OPERATION and SERVICE INSTRUCTIONS with ILLUSTRATED … · supply Operating, Servicing, and...

OPERATION and SERVICE

INSTRUCTIONS with

ILLUSTRATED PARTS BREAKDOWN

50 TON HYDRAULIC AIRCRAFTAXLE JACK - AIR ASSIST

MODEL NO. 5007-50 (55)

PART NO. 167D1100

COLUMBUS JACK CORPORATION2222 S. THIRD ST., COLUMBUS, OH 43207TOLL FREE: 1-877-264-5225(614)443-7492 FAX (614)445-3981 Revised August 2003

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COLUMBUS JACK CORPORATIONGROUND EQUIPMENT TECHNICAL DATA

PART NO. 167D1100

1

INTRODUCTION

1. Purpose

A. This manual is intended tosupply Operating, Servicing, and MaintenanceInstructions and an Illustrated Parts List for the50 Ton Axle Jack Assembly, Part Number167D1100.

B. This manual is organized intothree (3) chapters, each beginning with a table ofcontents, as follows:

Chapter 1 - General Information andOperating Instructions.

Chapter 2 - Maintenance Instructions.

Chapter 3 - Illustrated Parts List.

2. Precautions

A. Only properly trained personnelshould transport and operate this jack.

B. Warnings are provided to elimatepersonal injury or death to personnel operatingthe jack or other maintenance personnel in theoperating area.

C. Cautions are provided to protect

the jack, or other equipment being supported,from damage.

D. Notes are provided to clarifymaintenance procedures and save time.

3. Comments

Comments and suggestions for improvements orcorrections should be sent, in writing, to:Columbus Jack Corporation, 2222 South ThirdStreet, Columbus, Ohio 43207.

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PART NO. 167D1100

2

Chapter 1Table of Contents

General Information & Operating Instructions

DescriptionPhysical Description of Major Components

General Operating InstructionsPurpose and Use of ControlsSetup and Connection of JackOperation of Jack Under Normal ConditionsOperation of Jack Under Arctic ConditionsOperation of Jack Under Desert ConditionsOperation of Jack Under Extreme Weather ConditionsNormal Shutdown of JackEmergency Shutdown of Jack

Specifications & CapabilitiesLeading Particulars

ShippingPreparation

StoragePreservationPacking and Crating

Chapter/Section

1-1

1-2

1-3

1-4

1-5

Page

33

333344444

55

55

555

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PART NO. 167D1100

3

WARNING

WARNING

WARNING

1-1 DESCRIPTION

A. The 50 Ton Axle Jack, PartNumber 167D1100, provides a means to raise theaircraft axle. The major sub components of thejack assembly are: Reservoir, Lift Assembly andHigh Pressure Hydraulic Pump Assembly andLow Pressure Hydraulic Pump Assembly.

NOTE

Item call out numbers in thefollowing steps reference Chapter3, Figures 1 thru 4.

B. Physical Description of MajorComponents

1) Frame Assembly (2,Figure 1) houses system hydraulic fluid andattached jack components.

2) Cylinder assembly (1,Figure 1) consists of first, second and third stagerams (2, 3, 4, Figure 2), an extension screw (5,Figure 2), and spring assembly (4, Figure 1).

3) To maneuver jack,spring assembly (4, Figure 1) extends along amounted cylinder assembly (1, Figure 1) enablingthe zero pressure tire rubber wheel (3, Figure 1)to extend under axle load and retract when notloaded.

4) High Pressure AuxiliaryHydraulic Pump Assembly (8, Figure 1) providessystem hydraulic high pressure, low flow rate forlifting axle weight.

5) Low Pressure AuxiliaryHydraulic Pump Assembly (7, Figure 1) providessystem hydraulic low pressure, high flow rate foradjustment of jack to axle jack prior to lifting.

1-2 GENERAL OPERATINGINSTRUCTIONS

A. Purpose and Use of OperatingControls. The following paragraphs outline thepurpose and use of the operating controls.

B. Setup and Connection of Jack

1) Maneuver jack intoposition under axle jack pad.

2) Ensure area under frame(1, Figure 1) is clear of all loose rocks andobstructions.

3) Using slotted pumphandle (6, Figure 1), ensure valve body (5, Figure3) is snug in the clockwise direction.

C. Operation of Jack Under NormalConditions

EACH JACK IS OPERATED INDEPENDENTLYAND AIRCRAFT MUST BE RAISED EVENLY TOPROVIDE STABILITY. FAILURE TO USE SAFEJACKING PRACTICES MAY RESULY INEQUIPMENT DAMAGE AND INJURY TOPERSONNEL.

PERSONNEL NOT INVOLVED IN JACKING THEAIRCRAFT MUST REMAIN CLEAR OF THEIMMEDIATE AREA. OTHER WORK SHOULDNOT BE ACCOMPLISHED UNTIL JACKING ISCOMPLETED AND AIRCRAFT IS STABILIZED.DO NOT WORK UNDER SUSPENDED LOADSUNLESS REQUIRED. FAILURE TO FOLLOWSTRICT SAFETY PRECAUTIONS MAY RESULTIN EQUIPMENT DAMAGE AND PERSONNELINJURY OR DEATH.

