Tronair 02-7856-0100 Installation and operating instructions

Operation & Service Manual
Models:
02-7856-0100 02A7856-0100
02B7856-0100 02C7856-0100
5 Ton (4.5 Metric Ton)
Single Stage Jack
11/2004 - AA - Rev. 04
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]

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
TABLE OF CONTENTS PAGE
1.0 Product Information.......................................................................................................................................... 1
1.1 Usage..................................................................................................................................................... 1
1.2 List Of Drawings..................................................................................................................................... 1
2.0 Safety Information............................................................................................................................................ 1
2.1 Alarm And Warning Systems................................................................................................................. 1
2.2 Warning And Danger Signs ................................................................................................................... 1
2.3 Component Safety Features.................................................................................................................. 1
2.4 Functional Safety Features.................................................................................................................... 1
2.5 Features For Operator Safety................................................................................................................ 1
2.6 Environmental Safety Features.............................................................................................................. 1
2.7 Protection Systems................................................................................................................................ 2
2.8 Closed Circuits....................................................................................................................................... 2
2.9 Interlocking............................................................................................................................................. 2
2.10 Necessary Personal Protective Equipment............................................................................................ 2
2.11 Safety Guidelines................................................................................................................................... 2
2.12 Conditions For Safe Use........................................................................................................................ 2
2.13 Operator Qualifications .......................................................................................................................... 2
2.14 Additional Safety Measures ................................................................................................................... 2
3.0 Packaging And Storage................................................................................................................................... 3
3.1 Packaging Requirements....................................................................................................................... 3
3.2 Handling................................................................................................................................................. 3
3.3 Strapping................................................................................................................................................ 3
3.4 Packaging Protection............................................................................................................................. 3
3.5 Labeling Of Packaging........................................................................................................................... 3
3.6 Storage Compatibility............................................................................................................................. 3
3.7 Storage Environment ............................................................................................................................. 3
3.8 Storage Space And Handling Facilities.................................................................................................. 3
4.0 Transportation.................................................................................................................................................. 3
5.0 Assembly ......................................................................................................................................................... 4
5.1 General Instructions............................................................................................................................... 4
5.2 Pre-Use Checks..................................................................................................................................... 4
5.3 Personnel Requirements........................................................................................................................ 4
5.4 Inspection And Test Procedures............................................................................................................ 4
6.0 Installation........................................................................................................................................................ 4
7.0 Operation......................................................................................................................................................... 5
7.1 Operating Parameters............................................................................................................................ 5
7.2 Numerical Values................................................................................................................................... 5
7.3 Operator Controls................................................................................................................................... 5
7.4 Operating Instructions............................................................................................................................ 5
7.4.1 Rules For Operating: ................................................................................................................. 6
7.4.2 Jack Instructions........................................................................................................................ 6
8.0 Training............................................................................................................................................................ 8
9.0 Maintenance .................................................................................................................................................... 8
9.1 General .................................................................................................................................................. 8
9.2 Maintenance Schedule........................................................................................................................... 9
9.2.1 Storage/Low Usage:.................................................................................................................. 9
9.3 Servicing Jack........................................................................................................................................ 9
9.4 Removing And Servicing Pump............................................................................................................. 9
9.5 Jack Function Load Test........................................................................................................................ 9
9.6 Pneumatic Pump.................................................................................................................................. 10
10.0 Trouble Shooting............................................................................................................................................ 10
11.0 Provision Of Spares....................................................................................................................................... 10
12.0 Parts List........................................................................................................................................................ 11

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
13.0 In-Service Support......................................................................................................................................... 11
14.0 Guarantees.................................................................................................................................................... 11
15.0 Appendices.................................................................................................................................................... 11

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
REVISION DATE TEXT AFFECTED
03 04/2004 pg 17 Item 4 changes from H-2210-11 to H-1128-02
04 11/2004 pg 6 7.4.2 added warning and illustrations

