Tronair 02-7854C0110 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: 02-7854C0110
12 Ton (10.87Metric Ton) and
25 Ton (22.68 Metric Ton)
Axle Jack
03/2008 - Rev. 02

REVISION DATE TEXT AFFECTED
OR 10/2006 Original Release
01 04/2007 Modified Parts List - Item 19
Modified Illustrations
02 03/2008 Modified Parts List

Model: 02-7854C0110
12 & 25 Ton (10.87 & 22.68 Metric Ton) Axle Jack
03/2008 | 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 .........................................................................................................................................2
5.1 JACK INSTRUCTIONS.......................................................................................................................................2
6.0 MAINTENANCE................................................................................................................................................................2
6.1 GENERAL...........................................................................................................................................................2
6.2 SERVICING JACK..............................................................................................................................................2
6.3 JACK FUNCTION LOAD TEST...........................................................................................................................3
7.0 TROUBLE SHOOTING.....................................................................................................................................................3
8.0 PARTS LIST .....................................................................................................................................................................3
9.0 GUARANTEES/LIMITATION OF LIABILITY....................................................................................................................4
10.0 APPENDICES...................................................................................................................................................................4

Model: 02-7854C0110
12 & 25 Ton (10.87 & 22.68 Metric Ton) Axle Jack
03/2008 | 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., 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 DESCRIPTION
The Tronair Model 02-7854C0110 Hydraulic Axle Jack incorporates the following quality features:
Steel construction
Three-stage, telescoping 12 ton (10.87 Metric ton) rams
Two-stage, telescoping 25 ton (22.68 Metric ton) rams
Quick action mechanical extension
Two speed, manually operated pump
Uses standard MIL-PRF-5606 Hydraulic Fluid (Reference Appendix II - MSDS)
This jack is specifically designed for use on Global Express aircraft.
2.0 USAGE
The purpose of this jack is to lift aircraft for maintenance. Three-stage cylinder has a maximum capacity of 12 tons (10.87
Metric tons). Two-stage cylinder has a maximum capacity of 25 tons (22.68 Metric tons).
3.0 SPECIFICATIONS
Weight: 84 lbs (38 kg)
BUNA ‘N’ Seals
Three-Stage Cylinder: Two-Stage Cylinder:
Vertical capacity: 24,000 lbs (10.87 Metric tons) 50,000 lbs (22.68 Metric tons)
Minimum closed height: 4 in (11.16 cm) 7 in (17.78 cm)
Mechanical extension: 1.56 in (3.96 cm) 3.13 in (7.95 cm)
Hydraulic extension: 5.44 in (13.82 cm) 8.31 in (21.11 cm)
Maximum height obtainable: 11 in (27.94 cm) 18.44 in (46.84 cm)
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 Figure 1 on the following page and the Illustrated Parts Lists for identification. Ensure all components are present.
Generally check over unit to ensure 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.

