NAVAIR_19-70-521_00600_-_004_00.pdf

NAVAIR 19-70-521 006 00

Change 1 - 1 May 2005 Page 1 of 16

OPERATION AND INTERMEDIATE MAINTENANCE

WITH ILLUSTRATED PARTS BREAKDOWN

AIRCRAFT AXLE JACK A10-1HC

PART NUMBER 53D22004

Reference Material

Title Publication No.

Ground Support Equipment Cleaning and Corrosion Control......................................................... NAVAIR 17-1-125 Jack Tester, Portable ................................................................................................................................. WP 028 00 Jack Tester, Stationary .............................................................................................................................. WP 029 00 Periodic Maintenance Requirements Manual .......................................................................NAVAIR 19-600-135-6-2 Preoperational Checklist .......................................................................................................NAVAIR 19-600-135-6-1 Surface Inspection Acceptance Standards for Metals, Class 2 ..................................... NAVSEA 0900-LP-003-8000 Welding and Casting Standard ...........................................................NAVSEA TECH PUB S9074-AR-GIB-010/278

Alphabetical Index

Subject Page No.

Description Illustrated Parts Breakdown Introduction

Leading Particulars Maintenance

Assembly Cleaning Disassembly Finish Inspection Lubrication Periodic Maintenance Repair Testing

Operation Instructions Lifting Lowering Preoperation

Preparation for Use, Storage or Shipment Preparation for Storage or Shipment Preparation for Use

Principles of Operation Troubleshooting

Record of Applicable Technical Directives

Type/No. Date Title and ECP No. Date Inc. Remarks

SEB 438

Rev. A

11-28-84 Aircraft Jacks, Stenciling and Marking of Maximum Extension Screw Lengths

12-1-89 –

1. INTRODUCTION.

2. This work package has been prepared as the basic operation and maintenance procedure for the 10-Ton Hydraulic Aircraft Axle Jack, Model No. A10- 1HC, Part No. 53D22004, hereafter referred to as the jack.

3. Procedures and data covered in this work package are intended for use by operation and maintenance personnel at organizational and intermediate levels.

4. LEADING PARTICULARS. Leading particulars of the jack are shown below.

Item Characteristics

Use Vertical Load Lift Rated Load 10 tons (20,000 Ibs) Maximum Allowable Load 11 tons (22,000 Ibs) Operating Force (at rated load) 75 lbs (approx.)

Operating Fluid Specifications MIL-PRF-83282 Hydraulic System Fluid Capacity 3.6 pt Pump Handle Length 18 in Hydraulic Lift (Rams extended) 13 in Extension Screw Lift (Fully Extended) 4 in Height Overall

(Collapsed) 8.5 in (Fully extended) 25.5 in

Weight (with fluid) 50 lbs Length 13.5 in Width 8 in

5. DESCRIPTION.

6. The jack (Figure 1) is a portable, self-contained unit with a single speed, manually operated pump.

The lift consists of three rams and an extension screw, all encased within an outer cylinder which is integral with the base. A rectangular tank is welded to the base, forming the fluid reservoir. The jack is used for vertical lifting of loads up to 10 tons (20,000 pounds). At the maximum allowable load of 11 tons (22,000 pounds) the hydraulic operating fluid is bypassed within the jack by an automatic valve, and the jack will not continue to lift.

7. PRINCIPLES OF OPERATION.

8. The valve assembly (Figure 2) is located beneath the pump actuating cylinder. It contains a gravity check valve, a spring-loaded check valve and a safety bypass valve. On the upstroke, the pump piston draws hydraulic fluid from the reservoir. The downstroke forces fluid under pressure through the spring-loaded check valve into the base assembly cylinder and rams. This fluid pressure is retained by the spring-loaded check valve. Pressure is released and fluid is returned to the reservoir by opening the release valve. The safety bypass valve is operative when load to the rams exceeds the maximum allowable load of 11 tons (10 percent greater than rated load).

9. PREPARATION FOR USE, STORAGE OR

SHIPMENT.

Materials Required

Nomenclature Specification or P/N

Fluid, Hydraulic MIL-PRF-83282 Oil, Lubricating MIL-PRF-7870

10. PREPARATION FOR USE.

a. If the jack is crated, uncrate and inspect for physical damage and missing parts.

