Wiper.......................................................1
29................... ......................................................... 2nd Stage Rod Wiper......................................................1
K-3701 Kit, Cylinder Assembly Replacement; consists of:
10................... ......................................................... Screw, Socket Head Cap, ¼-20 x ¾" long......................1
11................... ......................................................... Washer, Retaining...........................................................1
12................... ......................................................... Ring, Retaining................................................................1
13................... ......................................................... O-ring, Retaining Plug.....................................................1
14................... ......................................................... Screw, Hex Set, 10-32 x 3/8" long....................................1
15................... ......................................................... Plug, Retaining................................................................1
17................... ......................................................... Backup Ring, 2nd Stage..................................................1
18................... ......................................................... O-ring, 2nd Stage............................................................1
19................... ......................................................... Backup Ring, 1st Stage...................................................1
20................... ......................................................... O-ring, 1st Stage.............................................................1
21................... ......................................................... Backup Ring, Outer Tube................................................1
22................... ......................................................... O-ring, Outer Tube..........................................................1
24................... ......................................................... Ram Tube, 1st Stage ......................................................1
26................... ......................................................... Ram Tube, 2nd Stage.....................................................1
27................... ......................................................... Tube, Outer .....................................................................1
28................... ......................................................... Rod Wiper, 1st Stage......................................................1
29................... ......................................................... Rod Wiper, 2nd Stage.....................................................1
30................... ......................................................... Tube, Outer Extension ....................................................1
31................... ......................................................... Tube, Inner Extension.....................................................1

Model: 02-7813-0100-A5
12 Ton (10.8 Metric Ton) Two Stage
Hydraulic Axle Jack
04/2003 – AB −Rev. 02
- 8 -
Parts List
This Axle Jack uses Mil-H-5606 Fluid Only.
When ordering Replacement Parts/Kits, please specify Model & Serial Number of your product.
ITEM PART NUMBER DESCRIPTION QTY
34...................H-2679 ............................................. Inlet Diffuser ....................................................................1
NOTE:
Optional Kit Available for Axle Jack (K-1945); consists of:
One (1) Extension Base Blocks (Z-2168-01, 1 inch height)
One (1) Extension Base Blocks (Z-2169-01, 2 inches height)

APPENDIX I
HC-1533-01
4,700 psi
Hand Pump
Parts List

04/1990 – Rev. OR
** When ordering Replacement Parts/Kits, please specify Model, Color and Serial Number of your Unit.**
Tronair, Inc.
1740 Eber Road
Holland, Ohio 43528-9794
USA
Telephone: [phone] • 800-426-6301
Fax: [phone]
Web Site: www.tronair.com E-mail: [e-mail]
Model: HC-1533-01
4700 PSI
Hand Pump
***
Parts List
With
Illustrations

Model: HC-1533-01
4700 PSI Hand Pump
04/1990 – Rev. OR
- 1 -
Parts List
This pump is compatible with MIL-H-5606 / MIL-H-83282 hydraulic fluid.
Reference Parts List Illustration on Page 3.
REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION QTY
2.........................CXC-890036-201....................... Pump Body......................................................................1
10.........................506-000...................................... Flange Half......................................................................4
13.........................507-050...................................... Piston...............................................................................1
14.........................504-050...................................... Tube ................................................................................1
18.........................520-050...................................... Snap Ring........................................................................1
22.........................503-001...................................... Valve Body ......................................................................1
23.........................518-000...................................... Socket Head Cap Screw, 1/4-20 x 3/4" long...................4
24.........................540-000...................................... Pipe Plug.........................................................................1
26.........................530-000...................................... Screw Retainer................................................................1
27.........................529-000...................................... Handle Grip .....................................................................1
28.........................511-240-001.............................. Handle.............................................................................1
All other parts available in Replacement Kits only.
REPLACEMENT KITS
ITEM PART NUMBER DESCRIPTION QTY
K-1936 Kit, Release Valve Replacement; consists of:
1......................... ................................................... Release Valve .................................................................1
26......................... ................................................... Screw Retainer................................................................1
K-1068 Kit, Linkage Replacement; consists of:
11......................... ................................................... Pivot.................................................................................1
12......................... ................................................... Pin Assembly...................................................................2
15......................... ................................................... Strap................................................................................2
16......................... ................................................... Clevis Pin Assembly........................................................1
17......................... ................................................... Pump Handle Bracket .....................................................1
K-1069 Kit, Internal Parts Replacement; consists of:
5......................... ................................................... Inlet Check Spring...........................................................1
6......................... ................................................... Outlet Check Spring........................................................1
7......................... ................................................... Outlet Check Ball.............................................................1
8......................... ................................................... Inlet Check Ball ...............................................................1
Not Shown.................... ................................................... ♦Release Ball.................................................................1
♦This item will not be used in HC-1533-01 pump.
Replacement Kits List continued on following page.

Model: HC-1533-01
4700 PSI Hand Pump
04/1990 – Rev. OR
- 2 -
Parts List
This pump is compatible with MIL-H-5606 / MIL-H-83282 hydraulic fluid.
Reference Parts List Illustration on Page 3.
REPLACEMENT KITS
ITEM PART NUMBER DESCRIPTION QTY
K-1939 Kit, Seal Replacement; consists of:
3......................... ................................................... Release Valve O-Ring.....................................................1
4......................... ................................................... Outlet Check O-Ring.......................................................1
9......................... ................................................... Valve Body O-Ring..........................................................1
19......................... ................................................... Rod Wiper........................................................................1
20......................... ................................................... Backup Ring....................................................................1
21......................... ................................................... Piston Seal O-Ring..........................................................1
25......................... ................................................... Tube Seal 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.

Model: HC-1533-01
4700 PSI Hand Pump
04/1990 – Rev. OR
- 3 -
Parts List Illustration