DO NOT WORK UNDER SUSPENDED LOADSUNLESS REQUIRED. FAILURE TO FOLLOWSTRICT SAFETY PRECAUTIONS MAY RESULTIN EQUIPMENT DAMAGE AND INJURY ORDEATH TO PERSONNEL. WHEN JACKINGOPERATIONS ARE COMPLETED AND

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PART NO. 167D1100

4

AIRCRAFT IS STABILIZED, NECESSARYPERSONNEL MAY COMPLETE REQUIREDMAINTENANCE ACTIONS UNDER AIRCRAFT.

1) Adjust extension screw(5, Figure 2) before jacking to desired height.

2) Operate low pressureauxiliary hydraulic pump assembly (7, Figure 1)to mate extension screw (5, Figure 2) with axlejack pad.

3) Operate high pressure hydraulic pump assembly (8, Figure 1) to raiseaircraft axle.

4) Ensure spring (4, Figure1) extends under axle load, raising springassembly (4, Figure 1).

5) To lower jack, useslotted pump handle (6, Figure 1) to turn valvebody (5, Figure 3) slowly counter-clockwise nomore than two full turns.

6) To fully retract cylinderassembly (1, Figure 1), ensure valve body (5,Figure 3) is open and force first, second and thirdstage rams (2, 3, 4, Figure 2) down untilretracted.

D. Operation of Jack Under ArcticConditions

1) Keep cylinder assembly(1, Figure 1) and low and high pressure hydraulicpump assemblies (7, 8, Figure 1) covered whennot in operation.

2) When operating jack intemperatures below -20 degrees F, use hydraulicfluid MIL-H-81019 or equivalent.

E. Operation of Jack Under DesertConditions

1) Keep cylinder assembly(1, Figure 1) and low and high pressure hydraulicpump assemblies (7, 8, Figure 1) covered to keepsand from entering operating components.

F. Operation of Jack UnderExtreme Weather Condiitions

1) Jack may be operatednormally in temperature ranges above -20degrees F and below 120 degrees F.

G. Normal Shutdown of Jack

1) Using pump handle (6,Figure 1), slowing turn valve body (5, Figure 3) counter-clockwise no more than two full turns.

2) Remove jack from axleand force first, second and third stage rams (2, 3,4, Figure 2) down until retracted.

H. Emergency Shutdown of Jack

1) Follow normal shutdownprocedures, steps 1 and 2.

2) Block and stabilize axle.

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PART NO. 167D1100

5

1-3 SPECIFICATIONS AND CAPABILITIES

Leading particulars and shipping dimensions for the jack are provided in Table 1-1.

Table 1-1. Leading Particulars

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.00 in X 53.00 in.Height Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25 in.Height Maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.50 in. Extension Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50 in. Hydraulic Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.75 in.Hydraulic System: Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Union UNAX AW 32 Artic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mil-H-81019* Operating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9683 psi Fluid Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -35 to 230 F* System Operating Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -35 to 120 F*

* Includes Arctic Operation

1-4 SHIPPING

A. Preparation

1) Ensure first, second andthird stage rams (2, 3, 4, Figure 2) are fullyretracted..

1-5 STORAGE

A. Preservation

1) Damage to paint (nicks,chips, etc) shall be repaired in accordance withCJC paint specification, BMS 10-11L Type 1,

Class A.

2) Damage through paint tothe primer shall be repaired in accordance withCJC requirements for primer, BMS 10-60H Type1, Class A.

B. Packing and Crating

1) Each jack will have aseparate shipping pallet.

2) Each pallet shall beequipped with lift pockets that can be carried bya forklift with 48" long forks.

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PART NO. 167D1100

6


Maintenance

Servicing

Troubleshooting

Removal & InstallationGeneral Removal InstructionsRemoval of Cylinder AssemblyInstallation of Cylinder AssemblyRemoval of Low Pressure Pump AssemblyInstallation of Low Pressure Pump AssemblyRemoval of High Pressure Pump AssemblyInstallation of High Pressure Pump Assembly

Removal of CastersInstallation of CastersRemoval of Tube Installation of TubeRemoval of Tow Handle AssemblyInstallation of Tow Handle Assembly

RepairsGeneral Disassembly InstructionsGeneral Cleaning ProceduresGeneral Inspection ProceduresGeneral Repair ProceduresGeneral Reassembly and Installation InstructionsWorkmanship and HandlingPaintingDisassembly of Cylinder AssemblyAssembly of Cylinder AssemblyDisassembly of High Pressure Pump Assembly

Model No. 566-02Assembly of High Pressure Pump Assembly

Model No. 566-02Disassembly of Low Pressure Pump Assembly

Model No. 566-06Assembly of Low Pressure Pump Assembly

Model No. 566-06

Chapter/Section

2-1

2-2

2-3

2-4

Page

7

11

1212121212121212121212131313

1313131414151515151516

16

16

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PART NO. 167D1100

7

2-1 SERVICING

A. Table 2-1 lists the periodicmaintenance inspections to be conducted andspecifies the intervals at which such inspectionsshould be performed. Intervals are nominal, basedon normal operating conditions. Intervals shouldbe adjusted accordingly for extremes oftemperature or other adverse operating conditionsexisting in the area of operation. Inspectionintervals to be observed on the jack set are

categorized as follows:

1) Daily (or before eachuse).

