Tronair 02-7802C0111, Operation & Service Manual

Page 1: ...onair Inc Phone 419 866 6301 800 426 6301 1 Air Cargo Pkwy East Web www tronair com Swanton OH 43558 Email sales tronair com Models 02 7802C0111 02A7802C0111 with Air Pump 12 Ton 10 88 Metric Ton Single Stage Jack 04 2008 Rev 01 ...

Page 2: ...REVISION DATE TEXT AFFECTED 01 04 2008 Original Release ...

Page 3: ... 3 2 HANDLING 2 3 3 STRAPPING 2 3 4 PACKAGING PROTECTION 2 3 5 LABELING OF PACKAGING 2 3 6 STORAGE COMPATIBILITY 2 3 7 STORAGE ENVIRONMENT 2 3 8 STORAGE SPACE AND HANDLING FACILITIES 3 4 0 TRANSPORTATION 3 5 0 ASSEMBLY 3 5 1 GENERAL INSTRUCTIONS 3 5 2 JACK ASSEMBLY 3 5 3 PRE USE CHECKS 3 5 4 PERSONNEL REQUIREMENTS 3 5 5 INSPECTION AND TEST PROCEDURES 3 6 0 INSTALLATION 4 6 1 AIR SUPPLY REQUIREMENT...

Page 4: ...ks 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 2 0 SAFETY INFORMATION 2 1 ALARM and WARNING SYSTEMS None 2 2 WARNING and DANGER SIGNS See labels on unit W...

Page 5: ...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 ...

Page 6: ...nce Figures 1 and 2 during the following 1 Loosely fasten brace machinings to each leg weldment using 7 16 20 x 2 in long hex head bolts 7 16 flatwashers and 7 16 20 elastic stopnuts 2 Raise each tripod leg so that casters can be fastened to leg Use 3 8 24 x 1 in long hex head bolts 3 8 flatwashers and 3 8 24 elastic stopnuts to secure casters to legs 3 Raise jack onto tripod and fasten with 7 16 ...

Page 7: ...4 5 0 ASSEMBLY continued 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 15 scfm 0 14 0 42 s cu m min FIGURE 2 ...

Page 8: ...btainable 154 in 391 79 cm Weight 500 lbs 226 8 8kg Pressure Relief Setting 3250 300 0 psig 224 21 0 bar Noise level is 64 dB A at a distance of 120 in 304 8 cm at an inlet pressure of 100 psi 6 9 bar 7 3 OPERATOR CONTROLS See Illustration 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 an...

Page 9: ... 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 ...

Page 10: ... Placements Results Of Locking Pin In Incorrect Location Ram Protection Ring Washer In Ram Protection Ring Ball Lock In Ram Protection Ring Washer On Top Of Ram Protection Ring Locking Pin Not In Ram Protection Ring and top Locking Pin in Mechanical Extension use only one pin Unacceptable Condition Acceptable Condition Damage and Deformation No Deformation ...

Page 11: ...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 m...

Page 12: ... SERVICING PUMP NOTE If pump is found faulty call the factory for replacement or replace seals as follows 2 Review Appendix III HC 1961 Hand Pump Parts List 3 Clamp suction push on hose and remove hose from pump 4 Uncouple fitting of hydraulic hoses from pump 5 Remove pump from jack 6 Remove cotter pin from clevis pin 7 Remove four 4 socket head cap screws 8 Remove flanges 9 Remove tube assembly 1...

Page 13: ...ot 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 1050 Kit Check cylinder and rams for rust and pitting on inside diameter walls See Section 9 0 Maintenance General 11 0 PROVISION OF SPARES Recommende...

Page 14: ...ailure 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 u...

Page 15: ...r Description Qty 1 HJ 557 Pad Jack 1 2 G 1300 25200 Pin Roll 1 4 diameter x 2 long 1 3 G 1318 1033 Pin 5 8 diameter x 3 3 long model D 1 4 HJ 225 04 Extension Mechanical 1 5 H 553 Ring Ram Protection 1 6 H 2331 Nut Ram 1 7 G 1151 107206 Screw Cap 3 8 16 X long 4 8 TR 1756 Plate Mounting 1 10 HJ 586 04 Assembly Ram 1 K 1050 Kit Seal Replacement consists of 9 HJ 554 Ring Guide 1 12 HC 2020 336 Ring...

Page 16: ...13 Parts List When ordering replacement parts kits please specify model serial number and color of your unit Item Part Number Description Qty 14 Z 5108 Weldment Jack 1 15 V 1001 Label Made in USA 1 16 V 1003 Label Serial Number 1 17 V 1776 Label Down 1 18 V 1775 Label Pump Force 1 19 V 1198 02 Label Tronair 1 ...

