Tronair 02-7813C0100 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]
Model: 02-7813C0100
12 Ton (10.8 Metric Ton) Two Stage
Hydraulic Axle Jack
01/2017 Rev. 04

REVISION DATE TEXT AFFECTED
OR 06/2006 Original Release
01 05/2011 Modified Parts Lists and Illustrations
03 07/2016 Major revision
04 01/17 Modified Parts List

Model: 02-7813C0100
12 Ton Two Stage Hydraulic Axle Jack
01/2017 | Rev. 04
TABLE OF CONTENTS PAGE
1.0 PRODUCT INFORMATION ..............................................................................................................................................1
1.1 DESCRIPTION....................................................................................................................................................1
1.2 MODEL & SERIAL NUMBER..............................................................................................................................1
1.3 MANUFACTURER..............................................................................................................................................1
1.4 USAGE ...............................................................................................................................................................1
1.5 SPECIFICATIONS..............................................................................................................................................1
2.0 SAFETY INFORMATION..................................................................................................................................................1
2.1 USAGE AND SAFETY INFORMATION..............................................................................................................1
3.0 ASSEMBLY INSTRUCTIONS...........................................................................................................................................1
3.1 GENERAL INFORMATION.................................................................................................................................1
3.2 PRE-USE CHECKS............................................................................................................................................1
4.0 TRAINING.........................................................................................................................................................................2
4.1 TRAINING REQUIREMENTS.............................................................................................................................2
4.2 TRAINING PROGRAM .......................................................................................................................................2
4.3 OPERATOR TRAINING......................................................................................................................................2
5.0 OPERATING INSTRUCTIONS .........................................................................................................................................2
5.1 JACK INSTRUCTIONS.......................................................................................................................................2
6.0 TROUBLE SHOOTING.....................................................................................................................................................2
7.0 MAINTENANCE................................................................................................................................................................3
7.1 GENERAL...........................................................................................................................................................3
7.2 SERVICING JACK..............................................................................................................................................3
7.3 REMOVING AND SERVICING PUMP................................................................................................................3
7.4 JACK FUNCTION LOAD TEST...........................................................................................................................3
8.0 PROVISION OF SPARES.................................................................................................................................................3
8.1 SOURCE OF SPARE PARTS.............................................................................................................................3
8.2 RECOMMENDED SPARE PARTS LISTS ..........................................................................................................3
9.0 GUARANTEES/LIMITATION OF LIABILITY....................................................................................................................4
10.0 APPENDICES...................................................................................................................................................................4

Model: 02-7813C0100
12 Ton Two Stage Hydraulic Axle Jack
01/2017 | 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., its 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
The Tronair Model 02-7813C0100 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-PRF-5606 hydraulic fluid
Preset relief/release valve
Two sizes of base spacer blocks
1.2 MODEL & SERIAL NUMBER
Reference nameplate on unit
1.3 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
1.4 USAGE
The purpose of this jack is to lift aircraft for maintenance. It has a maximum capacity of 12 tons (106.75 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.
1.5 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
NOTE: These numbers increase accordingly when base spacer blocks are used.
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.
3.0 ASSEMBLY INSTRUCTIONS
3.1 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.
3.2 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-PRF-5606 fluid as required.

Model: 02-7813C0100
12 Ton Two Stage Hydraulic Axle Jack
01/2017 | Rev. 04 Page | 2
4.0 TRAINING
4.1 TRAINING REQUIREMENTS
The employer of the operator is responsible for providing a training program sufficient for the safe operation of the unit.
4.2 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.
4.3 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.
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.
5.1 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 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
ram(s)
Damaged o-ring, backup ring or inner
cylinder wall
Remove ram(s) 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
Ram(s) 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)
Ram(s) 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

Model: 02-7813C0100
12 Ton Two Stage Hydraulic Axle Jack
01/2017 | Rev. 04 Page | 3
7.0 MAINTENANCE
7.1 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 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 2006/42/EC.
Capacity test (110% of jack’s rated capacity) annually
7.2 SERVICING JACK
To Disassemble Jack
2. Collapse jack rams.
3. Remove vent screw and drain all fluid from reservoir.
4. Remove cap screws (Item 25) surrounding jack cylinder, then remove flange, (Item 23).
5. Lift cylinder from jack base (Item 16). Operate jack hand pump to help remove cylinder.
6. Remove retaining ring (Item 12) and unscrew retaining plug, (Item 15).
7. 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.
7.3 REMOVING AND SERVICING PUMP
NOTE: If pump is found faulty, call the factory for replacement or replace seals as follows:
Review Appendix I - HC-2332-01 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 3/8socket head cap screw to 20-25 ft-lbs. Torque each ¼ socket head cap screw 10 to 12 ft-lbs.
7.4 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%.
4. Test annually.
8.0 PROVISION OF SPARES
8.1 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
8.2 RECOMMENDED SPARE PARTS LISTS
Reference the following page(s) for Replacement Parts and Kits available.
When ordering Replacement Parts/Kits, please specify Model & Serial Number of your product.

Model: 02-7813C0100
12 Ton Two Stage Hydraulic Axle Jack
01/2017 | Rev. 04 Page | 4
9.0 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.
10.0 APPENDICES
APPENDIX I Hydraulic Schematic
APPENDIX II HC-2332-01 Hand Pump (5,250 psi +300/-000) Parts List
APPENDIX III Safety Data Sheet –MIL-PRF-5606 Hydraulic Fluid
APPENDIX IV Declaration of Conformity
APPENDIX V Maintenance Schedule

Model: 02-7813C0100
12 Ton Two Stage Hydraulic Axle Jack
01/2017 | Rev. 04 Page | 5
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
This Axle Jack uses MIL-PRF-5606/MIL-PRF-83282 Fluid Only.
Item
Part Number
Description
Qty
2
H-1720
Screw, Vent
1
6
Z-9154-01
Assembly, Base Plate
1
7
N-2066-03-S-B
Plug, O-ring Hex #3
3
8
HC-2000-111
O-ring, Pump/Base
1
9
HC-2000-210
O-ring, Pump/Reservoir
1
K-4026
Kit, Pump Replacement; consists of:
1
HC-2332-01
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: 02-7813C0100
12 Ton Two Stage Hydraulic Axle Jack
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Model: 02-7813C0100
12 Ton Two Stage Hydraulic Axle Jack
01/2017 | Rev. 04 Page | 7
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.