Hydraulic Fluid, MIL-PRF-83282 1

b. Ensure that rams are fully collapsed prior to adding fluid. Fill reservoir to 1/4 inch of filler hole with hydraulic fluid, MIL-PRF-83282.

c. Complete fluid change is required every three years in accordance with NAVAIR 19-600-135-6-2.

006001

Figure 1. A10-1HC Aircraft Axle Jack

006002

Figure 2. A10-1HC Aircraft Axle Jack Flow Diagram

Change 1 Page 4

Damaged, defective or suspect parts shall be repaired or replaced before attempting to operate the jack. Defective parts or weak structural points may cause sudden jack failure and/or loss of lift load with potential danger to personnel.

d. Perform preoperational check in accordance with NAVAIR 19-600-135-6-1.

11. PREPARATION FOR STORAGE OR SHIP-

MENT.

Lubricating Oil, MIL-PRF-7870 2

a. Apply a light film of lubricating oil, MIL-PRF- 7870, to outer bearing surfaces of rams.

b. Fully collapse rams, close release valve, and close air vent screw.

c. Stow jack in a sheltered area. To prolong efficiency and useful life, use a water repellant cover.

Hydraulic Fluid, MIL-PRF-83282 1

d. For shipment, drain all hydraulic fluid from jack and turn in to supply activity for packing.

12. OPERATION INSTRUCTIONS.

13. PREOPERATION. Perform preoperational check in accordance with NAVAIR 19-600-135-6-1.

14. LIFTING.

Do not attempt to lift loads exceeding 10 tons (20,000 pounds) with this jack.

Overloading may result in lift failure and/or load loss hazard to personnel.

a. Close release valve fully, and unscrew air vent screw two turns.

b. Ensure that jack base rests on a firm and level foundation. If necessary, place a flat metal plate under jack base to provide secure footing for the jack.

c. Operate jack handle to lift rams partially.

Do not attempt to unscrew extension screw more than 4 inches; an internal stop pin limits screw extension screw loss or damage. Forcible loosening of extension screw post beyond its internal stop pin will damage or shear the pin, necessitating extension screw removal and repair.

d. Position jack under load and, if necessary, partially unscrew extension screw to contact the load and to provide additional lift. Operate handle to lift rams to contact the load if maximum extension screw is insufficient.

If jack lifting stops before rams are fully extended, and handle drops or goes soft, an overload is indicated. In this event, use a jack with a greater capacity to lift the load.

e. After jack is firmly positioned under the load, operate jack handle using long, smooth strokes until jack has lifted load.

15. LOWERING.

NOTE

Do not open release valve more than two complete turns when lowering.

a. Allow vent assembly air vent screw to remain open. Open release valve slowly, using slotted end of handle, until jack begins to lower. The rate of load descent is in proportion to the amount of release valve opening.

b. With release valve open, rams will lower until load supports itself. Withdraw jack. Lower extension screw and manually press rams until they are flush with base cylinder.

c. Fully close and tighten release valve. If jack is to be stowed, close air vent screw.

Table 1. Troubleshooting

Trouble Probable Cause Remedy

Rams fail to lift when pump is operated or jack fails to lift rated load. (See figure 3)

Incomplete closure of release valve.

Obstructed fluid suction passage.

Securely tighten release valve.

Disassemble jack. Blow passages clear with compressed air. Reassemble jack, flush and fill with clean fluid.

Low fluid level. Inspect and fill to correct fluid level if necessary (as outlined in paragraph 10b).

Bypass valve improperly adjusted. Remove screw. Adjust screw in valve assembly as outlined in paragraph 31.

Broken bypass valve spring in check valve.

Remove valve assembly. Replace, test and adjust as outlined in paragraph 31.

Ram will not fully elevate.

Low fluid level. Inspect and fill to correct fluid level if necessary (refer to paragraph 10b).

Leaking discharge valve. Remove valve assembly. Replace, test and adjust (refer to paragraph 31).

Rams will not support rated load.

Oil leaks at rams. Remove rams. Replace rings, gaskets and o-rings. Inspect bearings and bushings for damage, grooving and uneven wear.

Replace defective parts.

Leaking discharge or release valve ball or seat.

Remove, inspect and replace ball if necessary. Inspect ball seat in base assembly and reseat if necessary (refer to paragraphs 25 and 31).

Rams rise and fall with each stroke.

Incomplete closure of release valve. Tighten release valve securely.

Leaking discharge valve. Remove valve assembly. Replace, test and adjust (refer to paragraph 31).