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters)
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
- 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 PRODUCT INFORMATION
Name of Equipment: 5 TON SINGLE STAGE JACK
Model Numbers: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters
02C7856-0100 (with Spring Loaded Casters)
See Nameplate for Serial Number.
Manufactured By: TRONAIR, Inc, 1740 Eber Rd., Holland, OH 43528-9794 USA
1.1 USAGE
The device is intended to lift an aircraft by its fuselage and/or main wing with other hydraulic jacks
arranged by position and quantity to provide proper balance, and in conjunction with the correct jack
pad, whose maximum load on any one jack does not exceed the rated capacity of the jack.
The jacks are not intended for metal forming, metal working, or any purpose other than that stated
above.
1.2 LIST OF DRAWINGS
Reference Parts List and Illustrations, Pages 12 to 17.
2.0 SAFETY INFORMATION
2.1 ALARM and WARNING SYSTEMS
None.
2.2 WARNING and DANGER SIGNS
See labels on unit. WARNING!
The ram locknuts are user operated safety devices. Failure to utilize these locknuts may result
in personal injury or death.
2.3 COMPONENT SAFETY FEATURES
Ram Locknut prevents lowering of the ram. The Ram Locknut must be lowered as the aircraft is
being lifted.
2.4 FUNCTIONAL SAFETY FEATURES
Pressure Relief Valve prevents overload during raising operations.
2.5 FEATURES FOR OPERATOR SAFETY
• Cautions and Instruction Labels located on jack
• Ram Locknut
2.6 ENVIRONMENTAL SAFETY FEATURES
The jack is non-polluting. See Appendix for Material Safety Data concerning the recommended
hydraulic fluid (MIL-H-5606).
2.0 Safety Information continued on following page.

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters)
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
- 2 -
2.0 SAFETY INFORMATION (continued)
2.7 PROTECTION SYSTEMS
None.
2.8 CLOSED CIRCUITS
None.
2.9 INTERLOCKING
None.
2.10 NECESSARY PERSONAL PROTECTIVE EQUIPMENT
CAUTION!
Always wear safety glasses.
2.11 SAFETY GUIDELINES
CAUTION!
Do not place hands on top of jack near ram locknuts while lowering jack. Pinch points exist
between top of jack and threads on ram.
1. NEVER put hands between the aircraft and the 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.
WARNING!
The ram locknuts are user operated safety devices. Failure to utilize these locknuts may result
in personal injury or death.
2.12 CONDITIONS FOR SAFE USE
• Use in a clean dry environment on a level surface.
• Operate between -20°C and 50°C (-4°F and 122°F).
2.13 OPERATOR QUALIFICATIONS
This jack is intended to be used by the skilled and trained aircraft technician. The operator must be
familiar with the jacking procedures for the aircraft to be raised, and the operation of the jack.
Installation/Maintenance/Dismantling Qualifications: This jack is to be installed, maintained, and
dismantled by qualified technicians familiar with hydraulic systems.
2.14 ADDITIONAL SAFETY MEASURES
This jack must be used in accordance with this technical manual, and in accordance with the aircraft
manufacturer’s jacking procedures.

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters)
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
- 3 -
3.0 PACKAGING AND STORAGE
3.1 PACKAGING REQUIREMENTS
Jacks are to be packaged as required to prevent damage to legs or hydraulic equipment during
shipment.
3.2 HANDLING
Jacks can be rolled by hand on its casters.
3.3 STRAPPING
Jacks can be strapped down by suitable means to prevent unwanted movement during shipment.
3.4 PACKAGING PROTECTION
No special packaging material for cushioning or suspension is required.
3.5 LABELING OF PACKAGING
Packaging should be labeled DO NOT DROP.
3.6 STORAGE COMPATIBILITY
No special considerations.
3.7 STORAGE ENVIRONMENT
• Store jacks between -20°C and +50°C/-4°F and 122°F.
• Always store jack with ram all the way down.
• Suitable for outdoor storage by using a full coverage waterproof tarp or canvas.
3.8 STORAGE SPACE AND HANDLING FACILITIES
• Minimum Closed Height: 30 in (76.2 cm)
• Mechanical Extension: 12 in (30.48 cm)
• Hydraulic Extension: 22 in (55.88 cm)
• Maximum Height Obtainable: 64 in (162.56 cm)
• Weight: 105 lbs (47.63 kg)
4.0 TRANSPORTATION
Lifting can be accomplished by crane and strap thru top of tripod, or by fork truck under lower tripod support.
Approximate weight is 105 lbs (47.63 kg).

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters)
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
- 4 -
5.0 ASSEMBLY
This product is shipped completely assembled and tested and requires no further assembly before
operation. The following sections apply when servicing the unit.
5.1 GENERAL INSTRUCTIONS
1. 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.
2. All replacement parts must be the same as or better than the original parts supplied.
3. Dispose of waste per federal and local laws and regulations.
4. No modifications are allowed that will adversely affect the jacks safety performance.
5. The pressure relief valve is not serviceable. It must be replaced as a unit.
5.2 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.
• Replenish with MIL-H-5606 fluid as required.
• Fluid Level: 1.5 inches (3.8 cm) below vent.
NOTE: Refer to fluid manufacturer’s (Appendix) Material Safety Data Sheet, and advisory for
handling and disposal of fluid.
5.3 PERSONNEL REQUIREMENTS
This jack is to be assembled by qualified technicians familiar with hydraulic systems.
5.4 INSPECTION AND TEST PROCEDURES
1. Ensure fluid level is within 1.5 inches (3.8 cm) from reservoir vent cap.
2. Raise ram to full stroke, and check for leaks.
6.0 INSTALLATION
Installation and commissioning requires connection of the air valve to an adequate air supply (Air Pump
equipped Models only).
6.1 AIR SUPPLY REQUIREMENTS
• 25 psi (1.72 bar) Minimum
• 40 psi (2.75 bar) Recommended
• 125 psi (8.60 bar) Maximum