2) Periodic - Three monthsor 100 hours of operating time, whichever comesfirst.

3) Safety - Annual or 1000hours of operating time, whichever comes first.

Table 2-1. Preventive Maintenance List

Description Daily Periodic Safety

All Jacks WhenUsed

Three months or 100operating hours

Twelve months or1000 operatinghours

Inspect casters for cracks or deficient motion

Inspect all controls to verify proper operation

Visually inspect jack for: corrosion, exteriorcomponent damage, loose, broken or missingparts and signs of fluid leakage.

Visually check all hydraulic lines for cracks,breaks and signs of chafing or fluid leakage.

Test jack for pressure setting

Check fluid level in hydraulic reservoir.

X

X

X

X

X

X

B. Table 2-2 lists the supportequipment with associated part numbers requiredfor testing and maintaining the jack set. Theseitems are the authorized support equipmentrequired to perform the prescribed maintenanceprocedures. Use of authorized alternate parts isapproved unless the restriction "NOSUBSTITUTIONS AUTHORIZED" appears in the"PART NUMBER" column.

C. Tabel 2-3 provides a list ofconsumables for cleaning and repairing the jackset. Consumable materials are expendable items

and supplies consumed during operation of jackand performance of required preventivemaintenance. All consumables not identified inthe Illustrated Parts List (IPL) chapter are in thelist of consumables. Examples are: sealants,lubricants, cleaning solvents, paints, etc. Use ofauthorized alternate parts is approved unless therestriction "NO SUBSTITUTONS AUTHORIZED"appears in the "PART NUMBER" column. In thetext of this manual, consumables will bereferenced by their index number.

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PART NO. 167D1100

8

Table 2-2. Support Equipment List

# NOMENCLATURE PART NUMBER FSCM USE

1

2

3

Filter (440 micron)

Hydraulic or Hand Pump

Shipping Pallet

Commercially Avialable

Commercially Avialable

Commercially Available 00994

Filtering used hydraulic fluidfor subsequent use

Filling reservior to operatejacks

Shipping jack

Table 2-3. List of Consumables

INDEXNO. NOMENCLATURE PART NUMBER SPECIFICATION FSCM

12

34

56789

1011121314

15161718

Brush, Parts CleaningCloth, Lint-free

Conditioner, InkCorrosion-PreventiveCompoundFilter, HydraulicFluid, HydraulicGreaseInk, BlackInk, Red (stencil)Ink, White (stencil)Lubricant, ProtectivePaint, PrimerPaintPaper, Wrapping

Sheeting, PlasticSolvent, Dry-cleaningTape, TeflonThinner, Paint

ROL-IT-ON

9053T-10

Lubriplate PT11335GS-1GS-2GS-3WD-40

Commercially AvailableCommercially Avialable

MIL-B-43871CCC-C-46MIL-C-85043

MIL-O-6081

Arrow Inc.Union UNAX AW32

BMS 10-60HBMS 10-11LMIL-P-17667UU-P-268MIL-P-23536P-D-680, Type III

903169031690316

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PART NO. 167D1100

9

Figure 2-4. Dry Torque Limits

CAPSCREW HEAD MARKINGS

Manufacturer's marks may vary.

These are all SAE Grade 5 (3-line)

SIZETORQUE

SAE GRADENO. 2

SAE GRADE NO. 5

SAE GRADENO. 6 or 7

SAE GRADENO. 8

DIA.INCHES

THREADSPER INCH MILLIMETERS

POUNDSFEET

NEWTONMETERS

POUNDSFEET

NEWTONMETERS

POUNDSFEET

NEWTONMETERS

POUNDSFEET

NEWTONMETERS

1/41/4

5/165/163/83/8

7/16

7/161/21/2

9/169/165/85/83/43/47/87/81

11-1/81-1/81-1/41/1-41-3/81-3/81-1/21-1/2

20281824162414

2013201218111810169

148

127

127

126

126

12

5.356.357.947.949.539.53

11.11

12.70

14.29

15.88

19.05

22.23

25.40

25.58

31.75

34.93

38.10

56

1112202330

355055657590

100160180140155220

240300340420460560640740840

79

1516273141

47687588

102122136217244190210298

325407461570624759868

10031139

8101719303550

557590

110120150180260300400440580

640800880

112012401480158019402200

11142326414758

75102122149163203244353407542597786

86810851193151916811980227826312963

10122124404560

7095

100135150190210320360520580800

85011201260158017602080238027803100

14162833546181

95129136183203258285434488705786

1085

116515191709214223872820322737704204

12142525455070

80110120150170220240380420600660900

100012801440182020002380272031603560

14162833546181

95129136183203258285434488705786

1085

116815191709214223872820322737704204

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PART NO. 167D1100

10

Figure 2-5. Wet Torque Limits

CAPSCREW HEAD MARKINGS

Manufacturer's marks may vary.These are all SAE Grade 5 (3-line)

