Tronair 02-7836C0110 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: 02-7836C0110
12 Ton (10.87 Metric) Axle Jack
08/2010 - Rev. 02

REVISION DATE TEXT AFFECTED
01 05/2010 Original release
02 08/210 Modified 7.0 Trouble Shooting and Parts List

Model: 02-7836C0110
12 Ton (10.87 Metric) Axle Jack
08/2010| 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.......................................................................................................................................1
6.0 MAINTENANCE................................................................................................................................................................2
6.1 GENERAL...........................................................................................................................................................2
6.2 SERVICING JACK..............................................................................................................................................2
6.3 REMOVING AND SERVICING PUMP................................................................................................................2
6.4 JACK FUNCTION LOAD TEST...........................................................................................................................2
7.0 TROUBLE SHOOTING.....................................................................................................................................................3
8.0 GUARANTEES/LIMITATION OF LIABILITY....................................................................................................................3
9.0 APPENDICES...................................................................................................................................................................3

Model: 02-7836C0110
12 Ton (10.87 Metric) Axle Jack
08/2010| Rev. 02 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 DESCRIPTION
The Tronair Model 02-7836C0110 Hydraulic Axle Jack incorporates the following quality features:
Steel construction
Three-stage telescoping ram
Quick action mechanical extension
Single speed, manually operated pump
Uses standard MIL-PRF-5606 hydraulic fluid
Preset relief/release valve
2.0 USAGE
The purpose of this jack is to lift aircraft for maintenance.
Maximum capacity of this jack is 12 tons (10.87 metric tons).
3.0 SPECIFICATIONS
Vertical capacity: 24,000 lbs (10.87 metric tons)
Minimum closed height: 4.00 in (10.16 cm)
Mechanical extension: 1.37 in (3.48 cm)
Hydraulic extension: 5.63 in (14.30 cm)
Maximum height obtainable: 11.00 in (27.94 cm)
Weight: 60.00 lbs (27.00 kg)
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
Reference the Illustrated Parts List - Pages 4 & Error! Bookmark not defined. 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; between 0.50 and 0.75 inches (1.27 and 1.91 cm) from top of
reservoir fitting. Replenish with MIL-PRF-5606 fluid as required.
5.0 OPERATING INSTRUCTIONS
The user should be familiar with the following statements prior to using the jack(s).
CAUTION!
1. Aircraft jacking adaptors must rest in jack pad.
2. Never put hands between aircraft and jack pad.
3. 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. 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.

Model: 02-7836C0110
12 Ton (10.87 Metric) Axle Jack
08/2010| Rev. 02 Page | 2
6.0 MAINTENANCE
6.1 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.
6.2 SERVICING JACK
To Disassemble Jack
2. Collapse jack ram.
3. Remove vent screw and drain all fluid from reservoir.
4. Remove cap screws (Item 6) surrounding jack cylinder, then remove flange (Item 5).
5. Lift cylinder from jack base (Item 17). Operate jack hand pump to help remove cylinder.
6. Remove retaining rings (Items 33, 16 and 15).
7. Separate rams and replace all seals including retaining rings.
To Re-assemble Jack
1. Re-assemble in reverse order of above.
2. Torque each cap screw (Item 6) to 50 —55 ft-lbs (67.79 74.57 N-m).
6.3 REMOVING AND SERVICING PUMP
NOTE: If pump is found faulty, call the factory for replacement or replace seals as follows:
1. Review Appendix I: HC-2485 Hand Pump Parts List during the following procedure:
2. Drain all fluid from reservoir
3. Remove pump from jack
4. Remove cotter pin from clevis pin
5. Remove four (4) socket head cap screws
6. Remove flanges
7. Remove tube assembly
8. Replace O-rings and backup ring. (See Appendix I for kits available)
9. Re-assemble in reverse order
10. Torque each three-eighths inch (3/8") socket head cap screw to 20 - 25 ft/lbs (27.12 - 33.89 N-m). Torque each one-
quarter inch (1/4") socket head cap screw to 6 - 7.5 ft-lbs (8.13 - 10.17 N-m).
6.4 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.

Model: 02-7836C0110
12 Ton (10.87 Metric) Axle Jack
08/2010| Rev. 02 Page | 3
7.0 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
8.0 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.
9.0 APPENDICES
APPENDIX I Hydraulic Schematic
APPENDIX II HC-2485 Hand Pump (8000 psi/551.58 bar) Parts List
APPENDIX III Safety Data Sheet (SDS) Hydraulic Fluid (MIL-PRF-5606)
APPENDIX IV Declaration of Conformity
APPENDIX V Maintenance Schedule