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters)
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
- 5 -
7.0 OPERATION
7.1 OPERATING PARAMETERS
1. The user shall work in accordance with the Operator Manual.
2. At no time shall personnel work under the raised load until it is secured by suitable means,
i.e. ram locknut.
3. The employer of the operator shall provide for all necessary training and give information
about pumping and translating forces.
4. Operate between -20°C and 50°C (-4°F and 122°F).
7.2 NUMERICAL VALUES
• Rated Capacity: 10,000 lbs (4,536 kg)
• Minimum Closed Height: 30 in (76.2 cm)
• Mechanical Extension: 12 in (30.48 cm)
• Hydraulic Extension: 22 in (55.88 cm)
• Maximum Height Obtainable: 64 in (162.56 cm)
• Weight: 105 lbs (47.63 kg)
• Pressure Relief Setting: 1,950 + 195/-0 psig (1.34+13/-0 bar)
• Noise level is 64 dB(A) at a distance of 120 inches (304.8 cm) at an inlet pressure of 100 psi
(6.9 bars).
7.3 OPERATOR CONTROLS
(See Figure 7.3)
7.4 OPERATING INSTRUCTIONS
The user should be familiar with the
following statements prior to using the
jack(s):
CAUTION!
1. NEVER put hands between the
aircraft and the 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.
7.4 Operating instructions continued on following page.
FIGURE 7.3
−
Operator Controls

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters)
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
- 6 -
7.4 OPERATING INSTRUCTIONS (continued)
7.4.1 Rules For Operating:
1. The user shall work in accordance with the Operator and/or Technical
Manuals.
2. At no time shall personnel work under the raised load until it is secured by
suitable means, i.e. ram locknut.
3. The employer of the operator shall provide for all necessary training and
give information about pumping and translating forces.
4. Operate between -20°C and 50°C/-4°F and 122°F.
7.4.2 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.
WARNING!
The locking pin MUST be placed in the ram protection ring groove and fully through the
mechanical extension.
The locking pin washer and ball lock MUST be placed outside the ram protection ring.
• Do not place extra locking pins in
any other hole on the mechanical
extension.
• Insure mating surfaces to jack point
are free of debris and damage.
• Under no conditions should the
locking pin washer or washer groove
be inside the ram protection ring
groove.
• Under no conditions should the
locking pin’s ball lock be inside the
ram protection ring groove.
• Never use the jack if the ram
protection ring is not installed.
• Never use the locking pin without a
locking pin washer.
• Never use a locking pin that has
been damaged.
• Never use a ram protection ring that has been damaged or deformed.
• Failure to comply could result in premature failure below certified weight and could cause
serious injury including death.
JACKING POINT
SURFACE
MECHANICAL EXTENSION
LOCKING PIN WASHER
AND WASHER GROOVE
LOCKING PIN
BALL LOCK
RAM PROTECTION
RING GROOVE
RAM PROTECTION RING

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters)
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
- 7 -
7.4.2 Jack Instructions (continued)
3. Close pump release valve by turning clockwise.
NOTE: Turning the pump release valve counter-clockwise lowers the jack. Turning the pump
release valve clockwise stops the jacks descent, and allows it to be raised.
4. Operate the pump using the handle, or by opening the air valve (if
equipped with an air pump).
5. Lower ram locknuts as aircraft is raised.
7.4.2 Jack instructions continued on following page.
LOCKING PIN WASHER
AND WASHER GROOVE
LOCKING PIN
RAM PROTECTION RING
INCORRECT PIN
PLACEMENT
MECHANICAL EXTENSION
BALL LOCK
LOCKING PIN WASHER
AND WASHER GROOVE
LOCKING PIN
RAM PROTECTION RING
INCORRECT PIN
PLACEMENT
MECHANICAL EXTENSION
BALL LOCK
LOCKING PIN WASHER
AND WASHER GROOVE
LOCKING PIN
RAM PROTECTION RING
CORRECT PIN
PLACEMENT
MECHANICAL EXTENSION
BALL LOCK
AREAS TO BE FREE
OF INDENTATIONS
RAM PROTECTION RING