Leaking release valve ball or seat. Remove, inspect and replace ball if necessary. Inspect ball seat in base assembly and reseat if necessary (refer to paragraph 25).

Pump inoperative or difficult to operate.

Vacuum in reservoir due to closed vent assembly vent screw.

Unscrew vent screw two turns.

Air in pump chamber. Open release valve and pump rapidly several times; close valve.

Pump operates, and fluid pressure fails to bypass at maximum ram extension or with overload applied.

Bypass valve improperly adjusted.

Defective bypass spring or ball.

Remove screw. Adjust screw in check valve as outlined in paragraph 31.

Remove valve assembly. Replace, test and adjust (refer to paragraph 31).

Table 1. Troubleshooting – Continued

Trouble Probable Cause Remedy

Rams will not lower. Loose retainer ring lodged beneath ram.

Remove rams. Inspect and replace retainer rings if necessary.

Excessively worn rams have jammed. Relieve load with another jack. Remove, inspect and replace rams if necessary.

16. TROUBLESHOOTING.

17. To troubleshoot the jack in the event of abnormal operation or deterioration of performance refer to Table 1.

18. MAINTENANCE.

Support Equipment Required

Nomenclature Part Number

Caliper, Micrometer GGG-C-105 2-3 in

Caliper, Micrometer MT-308 3-4 in

Caliper, Micrometer 41C22 Inside, 0.2-1 in

Caliper, Micrometer T230R Outside, 0-1 in

Portable Aircraft Jack Tester 67A96D1-1 Rod and Sleeve 2-12 in 124B Stationary Aircraft Jack Tester 67A294C4-1/

1380AS100-1

Valve Seat Facing Tool —

Materials Required

Nomenclature Specification or P/N

Cleaning Compound, MIL-PRF-85570 Aircraft, Exterior Type II

Cloth, Aluminum Oxide, ANSI B74.18 Very Fine 320 Grit

Cloth, Lint-Free A-A-59323 Fluid, Hydraulic MIL-PRF-83282 Oil, Lubricating MIL-PRF-7870 Paint, Epoxy Polyamide MIL-PRF-85285

Black, Color No. 17938 Type II Paint, Epoxy Polyamide MIL-PRF-85285

Red, Color No. 11105 Type II Paint, Epoxy Polyamide MIL-PRF-85285

White, Color No. 17925 Type II Paint, Primer Epoxy MIL-PRF-85582

Polyamide Type I Spray, Dykem SP-1100

(Steel Blue Color) Tape, Masking SAE-AMS-T-23397

19. PERIODIC MAINTENANCE. For periodic maintenance, refer to NAVAIR 19-600-135-6-2.

20. Maintenance of the jack consists of disassembly cleaning, inspection, repair, lubrication, assembly, testing, and finishing.

21. During maintenance, the following apply:

a. Replace damaged or defective parts.

b. Replace the following parts if removed from installed position; cotter pins, retainer rings, o-rings, gaskets, backup rings, plunger and spring.

22. DISASSEMBLY.

Handle jack with care to avoid damaging critical, precision machined surfaces.

a. Place base of jack in drain pan.

b. Remove handle (1, Figure 3) and air vent assembly (2).

c. Remove adjusting valve plug screw (3) and gasket (4).

d. Remove release valve lock screw (5).

e. Remove release valve (6), o-ring (7) and ball (8).

f. Remove plug (9), spring (10) and screen (11).

Hydraulic Fluid, MIL-PRF-83282 1

g. Thoroughly drain jack of hydraulic fluid.

h. Remove cotter pins (12) and pins (13 and 14) links (15) and rocker pump arm (16).

i. Remove pump piston (17) and packing nut (18).

j. Remove backup ring (19) and o-ring (20).

k. Unscrew and remove pump body (21) from base assembly (47).

l. Remove upper pump valve gasket (22).

NOTE

For service and repair do not disassemble valve assembly (23). Replace valve assembly as necessary for each service or repair action. If valve assembly is defective, it shall be replaced as an entire unit. The new installed valve assembly shall be tested and adjusted as outlined in paragraph 31.

m. Screw a 1-1/2 inch long 1/4-20 UNC-2A screw into threaded hole atop valve assembly (23).

Lift valve assembly (23) from hole in base assembly (47). Remove lower valve gasket (22).

n. Remove cylinder bushing (24) and retainer ring (25).

o. Unscrew extension screw (26). Grasp extension screw and lift ram installation as a unit from cylinder and base assembly. Telescope ram components to inside out position to facilitate disassembly.

p. Remove first stage ram (27) and retainer ring (28).