SIZETORQUE

SAE GRADENO. 2

SAE GRADE NO. 5

SAE GRADENO. 6 or 7

SAE GRADENO. 8

DIA.INCHES

THREADSPER INCH MILLIMETERS

POUNDSFEET

NEWTONMETERS

POUNDSFEET

NEWTONMETERS

POUNDSFEET

NEWTONMETERS

POUNDSFEET

NEWTONMETERS

1/41/4

5/165/163/83/8

7/167/161/21/2

9/169/165/85/83/43/47/87/8

11

1-1/81-1/81-1/41/1-41-3/81-3/81-1/21-1/2

202818241624

142013201218111810169

14

8127

127

126

126

12

6.356.357.947.949.539.53

11.11

12.70

14.29

15.88

19.05

22.23

25.40

25.58

31.75

34.93

38.10

4589

1517

2425354050557080

120140110120

160170220260320360420460560620

67

11122023

33344754687595

108163190149163

217231298353434488570624760 841

67

13142325

354055658090

110130200220300320

440480600650840920

1100126014601640

89

16193134

47547588

108122149176271298407434

597651814895

113912481492170919802224

89

16183030

45507080

100110140160240280400440

600550840940

110013201560178020802320

111222244141

516895

108136149190217325380542597

814895

11391275149217902115241428203146

91018203535

55508090

110130170180280320460500

680740950

1080136015001780204023602660

121424274747

7581

108122149176231244380434624678

922100313201464184420342414277632003607

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PART NO. 167D1100

11

2-2 TROUBLESHOOTING

A. Refer to Table 2-6 for troubleshooting of jack assembly.

Table 2-6. Troubleshooting

Trouble Probable Cause Remedy

First, second or third stage ramsfail to lift when operated, or failsto lift rated load.

Incorrect setting of relief valve. Adjust set screw (8, Figure 3)clockwise to increase systemrelief pressure.

Low fluid level. Inspect and fill to correct level.

Release valve partially open. Using slotted pump handle (6,Figure 1), adjust valve body (5,Figure 3) clockwise until snug.

First, second or third stage ramswill not fully elevate.

Low fluid level. Inspect and fill to correct level.

Hole in hose assembly or loosehose connections.

Visually inspect tube (44, Figure1) for leaks and replace ifnecessary. Tighten maleconnector (25, Figure 1) andmale 90 degree elbow (12,Figure 1).

First, second or third stage ramswill not support load.

Oil leaks at first, second or thirdstage rams.

Remove first, second and thirdstage rams (2, 3, 4, Figure 2)from cylinder assembly. InspectO Rings (14, 15, 16, Figure 2)and Back Up Rings (18, 19, 20,Figure 2) and replace ifnecessary.

Incorrect setting of relief valve Adjust set screw (8, Figure 3)clockwise to increase systemrelief pressure.

First, second or third stage ramsrise and fall with each stroke.

Release valve partially open. Using slotted pump handle (6,Figure 1), adjust valve body (5,Figure 3) clockwise until snug.

Pump inoperative or difficult tooperate.

Vacuum created in frame due toclosed filler cap assembly.

Remove filler and vent (40,Figure 1).

First, second or third stage ramswill not lower.

Defective release assembly. Using slotted pump handle (6,Figure 1) remove valve body (5,Figure 3). Inspect and replace ifnecessary.

2-3 REMOVAL & INSTALLATION A. General Removal Instructions

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PART NO. 167D1100

12

1) Before attemptingremoval of any component, make certain jack isnot pressurized. Ensure controls are in CLOSEDposition before starting any removal procedures.

2) Ensure adequateclearance exists for removal of component.Disassemble adjacent components and structureto extent necessary to provide adequate workingclearance.

3) To facilitate reassemblyand installation, apply identifying tags to matingends of pneumatic lines as they are removed ordisconnected. Identify parts of similarconfiguration to ensure correct reassembly.

4) Carefully note or

diagram the relationship of components to thejack's body before disassembling jack. Duringreassembly, make certain that the originalrelationship is restored.

5) Removed assemblies,even though defective, must be treated asvaluable items because of reclamation orsalvageability.

B. Removal of Cylinder Assembly

1) Remove tube (44, Figure1) from elbow (12, Figure 1) and remove tube (42,Figure 1).

2) Remove captive sockethead screws (32, Figure 1), lockwashers (34,Figure 1) and cylinder assembly (1, Figure 1).

C. Installation of Cylinder Assembly

1) Position cylinderassembly (1, Figure 1) on frame (2, Figure 1).

2) Install lockwashers (34,Figure 1) and socket head captive screw (32,Figure 1).

3) Install tube (44, Figure1).

D. Removal of Low Pressure PumpAssembly

1) Remove screws (31,Figure 1) and lockwashers (33, Figure 1).

2) Lift low pressure pumpassembly (7, Figure 1) from frame (2, Figure 1).

E. Installation of Low PressurePump Assembly

1) Position low pressurepump assembly (7, Figure 1) on frame (2, Figure1).

2) Install lockwashers (33,Figure 1) and screws (31, Figure 1).

F. Removal of High Pressure PumpAssembly

1) Remove screws (31,Figure 1) and lockwashers (33, Figure 1).

2) Lift high pressure pumpassembly (8, Figure 1) from frame (2, Figure 1).