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters)
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
- 8 -
7.4.2 Jack Instructions (continued)
WARNING!
• The ram locknuts are user operated safety devices. Failure to utilize these locknuts may
result in personal injury or death.
• Do not place hands on top of jack near ram locknuts while lowering jack. Pinch points
exist between top of jack and threads on ram.
• Always wear safety glasses.
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 jack during washing operations, completely cover top of jack near ram
seal.
8.0 TRAINING
Training of operating personnel is the responsibility of the employer. This jack must be used in accordance
with aircraft manufacturer’s instructions.
9.0 MAINTENANCE
9.1 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 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 2.629 inches
(66.78 mm) 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.
• When refilling the hydraulic system the characteristics of the hydraulic fluid used in the jack and
the level of the hydraulic fluid as it is noted on the jack shall be observed.
• Jacks shall be maintained and repaired in accordance with the manufacturers instructions. Such
maintenance and repair shall be carried out by qualified persons.
• No modifications shall be carried out which adversely affect the compliance of the jack with draft
standard prEN 1494:1994.

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters)
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
- 9 -
9.0 MAINTENANCE (continued)
9.2 MAINTENANCE SCHEDULE
Check Fluid Level.........................................................................................................Each Use
Lubricate Casters..........................................................................................................3 Months
Cleaning.................................................................................................Annually Or As Needed
NOTE: Wipe with soft cloth only, do no pressure wash or spray water directly at ram seal.
9.2.1 Storage/Low Usage:
If jack is unused for 90 days, raise ram to full hydraulic extension, spray ram with
DoALL RPM, LPS or equivalent water repellant, BUNA N compatible lubricant.
9.3 SERVICING JACK
To Disassemble Jack:
1. Remove mounting plate (Item 37) by unscrewing three socket head cap screws (Item 36).
2. Raise ram assembly (Item 39) to the point where it can be lifted from the jack cylinder.
To Re-assemble Jack:
1. Re-assemble in reverse order of above.
NOTES:
⎯ Dispose of hydraulic fluid per local and federal regulations.
⎯ To minimize air entrapment under the ram, raise the oil level in the cylinder to chamfer of
the cylinder prior to ram insertion.
⎯ Torque socket head cap screws (Item 36) to 25 ft-lbs (34 Nm)
9.4 REMOVING AND SERVICING PUMP
NOTE: If pump is found faulty, call the factory for replacement or replace seals as follows:
1. Review Appendix III HC-1753 Hand Pump Parts List.
2. Clamp suction (push on) hose and remove hose from pump.
3. Uncouple fitting of hydraulic hoses from pump.
4. Remove pump from jack.
5. Remove cotter pin from clevis pin.
6. Remove four (4) socket head cap screws.
7. Remove flanges.
8. Remove tube assembly.
9. Replace O-rings and backup ring. (See Appendix III for kits available.)
10. Re-assemble in reverse order.
9.5 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%.
9.0 Maintenance continued on following page.

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters)
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
- 10 -
9.0 MAINTENANCE (continued)
9.6 PNEUMATIC PUMP
See Appendix II Haskel Air Pump Manufacturer Data for complete parts list and repair information.
10.0 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 (Reference Parts List
− K-1049 Kit)
Leaky release valve Tighten release valve (See Appendix III)
Leaky pump O-ring packing Repair pump (See Appendix III)
Lack of oil Refill reservoir with oil (MIL-H-5606).
Check system for leaks.
Sticking inlet check valve Open release valve. Pump rapidly to dislodge.
Or repair pump.
Air in hydraulic system Bleed system. With rams fully retracted, open release
valve. Pump rapidly and close release valve.
Jack will not lower
PROBABLE CAUSE CORRECTIVE ACTION
Ram lock nut not loosened Rotate nut as ram is lowered
Broken pump release valve Repair pump (See Appendix III)
Bent ram Replace suspected ram assembly
O-ring (Pinched or rolled) Replace packing (See Parts List
− K-1049 Kit)
Check cylinder and rams for rust and pitting on inside
diameter walls. (See Section 9.0 Maintenance/General)
11.0 PROVISION OF SPARES
Recommended Spares to be kept on hand:
K-1049 Kit, Ram Seal Replacement
HK-1685 Kit, Repair Fluid Seal (Air Option only)
HK-1686 Kit, Repair Air Seal (Air Option only)
K-1000 Kit, Pump Seal Replacement
Spare parts may be obtained from the manufacturer:
TRONAIR, INC. Telephone: [phone] or 800-426-6301
1740 Eber Road Fax: [phone]