NOTE

Rap lightly with a soft head mallet at inner bearing circumference to facilitate removal of bearings.

q. Remove first stage bearing (29).

r. Remove o-ring (30) and backup ring (31).

s. Remove retainer ring (32) and second stage ram (33).

t. Remove retainer ring (34) and second stage bearing (35).

u. Remove o-ring (36) and backup ring (37).

v. Remove third stage ram (38) and retainer ring (39).

w. Remove third stage bearing (40).

x. Remove o-ring (41), and backup ring (42).

y. Do not remove extension screw (26) from third stage ram (38) unless screw or ram is damaged.

Forcible extension screw removal will damage or shear plunger (43).

z. If damaged necessitates removal of extension screw, proceed as follows:

NOTE

If extension screw is removed, a new plunger (43) and spring (44) shall be installed in extension screw (26) prior to assembling extension screw into third stage ram (38).

(1) Using wood blocks to protect outer ram surfaces, carefully clamp third stage ram (38) in a vise.

(2) Unscrew and extend extension screw (26) until plunger (43) engages. Then forcibly unscrew and remove extension screw (26), from third stage ram (38), shearing plunger (43).

aa. If necessary, remove and replace nameplate

(45) by removing screws (46).

ab. If necessary, remove decal (47) from base assembly (48).

23. CLEANING.

a. Periodic cleaning shall be conducted in accordance with NAVAIR 19-600-135-6-2.

Maintenance operations shall be performed in a clean shop environment.

Wear goggles and gloves. Cleaning compound is a skin and eye irritant. If cleaning compound is splashed on bare skin or in eyes, rinse thoroughly with fresh water.

b. Each disassembled metal part of the jack shall be cleaned with MIL-PRF-85570, type II, cleaning solution, thoroughly rinsed with clean water, and then thoroughly dried before reassembly. Use low-pressure compressed air to blow out all passages in the base and intake screen.

c. Use lint-free cloth to wipe the parts after they have been cleaned. Do not permit lint or dirt to become lodged in any of the valves or oil passages.

24. INSPECTION.

a. Inspect all parts for damage, distortion, corrosion and other faults as outlined in Table 2.

Wear tolerances are contained in Table 3.

25. REPAIR.

a. Defective ball seat in release valve (6) located in base assembly (48) shall be refaced using a standard valve seat facing tool.

b. Using a brass dowel, a mallet and a ball of the same size used with the seat being refaced, form a new seat by tapping lightly on seat ball until a 1/64 inch wide seat is formed.

c. Discard ball used for seating operation.

Wear goggles and gloves. Cleaning compound is a skin and eye irritant. If cleaning compound is splashed on bare skin or in eyes, rinse thoroughly with fresh water.

d. Wash reface seat with MIL-PRF-85570, type II, cleaning solution. Rinse thoroughly with clean water. Dry thoroughly with low-pressure compressed air.

e. Install a new ball of proper size at refaced seat.

26. Welding.

All weld repairs must be performed in a well-ventilated area. All closed spaces within the jack shall be certified gas free prior to welding. Personnel injury can occur.

Table 2. Inspection

Part Index No. Inspect For

Pins 13, 14 Grooving.

Links 15 Out-of-round holes.

Arms 16 Out-of-round holes.

Piston 17 Grooving and scoring; out-of-round hole.

Nut 18 Grooving and scoring at ID; condition of threads.

Body 21 Grooving and scoring at ID; condition of threads.

Balls 8 Nicks and grooves; flat spots.

Spring 10 Cracks; free length of 1-1/2 inch.

Screen 11 Breaks in wire mesh; buckling; loosened ends.

Bushing 24 Grooving, scoring, and gouging; condition of threads.

Rams 27, 33, 38 Cracks, with magnetic particle inspection, MIL-STD-1949, grooving and scoring.

Bearings 29, 35, 40 Grooving and scoring.

Screw 26 Cracks, as outlined for rams (27, 33, 38); condition of threads.

Base Assy 48 Cracks as outlined for rams (27, 33, 38); grooving and scoring at cylinder ID; condition of threads; nicked and scratched seat for ball (8).

Table 3. Wear Tolerance

Parts & Index No.

(Figure 3) Description

Tolerance (in.)

