Tronair 02-7839-0111 Installation and operating instructions

Operation & Service Manual
Model: 02-7839-0111
18 Ton Single Stage Jack
09/2001 – Rev. 01
Includes Illustrated Parts Lists
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: 02-7839-0111
18 Ton Single Stage Jack
09/2001 – Rev. 01
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 Erecting Jack ....................................................................................................................................1
4.3 Pre-Use Checks ................................................................................................................................2
5.0 Operating Instructions ...................................................................................................................................2
5.1 Jack Instructions...............................................................................................................................2
6.0 Maintenance ..................................................................................................................................................3
General ..........................................................................................................................................................3
6.1 Servicing Jack ..................................................................................................................................3
6.2 Removing And Servicing Pump.......................................................................................................3
6.3 Jack Function Load Test...................................................................................................................4
7.0 Trouble Shooting...........................................................................................................................................4
Parts List Index...........................................................................................................................................................4
APPENDIX I HC-1752 Hand Pump (2500 psi) Parts List
APPENDIX II MSDS (MIL-H-5606) Hydraulic Fluid

Model: 02-7839-0111
18 Ton Single Stage Jack
09/2001 – Rev. 01
- 1 -
1.0 DESCRIPTION
The Tronair Single Stage Jack incorporates the following quality features:
• Steel Construction
• Mechanical ram lock nut that prevents lowering of jack under load
• Quick action mechanical extension
• Single speed, manually operated pump with pressure relief
• Uses standard MIL-H-5606 hydraulic fluid
2.0 USAGE
The purpose of the jack is to lift the aircraft for maintenance. See 3.0 Specifications for capacity of the jack.
3.0 SPECIFICATIONS
• Capacity: 36,000 lbs
• Closed Height: 120 inches
• Mechanical Extension: 16 inches
• Hydraulic Extension: 42 inches
• Fully Extended: 178 inches
• Weight: 900 lbs
4.0 ASSEMBLY INSTRUCTIONS
4.1 GENERAL INFORMATION
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.
All replacement parts must be the same as or equal to the original parts supplied.
4.2 ERECTING JACK
1. Refer to the jack illustrated parts breakdown and Figure 1 to assemble.
2. Loosely fasten brace machinings to each leg weldment using 7/16-20 x 2-1/2 inch long hex head
bolts, 7/16 flatwashers, and 7/16-20 elastic stopnuts.
3. Raise each tripod leg so that casters can be fastened to leg. Use 3/8-24 x 1-1/2 inch long hex head
bolts, 3/8 flatwashers and 3/8-24 elastic stopnuts to secure casters to legs.
4. Raise jack onto tripod and fasten with 7/16 flatwashers, and 7/16-20 elastic stopnuts. Once
securely fastened, the tripod braces can be tightened.
5. Tighten 7/16 bolts that fasten the brace weldments to the legs.
4.0 Assembly Instructions continued on following page.
FIGURE 1

Model: 02-7839-0111
18 Ton Single Stage Jack
09/2001 – Rev. 01
- 2 -
4.0 ASSEMBLY INSTRUCTIONS
4.3 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; three-quarter inch (3/4") below
vent. 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.
CAUTION
1. NEVER put hands between aircraft and 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.
5.1 JACK INSTRUCTIONS
To Raise Aircraft:
1. Place jack on a hard level surface.
2. Raise mechanical extension as close to aircraft jack pad as possible.
3. Close pump release valve and operate pump.
4. Lower ram locknuts as aircraft is raised.
To Lower Aircraft:
1. Lower all jacks simultaneously.
2. If ram locking nut(s) is tight, raise jack slightly to release nut(s).
3. Loosen pump release valve slightly to slowly lower aircraft. Raise locking nut(s), as jack ram(s)
lower.
NOTE: When using the jack during a washing or cleaning operation, the jack should be completely
covered to protect it from cleaning solution, dirt and/or foreign material which might get on or
between the ram and cylinder causing damage to the seals and O-rings.

Model: 02-7839-0111
18 Ton Single Stage Jack
09/2001 – Rev. 01
- 3 -
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 both O-rings and backup rings once removed. Cut and damaged O-rings
normally result in fluid leakage.
• If cylinder bore is found to be rusty, it may be honed to a maximum diameter of 4.506 inches and a
surface finish of 16 micro inches. If pitting in the bore cannot be removed by this process, the jack
cylinder must be replaced before the jack can be returned to service.
• At this time flush old hydraulic fluid and dirt from overall system and replenish with new, clean
hydraulic fluid.
90-Day Routine Maintenance
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 inside diameter. 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.
6.1 SERVICING JACK
To Disassemble Jack:
1. Remove mounting plate (Item 9) by unscrewing five (5) socket head cap screws (Item 7).
2. Raise ram assembly (Item 8) to the point where it can be lifted from the jack cylinder.
To Re-assemble Jack:
1. Re-assemble in reverse order of above. Note: Torque five (5) socket head cap screws (Item 7) to
100 ft-lbs.
2. Spray inside diameter of cylinder and outside diameter of ram (Items 1 & 8) 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.
NOTE: To minimize air entrapment under the ram, raise the oil level in the cylinder to
chamfer of the cylinder prior to ram insertion.
6.2 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-1752 Hand Pump Parts List.
2. Clamp suction (push on) hose and remove hose from pump.
3. Uncouple fitting of hydraulic hose from pump.
4. Remove pump from jack.
6.2 Removing and Servicing Pump continued on following page.