G. Installation of High PressurePump Assembly

1) Position high pressurepump assembly (8, Figure 1) on frame (2, Figure1).

2) Install lockwashers (33,Figure 1) and screws (31, Figure 1).

H. Removal of Casters

1) Raise back of jack untilcasters (3, Figure 1) clears the ground.

2) Remove hex head bolts(30, Figure 1), lockwasher (34, Figure 1) andcasters (3, Figure 1).

I. Installation of Casters

1) Raise back of jackenough to position caster (3, Figure 1) on frame(2, Figure 1).

2) Install lockwashers (34,Figure 1) and hex head bolts (30, Figure 1).

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PART NO. 167D1100

13

WARNING

J. Removal of Tube

1) Remove tube (44, Figure1) from male elbow (12, Figure 1).

K. Installation of Tube

1) Install tube (44, Figure1) to male elbow (12, Figure 1).

L. Removal of Tow HandleAssembly

1) Remove self-lockingnuts (36, Figure 1), flat washers (35, Figure 1)and hex head bolts (29, Figure 1).

2) Remove tow handle

assembly (5, Figure 1) from frame (2, Figure 1).

M. Installation of Tow HandleAssembly

1) Position tow handleassembly (5, Figure 1) on frame (2, Figure 1).

2) Install hex head bolts(29, Figure 1), flat washers (35, Figure 1) andself-locking nuts (36, Figure 1).

2-4 REPAIRS

A. General DisassemblyInstructions

1) The work area forassembly of any item must be kept as clean aspossible to avoid contamination of the internalparts of the mechanism. This is especially true ofcylinders or other components in the pneumaticor hydraulic systems.

2) Whenever possible, all

gaskets, packings, and seals removed in thecourse of repair should be discarded andreplaced with new parts. These items are usuallydamaged or destroyed during the process ofremoval. Similarly, all lock washers, cotter pins,and like items should be replaced at time ofreassembly.

3) When removing gaskets,packings, or seals, do not use any metal tool to

pry, pick or scrape, for to do so will scratch thesealing surfaces adjacent to these items. use apointed wooden dowel to remove packings fromtheir grooves. Use wood or plastic scrapers ongasket surfaces.

4) Before proceeding withdisassembly of any item, study the explodedview illustrations carefully, paying particularattention to the relationship of internal parts.Familiarization with the details of construction willspped up the process of disassembly andassembly and help to avoid improper assembly.

5) To facilitate assemblyand installation, apply identifying tags to matingends of pneumatic and hydraulic lines as theyare disconnected. Identify parts of similarconfiguration to ensure correct assembly.

6) To prevent moisture andforeign matter from entering open lines and otheropenings, apply protective covers as soon aspractical after disassembly. Wrap all parts inclean paper or dip parts in hydraulic fluid.

7) Remove only those partsrequiring repair or replacement. Do notdisassemble a component any further thannecessary to accomplish needed repairs.

B. General Cleaning Procedures

1) Where instructions callfor cleaning, use dry solvent per sper P-D-680,Type III.

SERIOUS INJURY CAN OCCUR WHENWORKING WITH COMPRESSED AIR. WEREEYE PROTECTION AND DO NOT DIRECTCOMPRESSED AIR AT OTHERS.

2) After soaking parts insolvent, deposits may be washed away byflushing or spraying, and where necessary, byremoving with a brush moistened in the solvent.Use a jet of dry-compressed air to dry parts,except bearings, after cleaning. Bearings must

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PART NO. 167D1100

14

CAUTION

be allowed to drip and air dry.

3) Do not use scrapters,wire brushes, abrasive wheels, or compounds incleaning parts, unless these procedures arespecifically approved in detailed instructions.

4) When cleaning ball orroller bearings, place them in a basket andsuspend them in a container of solvent overnight.If necessary, use a brush to remove caked ongrease, chips, etc. Avoid rotating the bearingbefore solid particles are removed to preventdamaging races and balls. When bearings havebeen cleaned, spin them immediately in lightlubricating oil to remove solvent.

5) Do not clean packings

or rubber parts in solvent. These parts should bewiped clean with a clean, dry cloth.

6) Prior to anydisassembly, the exterior of the jack should bethoroughly cleaned to remove accumulated mud,tar, and grease. This procedure will facilitateinspection and disassembly. For cleaningexterior parts, use a vapor-pressure spray-rinsecleaner.

C. General Inspection Procedures

1) Inspect all surfaces in contact with gaskets, packings, or seals toensure that no nicks, burrs, scratches, etc., existwhich might damage the new seals uponreassembly. If any suck defect is discovered,remove it as detailed under "General RepairInstructions" before reassembly.

2) Examine bearings forseparation or rusted or pitted balls or races.Examine balls and races for abrasion anddiscoloration. The following are causes forbearing rejections:

a) Cuts or groovesto ball or roller rotation.

b) Fatigue pits (asopposed to minor machine marks or scratches).

3) Inspection consists ofchecking for defects such as physical distortion,

wear, and cracks.

4) Check all hose surfacesfor broken or frayed fabric. Check for breakscaused by sharp kinks or rubbing against otherparts of the jack. Inspect rigid tubing for kinks.Inspect fitting threads for damage. Replace anypart found defective. Check for leaks followingreassembly and during initial operation period.