Max Min

Piston (17) Minor diameter 0.496

Nut (18) ID 0.507 ---

Body (21) Minor ID 0.502 ---

Bushing (24) ID 3.496 ---

Ram (27) Outer wear surface diameter --- 3.487

Major inner wear surface diameter 2.991 ---

Minor inner wear surface diameter 2.793 ---

Bearing (29) OD --- 3.667

Ram (33) Outer wear surface diameter --- 2.784

Major inner wear surface diameter 2.364 ---

Minor inner wear surface diameter 2.147 ---

Bearing (35) OD --- 2.980

Ram (38) Outer wear surface diameter --- 2.138

Bearing (40) OD --- 2.353

Base assembly (48) Cylinder wear surface ID 3.678 ---

a. Non-critical structural areas of the base assembly may be welded. Ensure that machined areas will be unaffected by the welding. Cracks or breaks at cylindrical machined surfaces necessitate replacement of base assembly. Before attempting to weld any portion of base assembly, wash, flush, and thoroughly drain fluid passages and reservoir with non-combustible solvent.

b. Welding repairs shall be in accordance with

NAVSEA TECH PUB S9074-AR-GIB-010/278.

Replace all components determined beyond weld repair.

27. ASSEMBLY.

Handle jack with care to avoid damaging critical, precisioned machined surfaces.

Hydraulic Fluid, MIL-PRF-83282 1

a. Prior to assembly immerse o-rings (20, 7, 30, 36, 41), new backup rings (19, 31, 37 and 42), gaskets (22, 4), and retainer rings (25, 32 and 39) in hydraulic fluid MIL-PRF-83282.

Change 1 Page 10

b. Apply a coating of hydraulic fluid, MIL-PRF- 83282, to the inside diameter of pump body (21), cylinder bore in base (48), first and second stage rams (27 and 33), and to the outside diameter of pump piston (17) and third stage ram (38).

Lubricating Oil, MIL-PRF-7870 2

c. Brush a film of oil, MIL-PRF-7870, to threads of extension screw (26) and pump rocker link pins (13 and 14).

d. Install valve assembly (23) with new upper and lower gaskets (22) into pump bore of base assembly (48).

e. Position valve assembly (23) so that adjustment setscrew aligns with threaded hole in base assembly for adjusting valve plug screw (3). Maintain hole alignment with a wood dowel until pump body

(21) is screwed firmly into place.

f. Screw pump body (21) into place, remove wooden dowel, and install new gasket (4) and plug screw (3).

g. Install ball (8), new o-ring (7), release valve (6), and release valve lock screw (5).

h. Install screen (11), new spring (10), and plug (9).

i. Install new o-ring (20), new backup ring (19), pump packing nut (18), and piston (17) into pump body (21).

j. Install rocker pump arm (16) and links (15) using pins (13 and 14); secure with new cotter pins (12).

NOTE

If extension screw (26) is removed, install a new plunger (43) and spring (44) in extension screw stop hole. Depress plunger and guide extension screw and third stage ram threads into engagement, screwing these parts together.

k. Install new backup ring (42) and new o-ring

(41) onto third stage ram (38).

l. Install third stage bearing (40) onto third stage ram (38) tapping lightly at lower edge of bearing with a soft head mallet until bearing is seated.

m. Install new retaining ring (39) on lower end of third stage ram.

n. Insert third stage ram into second stage ram until new retainer ring (32) groove is accessible.

Install new retainer ring (28).

o. Repeat procedures outlined in steps k through n for second stage ram (33), first stage ram

(27) and associated parts.

Mutual centering of rams (38, 33 and 27) and cylinder of base assembly (48) must be maintained as these parts are mated and assembled. Non-centered assembly of rams and cylinder will result in probable galling and serious damage to cylindrical mating surfaces. Ram packings and retaining rings shall be carefully guided into mating inside diameters. Forcible ram insertion with protruding packings and retainers will cut or chafe these ram seat components, resulting in fluid leakage and jack settling malfunction.

p. Center ram assemblies over cylinder bore of base assembly (48).

q. Install rams into cylinder bore.

r. Bottom rams in jack cylinder.

s. Install new retainer ring (25) and cylinder bushing (24) to secure rams.

t. If nameplate (45) requires replacement, transcribe all data from old nameplate to new nameplate. Install with screws (46) onto base assembly (48).