Model: 02-7839-0111
18 Ton Single Stage Jack
09/2001 – Rev. 01
- 4 -
6.0 MAINTENANCE
6.2 REMOVING AND SERVICING PUMP
5. Remove clevis pin assembly. (Item 18).
6. Remove four (4) socket head cap screws.
7. Remove flanges.
8. Remove tube assembly. (Item 16).
9. Replace O-rings and backup ring. (See Appendix I: HC-1752 for kits available).
10. Re-assemble in reverse order.
6.3 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 10%.
7.0 TROUBLE SHOOTING
RAM WILL NOT RISE OR RISES ERRATICALLY
P ROBABLE C AUSE C ORRECTIVE A CTION
High pressure leaks (at joint, plugs or tubing) Re-tighten or repair
Leaky discharge check valve Pump rapidly to dislodge;
Or repair pump
Leaky ram O-ring packing Replace packing
Leaky release valve Tighten release valve
Leaky pump O-ring packing Repair pump
Lack of oil Refill reservoir check system for leaks
Sticking inlet check valve Pump rapidly to dislodge;
Or repair pump
Closed air vent Open air vent
Air under ram Bleed system
JACK WILL NOT LOWER
P ROBABLE C AUSE C ORRECTIVE A CTION
Ram locknut not in correct position Rotate nut to top of ram
Broken pump release valve Repair pump
Bent ram Replace suspected ram assembly
Parts List Index
Replacement Parts ..............................................5
Replacement Kits ...............................................6
Parts List Illustrations.................................. 7 −8

Model: 02-7839-0111
18 Ton Single Stage Jack
09/2001 – Rev. 01
- 5 -
Parts List
Reference Illustrations on Pages 7 & 8.
REPLACEMENT PARTS
ITEM PART NUMBER DESCRIPTION QTY
1 HJ-557 Pad, Jack 1
2 H-2329 Nut, Extension 1
3 G-1300-31200 Pin, Roll, 5/16" diameter x 2" long 1
4 R-1150 Extension, Mechanical 1
5 H-2326 Nut, Ram 1
7 G-1151-109210 Screw, Cap 1/2-13 x 1" long 5
8 Z-1612 Assembly, Ram 1
9 TR-1740 Plate, Mounting 1
15 G-1100-105006 Bolt, Hex Head, Grade 5, 1/4-20 x 3/4" long 1
21 TF-1043-06*22.5 Assembly, Hose 1
27 N-2008-05-S Cap 1
28 N-2016-05-S Tee, Run Swivel Nut 1
29 N-2004-15-S Elbow, Extra Long Male 1
30 N-2250-10 Adapter, Expanding Pipe 1
31 G-1100-108512 Bolt, Hex Head, Grade 5, 7/16-20 x 1-1/4" long 12
32 G-1250-1080N Flatwasher, 7/16 Narrow 96
33 G-1202-1085 Stopnut, 7/16-20 Elastic 48
34 Z-3836-01-01 Weldment, Tripod Leg 2
35 Z-3845-03-01 Machining, Brace 3
36 Z-3845-02-01 Machining, Brace 3
37 Z-3845-01-01 Machining, Brace 3
42 G-1100-108522 Bolt, Hex Head, Grade 5, 7/16-20 x 2-1/4" long 36
43 H-1009-01 Assembly, Handle 1
44 Z-3836-02-01 Weldment, Tripod Leg 1
All other parts available in Replacement Kits only - See Page 6.

Model: 02-7839-0111
18 Ton Single Stage Jack
09/2001 – Rev. 01
- 6 -
Parts List
Reference Illustrations on Pages 7 & 8.
REPLACEMENT KITS
PART NUMBER DESCRIPTION QTY
K-1051 Kit, Seal Replacement; consists of:
- Item 6 HJ-706 Ring, Guide 1
- Item 10 HC-2000-346 O-Ring 1
- Item 11 HC-2020-346 Ring, Backup 1
K-2433 Kit, Caster Replacement; consists of:
- Item 38 G-1100-107512 Bolt, Hex Head, Grade 5, 3/8-24 x 1/2" long 4
- Item 39 G-1250-1070N Flatwasher, 3/8 Narrow 8
- Item 40 G-1202-1075 Stopnut, 3/8 Elastic 4
- Item 45 U-1020 Caster, Isolator 1
K-3436 Kit, Reservoir Replacement; consists of:
- Item 12 G-1202-1050 Stopnut, 1/4-20 Elastic 3
- Item 13 G-1250-1050N Flatwasher, 1/4 Narrow 5
- Item 14 H-1045 Breather 1
- Item 15 G-1100-105510 Bolt, Hex Head, Grade 5, 1/4-28 x 1" long 1
- Item 16 HJ-580-05-01 Weldment, Reservoir including Labels 1
- Item 17 TF-1047-04*10.0 Hose, Push-on 1
- Item 18 N-2208-01-S Tee, Male Branch 1
- Item 19 N-2205-02-S Plug, Hollow Hex 1
- Item 20 N-2412-09 Connector, Straight Male 1
K-3439 Kit, Pump Replacement; consists of:
- Item 17 TF-1047-04*10.0 Hose, Push-on 1
- Item 22 N-2001-08-S-B Elbow, Straight Thread 1
- Item 23 HC-1752 Pump, Hydraulic Hand 1
- Item 24 N-2410-05 Elbow, 90°Male 1
- Item 25 G-1251-1070R Lockwasher, 3/8 Regular 2
- Item 26 G-1100-107010 Bolt, Hex Head, Grade 5, 3/8-16 x 1" long 2
K-3440 Kit, Jack Weldment Replacement; consists of:
- Item 41 Z-5090-01 Jack Weldment including Labels 1

Model: 02-7839-0111
18 Ton Single Stage Jack
09/2001 – Rev. 01
- 7 -
Parts List Illustrations

Model: 02-7839-0111
18 Ton Single Stage Jack
09/2001 – Rev. 01
- 8 -
Parts List Illustrations