5) Visually inspect allweldments for cracks, using sufficient light and a2X magnifying glass. Parts upon which greatstress is placed may be inspected usingapproved methods.

D. General Repair Procedures

1) Remove residue and oilstains from bearing races.

2) Exterior painted partsmay be resurfaced where paint is damaged, orwhere parts have been repaired, by usingstandard repair equipment.

SUITABLE PRECAUTIONS SHOULD BE TAKENTO GUARD OTHER PARTS OF THE JACKFROM ABRASIVE DUST. THE OPERATIONSHOULD NOT BE PERFORMED NEAREXPOSED WORKING PARTS AND ALLOPENINGS WHICH WOULD ALLOW DUST TOREACH WORKING PARTS SHOULD BEMASKED.

3) Prior to resurfacing,scrape loose and blistered paint from damagedarea. Clean area to be painted by sanding orbuffing. Remove residual cleaning material withpaint thinner.

4) During repair operations,bare steel surfaces shall be protected fromoxidation when not actually undergoing repairwork, i.e., while awaiting any repair step,reinspection, or reassembly. Such protectionshall be accomplished by dipping parts in orspraying them with corrosion-preventive

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CAUTION

compound per specification MIL-O-6081 (4, Table2-3). The same protective coating shall be appliedto other metals, if necessary, to prevent oxidationunder climatic or atmospheric conditionsprevailing. Bare steel parts must be protected inall instances.

5) Replace all broken,frayed, crimped, or soft flexible lines and hoses.Replace fittings which are stripped or damaged.

6) Replace any bolt, screw,nut or fitting on which threads are damaged.Inspect tapped holes for thread damage.

E. General Reassembly andInstallation Instructions

1) Remove protectivegrease coatings from new parts prior toinstallation.

2) To replace a preformedpacking, first lubricate with clean (from anunopened can or filtered through a five micronfilter) hydraulic fluid (6, Table 2-3). Roll sealbetween fingers to ensure packing is not twisted.Stretch packing just enough to place into sealinggroove. When packing is in groove, ensurepacking is not twisted, nicked or damaged.

3) Use teflon tape (17,Table 2-3) when replacing pipe plugs.

4) Lubricate bearings priorto reassembly with grease (7, table 2-3).

5) Refer to identifying tagsattached at removal.

6) After installation, inspectfor leaks, binding and misalignment duringoperation.

F. Workmanship and Handling

Maintenance practices to be employedduring performance of these procedures withinthis manual shuld be of the highest standard. Theproper tools for the accomplishment of each taskshould be obtained prior to beginning the work.The work area should be kept as clean as ispractical, and new parts should not be laid out

where they will be exposed to dirt or dust prior toinstallation.

G. Painting

All repair to paint is to be done withinguidelines established in paragraph 4-D. Paint,primer and associated activator specifications aredetailed in Table 2-3, List of Consumables.

H. Disassembly of CylinderAssembly

ALWAYS DEPRESSURIZE JACK BEFORE ANYMAINTENANCE IS PERFORMED.

1) Remove bearing (6,Figure 2) and pull first, second and third stagerams (2, 3, 4, Figure 2) from cylinder assembly(1, Figure 1).

2) Push third stage ram (4,Figure 2) from bottom to expose retainer ringgroove and remove retainer ring (8, Figure 2).Third stage ram (4, Figure 2) is now free to dropthrough second stage ram (3, Figure 2).

3) Remove seal (16, Figure2) from third stage ram (4, Figure 2).

4) Push second stage ram(3, Figure 2) from bottom to expose retainer ringgroove and remove retainer ring (8, Figure 2).Second stage ram (3, Figure 2) is now free todrop through first stage ram (2, Figure 2).

5) Remove seal (15, Figure2) from second stage ram (3, Figure 2).

6) Remove seal (14, Figure2) from first stage ram (2, Figure 2).

7) Inspect all parts. Rejectany that are cracked, distorted, or show signs ofunusual wear.

I. Assembly of Cylinder Assembly

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1) Install seal (14, Figure 2)on first stage ram (2, Figure 2).

2) Install seal (15, Figure 2)on second stage ram (3, Figure 2).

3) Position second stageram (3, Figure 2) up through first stage ram (2,Figure 2) to expose retainer ring groove andinstall retainer ring (8, Figure 2).

4) Install seal (16, Figure 2) on third stage ram (4, Figure 2).

5) Position third stage ram(4, Figure 2) up through second stage ram (3,Figure 2) to expose retainer ring groove andinstall retainer ring (8, Figure 2).

J. Disassembly of High PressurePump Assembly, Model 566-02

1) Remove o ring (23,Figure 3), filter (9, Figure 3) and o ring (24, Figure3

2) Remove spring (10,Figure 3) and steel ball (7, Figure 3).

3) Remove cotter pins (17,Figure 3), pin (15, Figure 3), links (4, Figure 3)and fulcrum (3, Figure 3).

4) Pull plunger (2, Figure 3)from pump base (1, Figure 3) and remove o ring(22, Figure 3), back up ring (21, Figure 3) andwiper (20, Figure 3).