28. LUBRICATION. For periodic lubrication schedule refer to NAVAIR 19-600-135-6-2.

29. TESTING.

The axle jack is to be tested for 10 ton plus 10 percent of rated load. Failure to comply may cause sudden jack failure and/or loss of lift load with potential danger or injury to personnel.

a. If a malfunction occurs during testing refer to Table 1, Troubleshooting. After correction of defect, repeat test.

b. Adjustment and test shall utilize Stationary Aircraft Jack Tester, Part No. 67A294C41/ 1380-AS100-1 or Portable Tester, Part No. 67A96D1- 1.

c. Prepare the jack tester for use in accordance with Work Package 028 00 or 029 00.

d. Perform preoperational check on the jack in accordance with NAVAIR 19-600-135-6-1.

30. Functional Test.

a. Adjust jack tester opening for the jack being tested.

Do not extend the extension screw more than 4 inches. Damage to internal plunger will result.

b. Close release valve (6, Figure 3).

c. Place pump handle (1) on pump arm (16).

d. Pump jack handle so that first and second stage rams are fully extended and third stage ram is contacting jack pad of tester.

e. Tester gauge shall read between 20,000 and 22,000 pounds.

f. Observe that pump bypass relief valve opens between 20,000 and 22,000 pounds. (Pump handle should drop or go soft at this time.) If valve does not open within indicated range adjust valve in accordance with paragraph 31.

31. Pump Bypass Relief Valve Adjustment. Using test stand, adjust bypass valve in valve assembly (23, Figure 3).

a. Check that the reservoir is filled with fluid, and that jack is in operating condition.

b. Using test stand, apply a 10-1/2 ton load to the jack. Operate handle (1) to lift the load. Third-stage ram (38) shall extend partially. If lift ceases, remove screw (3), rotate adjustment screw slightly clockwise. Replace screw (3) and attempt to lift load.

If necessary, repeat clockwise adjustment of adjustment screw until partial lift of third-stage ram is permitted with the 10-1/2 ton load.

If handle fails to drop or go soft with continued pumping at full ram extension, cease pumping at full ram extension, cease pumping immediately. Serious injury may result because of excessively high bypass pressure and sudden collapse of load.

NOTE

An exact adjustment setting to a maximum lift load (with bypass functioning) of 10-1/2 tons is often difficult. Therefore, a safety tolerance of plus 1/2 is allowable (11 ton maximum load). However, whenever possible, the 10-1/2 ton limit setting must be observed.

c. If excessively high-pressure adjustment is evidenced, adjustment screw must be adjusted slightly counterclockwise until bypass valve is operative when pumping is continued at 10-1/2 ton load with third stage ram partially extended.

d. Allow jack to remain with third-stage ram partially extended and increase load from 10-1/2 tons to 10-3/4 tons. Adjustment screw must be set so that next pumping stroke of handle (1) will operate bypass valve, causing handle to drop or go soft.

32. Proofload Testing.

a. Position assembled jack into jack tester.

Rotate extension screw counterclockwise until it is fully extended. An internal stop prevents over-extending the screw.

b. Operate jack until third stage ram is partially extended and pressure gauge registers. Check jack and tester for any distortion. If evident, jack is not positioned properly in tester.

c. Release pressure, reposition jack and resume test.

d. Operate jack until 20,000 pounds is registered on gauge. Jack should be capable of imposing this load without exerting more than 75 to 80 pounds pressure on jack handle.

e. Visually inspect pump packing and ram assembly for signs of leakage. There should be no evidence of leakage at any point.

f. Inspect for distortion, binding, and swaying motion in ram or screw extension. None should be evident.

g. Inspect structural parts for cracks, dents, wear, distortion and general condition.

h. The jack should hold rated load at any point of ram extension. The setting rate should not exceed

0.020 inch per half hour.

The release valve controls the speed of descent of the rams. Do not open release valve too quickly.

i. On completion of test, slowly open jack release valve by turning counterclockwise. Rams are collapsed by body weight.

j. Rework any failed part and repeat test.

k. Restore jack to operational status. Check fluid level in accordance with paragraph 10.b, after completion of testing.

Paint, Red, MIL-PRF-85285, Type II, 5 Color Number 11105

l. Affix with Julian Date, one-inch letters in red, “DATE TESTED _____________ ”, and “NEXT INSPECTION _______________ ”, The next inspection date should reflect the next scheduled inspection, whether it is a proof load test, a functional test, or a preventive maintenance action.

m. Placement of stencil should be near the pump. Choose most conspicuous location.

33. FINISH.

NOTE

Corrosion control shall be in accordance with NAVAIR 17-1-125.