Model: 02-7854C0110
12 & 25 Ton (10.87 & 22.68 Metric Ton) Axle Jack
03/2008 | Rev. 02 Page | 2
FIGURE 1
1
5.0 OPERATING INSTRUCTIONS
The user should be familiar with the following statements prior to using the jack(s).
CAUTION!
1. Jacking adapters must be fully seated on mechanical extension.
2. Never put hands between aircraft and jack pad.
3. Always open reservoir vent screw before operating.
5.1 JACK INSTRUCTIONS
To Raise Nose Gear:
1. Place jack on hard level surface.
2. Connect pump hose to three-stage ram.
3. Open reservoir vent screw.
4. Screw out mechanical extension.
5. Close pump release valve and operate
pump.
To Raise Main Gear:
1. Place jack on hard level surface.
2. Connect the pump hose to two-stage ram.
3. Open the reservoir vent screw.
4. Adjust mechanical extension so the pad is
approximately one-quarter inch (0.25 in/0.63 cm) below the
bottom of the jack pad on the aircraft.
5. Place the jack between the tires and check the clearance
between the mechanical extension and the bottom of the jack
pad.
6. Measurement should be approximately one-quarter inch
(0.25 in/0.63 cm).
7. Close pump release valve and slowly begin to pump the jack to raise the aircraft wheel. Verify that there is clearance
between the jack cylinder assembly and the brake casting.
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/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 MIL-PRF-5606 hydraulic
fluid.
No modifications shall be carried out which adversely affect the compliance of the jack with draft standard 98/37/EC.
6.2 SERVICING JACK
(Reference Parts List Illustrations during the following procedures.)
To Disassemble Jack:
1. Collapse jack ram.
2. Remove cap screws (Items 26 & 28) surrounding jack cylinder, then remove retaining rings, (Items 27 & 29).
3. Lift cylinder from axle jack base (Item 30). Operate jack hand pump to help remove cylinder.
4. Separate three-stage rams by removing internal rings (Items 6, 7 &8).
5. Separate two-stage rams by pushing second stage ram through bottom of cylinder. Unscrew first stage piston end cap
and pull out second stage piston end cap.
To Re-assemble Jack:
1. Replace all seals including internal rings.
2. Re-assemble in reverse order of above.
3. Torque each cap screw (Item 26) to 30 ft-lb (40.67 N-m) and Item 28 to 50 ft-lb (67.79 N-m) using standard cross torque
procedure.
6.2 Servicing jack continued on following page.

Model: 02-7854C0110
12 & 25 Ton (10.87 & 22.68 Metric Ton) Axle Jack
03/2008 | Rev. 02 Page | 3
6.2 SERVICING JACK (continued)
To Bleed Jack for Air:
1. Open reservoir vent screw on hand pump.
2. Pump unit to fully extended position.
3. Turn jack upside down.
4. Push jack back to fully collapsed position.
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. Apply a test load equal to the jack rated capacity plus 10%. Do not exceed this load.
4. Test annually.
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
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
8.0 PARTS LIST
Reference the following pages for Replacement Parts and Kits available.

Model: 02-7854C0110
12 & 25 Ton (10.87 & 22.68 Metric Ton) Axle Jack
03/2008 | Rev. 02 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 Enerpac Instructions & Repair Parts List
APPENDIX II Safety Data Sheet Hydraulic Fluid MIL-PRF-5606
APPENDIX III Declaration of Conformity
APPENDIX IV Maintenance Schedule

Model: 02-7854C0110
12 & 25 Ton (10.87 & 22.68 Metric Ton) Axle Jack
03/2008 | Rev. 02 Page | 5
Parts List

Model: 02-7854C0110
12 & 25 Ton (10.87 & 22.68 Metric Ton) Axle Jack
03/2008 | Rev. 02 Page | 6
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Item
Part Number
Description
Qty
1
HC-2008-236
O-ring, Series 2
1
2
G-1300-13040
Pin, 1/8 diameter x ½" long
3
3
R-1628-02
Extension, Mechanical
1
4
R-1627
Pad, Jack
1
5
HC-2000-218
O-ring, Series 2
1
6
G-1398-150
Ring, Internal
1
7
G-1398-200
Ring, Internal
1
8
G-1398-250
Ring, Internal
1
9
R-1716
Plug, End
1
10
HC-1697-20
Wiper, Ring
1
11
HC-2023-224
Ring, Backup
1
12
HC-2000-224
O-ring, Series 2
1
13
HC-1697-24
Wiper, Ring
1
14
HC-2023-228
Ring, Backup
1
15
HC-2000-228
O-ring, Series 2
1
16
HC-1697-28
Wiper, Ring
1
17
HC-2023-232
Ring, Backup
1
18
HC-2000-232
O-ring, Series 2
1
19
R-2185
Extension, Mechanical
1
20
HC-2008-032
O-ring, Series 2
1
21
HC-2008-240
O-ring, Series 2
1
22
HC-1697-26
Wiper, Urethane Rod
1
23
HC-1670-134
Seal, Polypak (Mineral Base)
1
24
HC-1730-32
Wiper, Urethane Rod
1
25
HC-1670-164
Seal, Polypak (Mineral Base)
1
K-2606
Kit, Cylinder Seal Replacement; consists of:
1
HC-2008-236
O-ring, Series 2
1
5
HC-2000-218
O-ring, Series 2
1
10
HC-1697-20
Wiper, Ring
1
11
HC-2023-224
Ring, Backup
1
12
HC-2000-224
O-ring, Series 2
1
13
HC-1697-24
Wiper, Ring
1
14
HC-2023-228
Ring, Backup
1
15
HC-2000-228
O-ring, Series 2
1
16
HC-1697-28
Wiper, Ring
1
17
HC-2023-232
Ring, Backup
1
18
HC-2000-232
O-ring, Series 2
1
K-2665
Kit, Cylinder Seal Replacement; consists of:
20
HC-2008-032
O-ring, Series 2
1
21
HC-2008-240
O-ring, Series 2
1
22
HC-1697-26
Wiper, Urethane Rod
1
23
HC-1670-134
Seal, Polypak (Mineral Base)
1
24
HC-1697-32
Wiper, Urethane Rod
1
25
HC-1670-164
Seal, Polypak (Mineral Base)
1