5) Remove pipe plug (14,Figure 3), cotter pin (16, Figure 3) and turn pumpbase (1, Figure 3) upside down to remove steelball (7, Figure 3).

6) Remove roll pin (19,Figure 3), set screw (8, Figure 3), o ring (25,Figure 3), spring (11, Figure 3) and needle (6,Figure 3) from valve body (5, Figure 3).

K. Assembly of High PressurePump Assembly, Model 566-02

1) Install o ring (23, Figure3) and valve body (5, Figure 3) into pump base (1,Figure 3) finger tight.

2) Install needle (6, Figure3), spring (11, Figure 3), o ring (25, Figure 3), setscrew (8, Figure 3) and roll pin (19, Figure 3) invalve body (5, Figure 3). Use slotted pump handle(6, Figure 1) to tighten valve body (5, Figure 3).

3) Drop steel ball (7, Figure3) in pump base (1, Figure 3) and install cotterpin (16, Figure 3) and pipe plug (14, Figure 3).

4) Install wiper (20, Figure3), back up ring (21, Figure 3) and o ring (22,Figure 3) on plunger (2, Figure 3) and positionplunger in pump base (1, Figure 3).

5) Position links (4, Figure3) on pump base (1, Figure 3) and install pin (15,Figure 3) and cotter pin (17, Figure 3).

6) Position fulcrum (3,Figure 3) on plunger (2, Figure 3) and links (4,Figure 3) and install pins (15, Figure 3) and cotterpins (17, Figure 3).

7) Install o ring (24, Figure3), filter (9, Figure 3) and o ring (23, Figure 3) inpump base (1, Figure 3) bottom.

8) Install steel ball (7,Figure 3), spring (10, Figure 3) and o ring (23,Figure 3) in pump base (1, Figure 3) bottom.

L. Disassembly of Low PressurePump Assembly, Model 566-06

1) Remove o ring (9, Figure4), filter (5, Figure 4) and o ring (10, Figure 4).

2) Remove o ring (9, Figure4), spring (6, Figure 4) and steel ball (14, Figure4).

3) Remove cotter pins (15,Figure 4), pin (8, Figure 4), pins (7, Figure 4),links (4, Figure 4) and fulcrum (3, Figure 4).

4) Pull plunger (2, Figure 4)from pump base (1, Figure 4) and remove o ring(11, Figure 4), back up ring (12, Figure 4) andwiper (13, Figure 4).

5) Remove pipe plug (17,Figure 4), cotter pin (16, Figure 4) and turn pump

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base (1, Figure 4) upside down to remove steelball (14, Figure 4).

M. Assembly of Low PressurePump Assembly, Model 566-06

1) Drop steel ball (14,Figure 4) in pump base (1, Figure 4) and installcotter pin (16, Figure 4) and pipe plug (17, Figure4).

2) Install wiper (13, Figure4), back up ring (12, Figure 4) and o ring (11,Figure 4) on plunger (2, Figure 4) and position inpump base (1, Figure 4).

3) Position links (4, Figure4) on pump base (1, Figure 4) and install pin (8,Figure 4) and cotter pin (15, Figure 4).

4) Position fulcrum (3,Figure 4) on plunger and links and install pins (7,Figure 4) and cotter pins (15, Figure 4).

5) Install o ring (10, Figure4), filter (5, Figure 4) and o ring (9, Figure 4) inpump base (1, Figure 4) bottom.

6) Install steel ball (14,Figure 4), spring (6, Figure 4) and o ring (9,Figure 4) in pump base (1, Figure 4) bottom.

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Illustrated Parts List

Introduction

Figure 1 - 50 Ton Axle Jack, Model No. 5007-50 (55)

Detailed Parts List, Jack Assembly

Figure 2 -Lift Assembly

Detailed Parts List, Lift Assembly

Figure 3 - High Pressure Pump Assembly, Model 566-02Detailed Parts List, High Pressure Pump Assembly

Figure 4 - Low Pressure Pump Assembly, Model 566-06

Detailed Parts List, Low Pressure Pump Assembly

Chapter/Section

3-1

3-2

Page

19

20

21

22

22

23

24

25

26

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1. INTRODUCTION

A. Purpose of the Illustrated PartsList. the Illustrated Parts List is intended for usein provisioning, requisitioning, storing and issuingthe replaceable ground equipment componentsand in identification of new and reclaimed parts.

B. How to use the Illustrated PartsList. Refer to the Table of Contents at thebeginning of this chapter and select theappropriate descriptive title, then go to thereferenced figure and page number.

C. Model of the Equipment in theIllustrated Parts List. This parts list is applicable

to the 50 Ton Axle Jack, Model No. 5007-50 (55).

D. Effectivity of Equipment in theIllustrated Parts List. Only one configuration ofthe axle jack is included in this manual, therforethere are no effectivity codes listed in the EFFColumn.

E. Manufacturer Identificaton List. Alist of all manufacturer's names and addressesused in the Illustrated Parts List is provided. Thelist is in two (2) parts. Part I consists of analphabetical list of vendors who have no assignedFederal Supply Code. Part II contains anumerical listing of vendors with assigned codes.