Wear goggles and gloves. Cleaning compound is a skin and eye irritant. If cleaning compound is splashed on bare skin or in eyes, rinse thoroughly with fresh water.

a. Clean with MIL-PRF-85570, type II, cleaning solution. Rinse thoroughly with clean water. Dry thoroughly with low-pressure compressed air. Spot paint as required.

b. Stencil jack and replace decals.

c. Extension screw stenciling and marking.

(1) Choose most conspicuous location on jack housing.

(2) Clean area to be stenciled with MIL-PRF- 85570, type II, cleaning solution, rinse thoroughly with clean water, and dry thoroughly with low-pressure compressed air.

Paint, Black, MIL-PRF-85285, Type II, 6 Color Number 17038

(3) Stencil half inch lettering “CAUTION MAX SCREW EXT. 4 INCHES.” on jack base.

(4) Ensure that extension screw captivating pin and plunger are intact by extending screw until it engages stop. Do not force beyond stop unless screw removal is intended.

(5) With extension screw extended against stop, clean threads and adjacent ram top with MIL- PRF-85570, type II, cleaning solution. Rinse thoroughly with clean water. Dry thoroughly with low-pressure compressed air.

(6) Use masking tape SAE-AMS-T-23397 to mask extension screw and adjacent ram top except for lowest exposed one inch of extension screw thread.

Dykem Spray, SP-1100 3

(7) Spray exposed one inch of screw thread with blue DYKEM spray. Red or orange dye may be substituted. Paint is not visually suitable.

d. Replace missing or unreadable name and data plates.

Paint, Red, MIL-PRF-85285, Type II, 5 Color Number 11105

e. Affix with Julian Date, one-inch letters in red, “DATE TESTED ______________”, and “NEXT INSPECTION ________________”, The next inspection date should reflect the next scheduled inspection, whether it is a proof load test, a functional test, or a preventive maintenance action.

f. Placement of stencil should be near the pump.

Choose most conspicuous location.

34. ILLUSTRATED PARTS BREAKDOWN.

35. WP 002 00 contains information on use of the illustrated parts breakdown.

00600301

Figure 3. Aircraft Axle Jack, Model A10-1HC, Part Number 53D22004 (Sheet 1 of 3)

INDEX

NO.

PART NUMBER DESCRIPTION

1 2 3 4 5 6 7

U N

IT

S

PE

R

AS

SY

U

SA

BL

E

O N

C O

D E

SM&R

CODE

53D22004 AIRCRAFT AXLE JACK MODEL A10-1HC

/00994/ REPAIR KIT AVAILABLE

REF PAOGG

1 53B22101 . HANDLE, PUMP /30003/ ................................ 1 PAGZZ

2 1128AS121 . VENT ASSEMBLY, AIR /07878/ ..................... 1 PAGZZ

3 53A22045 . SCREW, ADJUST VALVE PLUG /80049/ ...... 1 PAGZZ

4 53A22098 . GASKET, ADJUSTING VALVE PLUG

/00994/

1 PAGZZ

5 53A22043 . SCREW, RELEASE VALVE LOCK

/98750/

1 PAGZZ

6 53A2257 . VALVE, RELEASE /80049/............................. 1 PAGZZ

7 MS28775-011 . O-RING ........................................................... 1 PAGZZ 8 216-1-24 . BALL /88042/ .................................................. 1 PAGZZ 9 MS27769-4 . PLUG .............................................................. 1 PAGZZ

10 53A22038 . SPRING, OIL SCREEN /80049/ ..................... 1 PAGZZ

11 53A22044 . SCREEN, PUMP INTAKE /80049/ ................. 1 PAGZZ

12 MS24665-300 . PIN, COTTER ................................................. 3 PAGZZ 13 MS20392-4R25 . PIN .................................................................. 2 PAGZZ 14 MS20392-4R33 . PIN .................................................................. 1 PAGZZ 15 53B22097-2 . LINK, PUMP /80049/....................................... 2 PAGZZ