Model: 02-7854C0110
12 & 25 Ton (10.87 & 22.68 Metric Ton) Axle Jack
03/2008 | Rev. 02 Page | 7
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Item
Part Number
Description
Qty
26
G-1151-109716
Screw, Socket Head Cap, ½-20 x 1 ¾" long
4
27
J-2351
Ring, Retaining
1
28
G-1151-110716
Screw, Socket Head Cap, 5/8-18 x 1 ¾" long
4
29
J-2485
Ring, Cylinder Retaining
1
30
Reference K-3769 Axle Jack Base Kit
31
H-2008-109
O-ring, Series 2
1
32
N-2066-02-S-B
Plug, Hex Head with O-ring
1
33
Z-5543
Assembly, Cylinder
1
34
Reference K-3770 Cylinder Assembly Kit
35
G-1151-107220
Screw, Socket Head Cap, 3/8-16 x 2" long
2
36
Z-5156-01
Weldment, Manifold
2
37
HC-1969
Fuse, Velocity 2.6 gpm
1
38
HC-2000-012
O-ring, Series 2
2
39
N-2214-03-S-B
Adapter, #6 O-ring x ¼ NPT
1
40
N-2713
Coupler, Hydraulic (Male)
1
41
Reference K-3771 Hand Pump Kit
42
N-2009-10-S
Connector, Male #6 JIC - Fem 3/8 NPT
1
43
TF-1104-01*31.0
Assembly, Hose (#4 Mineral Base)
1
44
N-2009-08-S
Connector, Male
1
45
N-2712
Coupler, Hydraulic (Female)
1

Model: 02-7854C0110
12 & 25 Ton (10.87 & 22.68 Metric Ton) Axle Jack
03/2008 | Rev. 02 Page | 8
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Item
Part Number
Description
Qty
K-3769
Kit, Replacement Axle Jack Base; consists of:
30
J-3261-01
Plate, Jack Base (with Labels)
1
31
HC-2008-109
O-ring, Series 2
2
32
N-2066-02-S-B
Plug, Hex Head with O-ring
2
35
G-1151-107220
Screw, Socket Head Cap, 3/8-16 x 2" long
4
36
Z-5156-01
Weldment, Manifold
2
37
HC-1969
Fuse, Velocity 2.6 gpm
2
38
HC-2000-012
O-ring, Series 2
4
39
N-2214-03-S-B
Adapter, #6 O-ring x ¼ NPT
2
K-3770
Kit, Replacement Cylinder; consists of:
34
Z-5157
Assembly, Cylinder (with Label)
1
K-3771
Kit, Replacement Hand Pump; consists of:
41
H-1595-13
Hand Pump with Label
1

APPENDIX I
Enerpac
Instructions & Repair Parts