Part I - Name, Division and Address of ManufacturerNone

Part II - Federal Supply Code Name, Division and Address of Manufacturer

V00994 Columbus Jack Corporation2222 South Third StreetColumbus, OH 43207

V7F988 Alemite Co. Of Ohio Valley1475 S. Floyd StLouisville, KY 40208-2015

V71447 California Spring CompanyDiv. Peterson American Corp7803 Industry AvePico Rivera, CA 90660-4305

V79470 DANA CorpWeatherhead Div6615 Brotherhood WayFt. Wayne, IN 46825

V88044 Aeronautical Standards GroupDept. Of Navy and Air Force

V89967 Smith-Nelson Corp.Santa Barbara, CA

V96906 Military Standards Promulgatedby Military Departments Under Authority of DefenseStandardization Manual 4120 3-M

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Figure 1 - 50 TonAxle Jack Assembly

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INDEXNO.

PART NUMBER DESCRIPTION

1 2 3 4 5 6 7

UNITSPER ASSY

1-1123456789

11121314151617181924252627282930313233343536373839404142434445464748495051

167D1100167D1200-1167D1400450A3820349D1014117C1406469B1211566-06566-02450A3300167C2000450A3108450A3344450A3107450A4554450A3202483-10606450A3247450A3027P10001-025450A3111450A3115450A3012450A31083/4-10 X 5 ½450A3720450A39143/8-16NCX3/4450A3966450A39723/4 NOM450A3722450A3004450A37231/4 NOM12" LG14" LG46" LG24" LG40" LG160B600167B1600MS16995-55167B1300167B1500450A38518-32UNCX.375

50 TON AXLE JACK ASSEMBLYLIFT ASSEMBLYFRAME WELDMENTCASTERSPRING ASSEMBLYTOWBARPUMP HANDLEPUMP ASSEMBLYPUMP ASSEMBLYFILLER ASSEMBLYCOVER ASSEMBLYMALE ELBOWPNEUDRAULIC PUMPMALE ELBOWVALVEVALVEHEX NIPPLEPOP SAFETY VALVEPIPE TEEMUFFLERMALE CONNECTORMALE CONNECTORPIPE PLUGMALE ELBOWCAP SCREWCAP SCREWCAP SCREWBOLTLOCKWASHERLOCKWASHERLOCKWASHERHEX NUTHE NIPPLECAP SCREWLOCKWASHERTUBETUBETUBETUBETUBEDECALPLATE OPERATING INSTRUCTIONSCREWCOVERPLATE CAUTIONTUBE CLIPSCH CAP SCREW

REF1121111111111111112321318444

1211147111111131122

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INDEXNO.


1 2 3 4 5 6 7

UNITSPER ASSY

2-1123456789

1011121314151617181920

167D1200-1167C1201167C1212167C1213167C1214871B1205167C1216167B1207871B1211-2871B1211-1450A5348450A5347450A5346450A5340450A3493450A3492450A3491450A4253-258512C1100-12512C1100-13512C1100-14

LIFT ASSEMBLYCYLINDER ASSEMBLYRAM FIRST STAGERAM SECOND STAGERAM THIRD STAGESCREW EXTENSIONBEARINGNUTRETAINER RINGRETAINER RINGD RINGD RINGD RINGSET SCREWO RINGO RINGO RINGO RINGBACK UP RINGBACK UP RINGBACK UP RING

REF11111111111111111111

Figure2 - Lift Assembly

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Figure 3 - High Pressure Pump Assembly, Model No. 566-02

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INDEXNO.


1 2 3 4 5 6 7

UNITSPER ASSY

3-1123456789

10111213141516171819202122232425

566-0230-18270-88230-23220-1920-11820-2-23MS19059-241520-2-51250A024-1240-14240-9-01566-08-1N/A1/8 NPTFAN395-65MS24665-291MS24665-281AN395-4959-048-250-1000151-9-02MS28782-9AN6227-9AN6227-11AN6227-7AN6227-5

HIGH PRESSURE PUMP ASSEMBLYBASE PUMPPLUNGERFULCRUMLINKBODY VALVENEEDLESTEEL BALLSET SCREWFILTERSPRINGSPRINGPLUGN/AHEX SOCKETPINCOTTER PINCOTTER PINPINROLL PINWIPERBACK UP RINGO RINGO RING O RINGO RING

REF111211211111

121311111311

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Figure 4 - Low Pressure Pump Assembly, Model No. 566-06

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INDEXNO.


1 2 3 4 5 6 7

UNITSPER ASSY

4-1123456789

1011121314151617

566-0630C21770A110230-23220A25250A024-1240-14AN395-49AN395-65AN6227-11AN6227-7AN6227-27MS28782-2771X6223MS19059-24153/32 X ½ LG3/32 X 1 3/4 LG450A3011

LOW PRESSURE PUMP ASSEMBLYBASE PUMPPLUNGERFULCRUMLINKFILTERSPRINGPINPINO RINGO RINGO RINGBACK UP RINGWIPERSTEEL BALLCOTTER PINCOTTER PINPIPE PLUG

REF11121112211112311

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OPERATION and SERVICE INSTRUCTIONS with ILLUSTRATED … · supply Operating, Servicing, and...

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