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters)
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
- 11 -
12.0 PARTS LIST
Reference Pages 12 to 17 for Parts Lists and Illustrations.
When ordering Replacement Parts/Kits, please specify Model & Serial Number of your product.
13.0 IN-SERVICE SUPPORT
Contact Tronair for technical services and information.
14.0 GUARANTEES
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 warranty does not cover the following items:
a) Parts required for normal maintenance
b) Parts covered by a component manufacturers warranty
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, since 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 Number
(RMA) will be issued for reference purposes on any shipping documents. 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.
15.0 APPENDICES
APPENDIX I Hydraulic Schematic
APPENDIX II Haskel Air Pump Manufacturer Data
APPENDIX III HC-1753 Hand Pump Parts List
APPENDIX IV Material Safety Data Sheet – MIL-H-5606 Hydraulic Fluid

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters)
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
- 12 -
Parts List
When ordering Replacement Parts/Kits, please specify Model & Serial Number of your product.
ITEM PART NUMBER DESCRIPTION QTY
6...................H-1009-01 ........................................ Assembly, Pump Handle.................................................1
9...................G-1203-1095.................................... Jamnut, ½-20, Elastic......................................................2
10...................U-1002 ............................................. Wheel ..............................................................................2
11...................G-1100-109526................................ Bolt, Hex Head, ½-20 x 2 ¾" long...................................2
12...................HJ-532-02 ........................................ Pad, Jack.........................................................................1
K-3347 Kit, Jack Weldment Replacement; consists of:
1...................Z-4965-01......................................... Weldment, Jack...............................................................1
2...................V-1001.............................................. Label, Made in USA ........................................................1
3...................V-1003.............................................. Label, Serial Number.......................................................1
4...................V-1805.............................................. Label, ISO General Danger.............................................1
5...................V-1198-02 ........................................ Label, Tronair ..................................................................1
7...................V-1775.............................................. Label, Pump Force..........................................................1
8...................V-1776.............................................. Label, Down.....................................................................1

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters)
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
- 13 -
Parts List
When ordering Replacement Parts/Kits, please specify Model & Serial Number of your product.
ITEM PART NUMBER DESCRIPTION QTY
13...................TF-1043-03*15.0.............................. Assembly, Hose, 15" long...............................................1
17...................N-2004-06-S..................................... Elbow,
3/8JIC x ¼ NPT....................................................1
K-1901-01 Kit, Pump Replacement; consists of:
14...................N-2001-08-S-B................................. Elbow, Straight Thread, SAE #6 x 3/8-37°JIC................1
15...................HC-1753........................................... Pump, Hydraulic Hand ....................................................1
16...................N-2410-11........................................ Elbow, 90°.......................................................................1
18...................G-1251-1070R ................................. Lockwasher,
3/8Regular..................................................2
19...................G-1100-107010................................ Bolt, Hex Head, Grade 5, 3/8-16 x 1" long ......................2
21...................TF-1047-01*09.0.............................. Hose, ¼ Gray x 9" long ...................................................1

5 Ton (4.5 Metric Ton) Single Stage Jack
Models: 02-7856-0100 (Standard)
02A7856-0100 (with Air Pump Option)
02B7856-0100 (with Air Pump Option & Spring Loaded Casters)
02C7856-0100 (with Spring Loaded Casters)
11/2004 - AA - Rev. 04
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Parts List
When ordering Replacement Parts/Kits, please specify Model & Serial Number of your product.
ITEM PART NUMBER DESCRIPTION QTY
K-1061-04 Kit, Reservoir Replacement; consists of:
20...................N-2410-01........................................ Elbow, 90°Male ..............................................................1
21...................TF-1047-01*09.0.............................. Hose, ¼ Gray x 9” long ...................................................1
22...................H-1045 ............................................. Breather...........................................................................1
23...................Z-1539-04-01 ................................... Weldment, Reservoir.......................................................1
24...................V-1102-01 ........................................ Label, Use MIL-H-5606...................................................1
25...................V-1016.............................................. Label, Capacity 10,000 lbs..............................................1
26...................V-1819.............................................. Label, Hydraulic Jack Caution.........................................1
27...................V-1820.............................................. Label, Hydraulic Jack Instruction ....................................1
28...................G-1250-1050N ................................. Flatwasher, ¼ Narrow.....................................................3
29...................G-1202-1050.................................... Stopnut, ¼-20 Elastic......................................................3