Model: 02-7836C0110
12 Ton (10.87 Metric) Axle Jack
08/2010| Rev. 02 Page | 4
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Item
Part Number
Description
Qty
1
Z-2878
Assembly, Vent
1
2
HC-2485
Assembly, Hydraulic Hand Pump (8000 psi)
1
18
HC-2008-109
O-ring, Series 2
2
19
N-2205-02-S
Plug, Hex Head, 1/2 NPT
1
21
G-1151-107212
Screw, Hex Socket Head Cap, 3/8-16 x 1-1/4" long
4
34
N-2066-02-S-B
Plug, Hex Head with O-ring
1
35
H-1009-01
Assembly, Handle
1
K-2607
Kit, Reservoir Replacement; consists of:
3
Z-3495
Assembly, Reservoir
1
20
HC-2000-204
O-ring, Series 2
1
22
G-1151-105210
Screw, Hex Socket Head Cap, 1/4-20 x 1" long
4

Model: 02-7836C0110
12 Ton (10.87 Metric) Axle Jack
08/2010| Rev. 02 Page | 5
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Item
Part Number
Description
Qty
5
J-2351
Ring, Retaining
1
6
G-1151-109716
Screw, Socket Head Cap, 1/2-20 x 1-3/4" long
4
7
TR-1541
Cylinder, Main
1
8
TR-1801
Cylinder, Stage 1
1
9
TR-1799
Cylinder, Stage 2
1
10
TR-1800
Cylinder, Stage 3
1
11
G-1300-13040
Pin, Roll, 1/4" diameter x 1/2" long
2
12
R-1628-02
Extension, Mechanical
1
13
R-1627
Pad, Jack
1
15
G-1398-150
Ring, Internal
1
16
G-1398-200
Ring, Internal
1
17
Z-3493-01
Weldment, Base Plate
1
33
G-1398-250
Ring, Internal
1
23
R-1716
Plug, End
1

Model: 02-7836C0110
12 Ton (10.87 Metric) Axle Jack
08/2010| Rev. 02 Page | 6
Item
Part Number
Description
Qty
K-2606
Kit, Replacement Cylinder Seals; consists of:
4
HC-2008-236
O-ring, Series 2
1
14
HC-2000-218
O-ring, Series 2
1
24
HC-1697-20
Wiper, Ring
1
25
HC-2023-224
Ring, Backup
1
26
HC-2000-224
O-ring, Series 2
1
27
HC-1697-24
Wiper, Ring
1
28
HC-2023-228
Ring, Backup
1
29
HC-2000-228
O-ring, Series 2
1
30
HC-1697-28
Wiper, Ring
1
31
HC-2023-232
Ring, Backup
1
32
HC-2000-232
O-ring, Series 2
1

Model: 02-7836C0110
12 Ton (10.87 Metric) Axle Jack
08/2010| Rev. 02 Page | 7

APPENDIX I
Hydraulic Schematic

Hydraulic Schematic

APPENDIX II
HC-2485
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-2485
8000 psi
Hand Pump
***
Parts List
With Illustrations
05/2010 –Rev. 01

Model: HC-2485
8000 PSI Hand Pump
05/2010 | 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
When ordering Replacement Parts/Kits, please specify Model, Color and Serial Number of your Unit.
This pump is compatible with MIL-PRF-5606/MIL-PRF-83282 Hydraulic Fluids only.
Reference Parts List Illustration on following page.
Item
Part Number
Description
Qty
8
506-034
Flange
1
18
518-034
Screw, Socket Head Cap
4
K-4215
Kit, Seal Replacement; consists of:
5
O-Ring, Outlet Check
1
7
O-Ring, Tube Seal
1
17
Wiper, Rod
1
19
Ring, Backup
1
20
O-Ring, Piston
1
22
O-Ring, Valve Body
1
23
Ring, Backup
1
27
O-Ring, Release Screw
1
32
O-Ring, Relief Valve
1
33
Ring, Back-Up
1
34
O-Ring, Relief Valve
1
K-1068
Kit, Linkage Replacement; consists of:
9
Pivot
1
10
Assembly, Linkage Pin
2
13
Strap
2
14
Assembly, Clevis Pin
1
15
Bracket, Pump Handle
1
K-4216
Kit, Internal Parts Replacement; consists of:
2
Spring, Inlet Check
1
3
Spring, Outlet Check
1
4
Ball, Outlet Check
1
6
Ball, Inlet Check
1
24
Ball
1
25
Spring
1
K-3875
Kit, Piston/Cylinder Replacement; consists of:
11
Piston
1
12
Tube
1
16
Retainer, Wiper
1
21
Assembly, Valve Body (Includes Items 1, 2, 6, 21)
1
K-3876
Kit, Piston/Seal Replacement; consists of:
11
Piston
1
19
Ring, Backup
1
20
O-Ring, Piston
1
K-4214
Kit, Release Screw Replacement; consists of:
29
Screw, Release
1
28
Retainer, Screw
1
NOTE: Entire pump assembly can be purchased as a kit.See Hydraulic Jack Parts list.

Model: HC-2485
8000 PSI Hand Pump
05/2010 | Rev. 01 Page | 2
Parts List Illustration
This pump is compatible with MIL-PRF-5606/MIL-PRF-83282 Hydraulic Fluids only.
WARNING
Item 31 (H-3327) is a preset relief valve. Do Not disassemble this valve.
Replacement parts are available as a preset relief valve assembly.