Page 17: ...unit Item Part Number Description Qty 20 TF 1043 06 18 0 Assembly Hose 1 K 1901 02 Kit Pump Replacement consists of 21 N 2001 08 S B Elbow Straight Thread 1 22 HC 1751 Pump Hydraulic Hand 1 23 N 2410 11 Elbow 90 Male 1 24 G 1251 1070R Lockwasher 3 8 Regular 2 25 G 110 107010 Bolt Hex Head Grade 5 3 8 16 x 1 long 2 N S TF 1047 01 12 0 Hose Push on 1 Reference HC 1751 Hand Pump Appendix for componen...

Page 18: ... Breather 1 29 HJ 580 07 01 Weldment Reservoir 1 30 G 1100 105006 Bolt Hex Head Grade 5 20 x 3 4 long 1 31 V 1017 Label Capacity 24 000 lbs 1 32 V 1102 01 Label Use MIL PRF 5606 1 33 V 1805 Label ISO General Danger 1 34 V 1819 Label Hydraulic Jack Caution 1 35 V 1820 Label Hydraulic Jack Instruction 1 36 TF 1047 01 24 0 Hose Push on 1 37 N 2208 01 S Tee Male Branch 1 38 N 2205 02 S Plug Hollow Hex...

Page 19: ...mp 12 Ton 10 88 Metric Ton Single Stage Jack 04 2008 Rev 01 Page 16 Parts List When ordering replacement parts kits please specify model serial number and color of your unit Item Part Number Description Qty 43 N 2004 15 S Elbow Extra Long Male 1 ...

Page 20: ...ndix II 53 HK 1686 Haskel Air Seal Repair Kit Ref Appendix II 54 50866 Haskel Seal Lubricant Ref Appendix II 56 K 3333 Assembly Blowgun 1 Z 5899 Kit Air Pump Replacement consists of 45 G 1202 1055 Stopnut 28 Elastic 4 46 G 1250 1050N Flatwasher Narrow 8 47 J 3415 01 Bracket Air Pump Mounting 1 49 N 2410 11 Elbow 90 Male 1 50 G 1100 105510 Bolt Hex Head Grade 5 28 x 1 long 4 51 H 1174 Pump Air 1 55...

Page 21: ...250 1080N Flatwasher 7 16 Narrow 90 62 G 1202 1085 Stopnut 7 16 20 Elastic 45 63 Z 1061 01 01 Weldment Tripod Leg 2 64 TS 1028 03 01 Machining Brace 3 65 TS 1028 02 01 Machining Brace 3 66 TS 1028 01 01 Machining Brace 3 67 G 1100 107514 Bolt Hex Head Grade 5 3 8 24 x 1 long 12 68 G 1250 1070N Flatwasher 3 8 Narrow 24 69 G 1202 1075 Stopnut 3 8 24 Elastic 12 70 U 1020 Caster Isolator 3 71 G 1100 1...

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Page 23: ...APPENDIX I Hydraulic Schematic ...

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Page 25: ...Hydraulic Schematic ...

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Page 27: ...APPENDIX II Air Pump Manufacturer Data ...

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Page 55: ...APPENDIX III HC 1961 Hand Pump Parts List ...

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Page 57: ...ronair Inc Phone 419 866 6301 800 426 6301 1 Air Cargo Pkwy East Web www tronair com Swanton OH 43558 Email sales tronair com Model HC 1961 3250 psi Hand Pump Parts List With Illustrations 05 2005 Rev OR ...

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Page 59: ...y model serial number and color of your unit Reference Illustrations on following page Item Part Number Description Qty 4 518 000 Screw Socket Head Cap 4 9 Not Sold Separately Pump Body 1 10 H 2606 Assembly Relief Screw 1 24 506 000 Flange Half 4 Not Shown H 1009 01 Handle 1 K 1068 Kit Linkage Replacement consists of 17 Bracket Pump Handle 1 18 Assembly Clevis Pin 1 19 Assembly Linkage Pin 2 20 St...

Page 60: ...eplacement consists of 2 Wiper Rod 1 3 Ring Backup 1 5 O ring Piston 1 6 O ring Valve Body 1 8 O ring Tube Seal 1 11 O ring Relief Screw 1 16 O ring Release Screw 1 27 O ring Outlet Check 1 34 Ring Backup Relief Screw 1 35 O ring Relief Screw 1 Parts List Illustrations WARNING Item 10 H 2606 is a preset relief valve Do Not disassemble this valve Replacement parts are available as a preset relief v...

Page 61: ...APPENDIX IV Safety Data Sheet MIL PRF 5606 Hydraulic Fluid ...

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Page 75: ...APPENDIX V Declaration of Conformity ...

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Page 77: ... design development and manufacture is in accordance with European Community guidelines Tripod Jack 02 7802C0111 02A7802C0111 Relevant provisions complied with by the machinery 2006 42 EC Relevant standards complied with by the machinery EN ISO 12100 1 Identification of person empowered to sign on behalf of the Manufacturer Quality Assurance Representative ...

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Page 79: ...APPENDIX VI Maintenance Schedule ...

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