Model: 02-7813C0100
12 Ton Two Stage Hydraulic Axle Jack
01/2017 | Rev. 04 Page | 8
Parts List
This Axle Jack uses MIL-PRF-5606/MIL-PRF-83282 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-1399-256
Retaining Ring
1
14
G-1163-16
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-1151-109512
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
G-1399-256
Retaining Ring
1
13
HC-2000-136
Retaining Plug O-ring
1
17
HC-2023-142
2nd Stage Backup Ring
1
18
HC-2000-142
2nd Stage O-ring
1
19
HC-2023-150
1st Stage Backup Ring
1
20
HC-2000-150
1st Stage O-ring
1
21
HC-2023-042
Outer Tube Backup Ring
1
22
HC-2000-042
Outer Tube O-ring
1
28
HC-1697-29
1st Stage Rod Wiper
1
29
HC-1697-24
Outer Rod Wiper
1
K-3701
Kit, Cylinder Assembly Replacement; consists of:
10
G-1151-105006
Screw, Socket Head Cap, ¼-20 x ¾" long
1
11
G-1475
Washer, Retaining
1
12
G-1399-256
Ring, Retaining
1
13
HC-2000-136
O-ring, Retaining Plug
1
14
G-1163-16
Screw, Hex Set, 10-32 x 3/8" long
1
15
R-1325
Plug, Retaining
1
17
HC-2023-142
Backup Ring, 2nd Stage
1
18
HC-2000-142
O-ring, 2nd Stage
1
19
HC-2023-150
Backup Ring, 1st Stage
1
20
HC-2000-150
O-ring, 1st Stage
1
21
HC-2023-042
Backup Ring, Outer Tube
1
22
HC-2000-042
O-ring, Outer Tube
1
24
TR-1299
Ram Tube, 2nd Stage
1
26
TR-1298
Ram Tube, 1st Stage
1
27
TR-1300
Tube, Outer
1
28
HC-1697-29
1st Stage Rod Wiper
1
29
HC-1697-24
Outer Rod Wiper
1
30
TR-1809
Outer Mechanical Extension
1
31
TR-1810
Inner Mechanical Extension
1

Model: 02-7813C0100
12 Ton Two Stage Hydraulic Axle Jack
01/2017 | Rev. 04 Page | 9
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
This Axle Jack uses MIL-PRF-5606/MIL-PRF-83282 Fluid Only.
Item
Part Number
Description
Qty
34
Z-2168-01
1" Base Spacer Block
1
35
Z-2169-01
2" Base Spacer Block
1
36
HC-2719
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
Hydraulic Schematic

Hydraulic Schematic

APPENDIX II
HC-2332-01
5,250 psi Hand Pump Parts List

Tronair, Inc. Phone: [phone] | 800-426-6301
1 Air Cargo Pkwy East Web: www.tronair.com
Swanton, OH 43558 Email: [email protected]
Model: HC-2332-01
5250 psi
Hand Pump
***
Parts List
With Illustrations
05/2011 –Rev. 01
When ordering Replacement Parts/Kits, please specify Model, Color and Serial Number of your Unit.

Model: HC-2332-01
5250 PSI Hand Pump
05/2011 | Rev. 01 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., its suppliers, distributors, employees, or financial institutions from any liability
from consequences that may occur. Only Tronair OEM replacement parts shall be used.
Parts List
This pump is compatible with MIL-PRF-5606/MIL-PRF-83282 hydraulic fluid.
Item
Part Number
Description
Qty
1
CXD-060025-001
Pump Body
1
9
506-000
Flange Half
4
11
511-360-001
Handle
1
13
507-050
Piston
1
15
504-050
Tube
1
16
529-000
Handle Grip
1
19
520-050
Snap Ring
1
23
518-000
Socket Head Cap Screw, 1/4-20 x 3/4" long
4
24
503-001
Valve Body
1
25
540-000
Pipe Plug
1
32
13-0703
Plug, O-ring Hex #2
1
34
CXD-000003-04
Screw Retainer
1
H-1009-01
Handle, Pump: consists of:
11
511-360-001
Handle
1
16
529-000
Handle Grip
1
K-4027
Kit, Release Valve Replacement; consists of:
34
Screw Retainer
1
35
Release Valve
1
K-1068
Kit, Linkage Replacement; consists of:
10
Pivot
1
12
Pin Assembly
2
14
Strap
2
17
Pump Handle Bracket
1
18
Clevis Pin Assembly
1
K-4028
Kit, Internal Parts Replacement; consists of:
4
Outlet Check Spring
1
5
Outlet Check Ball
1
6
Inlet Check Spring
1
8
Inlet Check Ball
1
30
Ball
1
31
Spring
1
K-4029
Kit, Seal Replacement; consists of:
2
Outlet Check O-Ring
1
7
Tube Seal O-Ring
1
8
Valve Body O-Ring
1
20
Rod Wiper
1
21
Backup Ring
1
22
Piston Seal O-Ring
1
27
Relief Valve O-Ring
1
28
Relief Valve Back Up Ring
1
29
Relief Valve O-Ring
1
33
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.