16 53B22091 . ARM, ROCKER PUMP /80049/ ...................... 1 PAGZZ

17 53A22103 . PISTON, PUMP /80049/ ................................. 1 PAGZZ

18 53A22090 . NUT, PUMP PACKING /80049/ ...................... 1 PAGZZ

19 53B22036-1 . RING, BACKUP /80049/ ................................. 1 PAGZZ

20 MS28775-112 . O-RING ........................................................... 1 PAGZZ

21 53A22102 . BODY, PUMP /80049/ .................................... 1 PAGZZ

22 53A22099 . GASKET, PUMP VALVE /80049/ ................... 1 PAGZZ

23 53C22096-2 . VALVE ASSEMBLY /80049/ ........................... 1 PAGZZ

24 53A220101 . BUSHING, CYLINDER /80049/ ...................... 1 PAGZZ

25 53C22035-9 . RING, RETAINER /80049/.............................. 1 PAGZZ

26 53B22014 . SCREW, EXTENSION /80049/....................... 1 PAGZZ

27 53C22011 . RAM, FIRST STAGE /80049/ ......................... 1 PAGZZ

28 53C22035-6 . RING, RETAINER /80049/.............................. 1 PAGZZ

29 53A22015 . BEARING, FIRST STAGE /80049/ ................. 1 PAGZZ

30 MS28775-339 . O-RING ........................................................... 1 PAGZZ

31 53C22069-4 . RING, BACKUP /80049/ ................................. 1 PAGZZ

32 53C22035-10 . RING, RETAINER /80049/.............................. 1 PAGZZ

33 53C22012 . RAM, SECOND STAGE /80049/ .................... 1 PAGZZ

34 53C22035-7 . RING, RETAINER /80049/.............................. 1 PAGZZ

35 53A22016 . BEARING, SECOND STAGE /80049/ ............ 1 PAGZZ

36 MS28775-335 . O-RING ........................................................... 1 PAGZZ

37 53C22069-5 . RING, BACKUP /98750/ ................................. 1 PAGZZ

38 53C22018 . RAM, THIRD STAGE /80049/......................... 1 XBGZZ

39 53C22035-8 . RING, RETAINER /80049/.............................. 1 PAGZZ

40 53A22017 . BEARING, THIRD STAGE /80049/ ................ 1 PAGZZ

Figure 3. Aircraft Axle Jack, Model A10-1HC, Part Number 53D22004 (Sheet 2)

INDEX

NO.

PART NUMBER DESCRIPTION

1 2 3 4 5 6 7

U N

IT

S

PE

R

AS

SY

U

SA

BL

E

O N

C O

D E

SM&R

CODE

41 MS28775-329 . O-RING ........................................................... 1 PAGZZ

42 53C22069-6 . RING, BACKUP /98750/ ................................. 1 PAGZZ

43 53A22041 . PLUNGER, EXTENSION SCREW

RETAINER /80049/

1 PAGZZ

44 53A22040 . SPRING, JACK EXTENSION SCREW

/80049/

1 PAGZZ

45 B-2908-40 . NAMEPLATE /00994/ ..................................... 1 PAGZZ

/ATTACHING PARTS/

46 MS21318-7 . SCREW........................................................... 4 PAGZZ

47 53A22164 . DECAL, AIR VENT /98750/ ............................ 1 PAGZZ

48 53022007 . BASE ASSEMBLY, JACK /30003/.................. 1 XAGZZ

TES 3-7 . REPAIR /30003/.............................................. 1 PAGZZ

Figure 3. Aircraft Axle Jack, Model A10-1HC, Part Number 53D22004 (Sheet 3)

NAVAIR 19-70-521 004 00

Change 1 - 1 May 2005 Page 1 of 16

OPERATION AND INTERMEDIATE MAINTENANCE

WITH ILLUSTRATED PARTS BREAKDOWN

AIRCRAFT AXLE JACK A5-1HC

PART NUMBER 53D22020

Reference Material

Title Publication No.

Ground Support Equipment Cleaning and Corrosion Control......................................................... NAVAIR 17-1-125 Jack Tester, Portable ................................................................................................................................. WP 028 00 Jack Tester, Stationary .............................................................................................................................. WP 029 00 Periodic Maintenance Requirements Manual .......................................................................NAVAIR 19-600-135-6-2 Preoperational Checklist .......................................................................................................NAVAIR 19-600-135-6-1 Surface Inspection Acceptance Standards for Metals, Class 2 ..................................... NAVSEA 0900-LP-003-8000 Welding and Casting Standard ...........................................................NAVSEA TECH PUB S9074-AR-GIB-010/278

Alphabetical Index

Subject Page No.

Description Illustrated Parts Breakdown Introduction

Leading Particulars Maintenance

Assembly Cleaning Disassembly Finish Inspection Lubrication Periodic Maintenance Repair Testing

Operation Instructions Lifting Lowering Preoperation

Preparation for Use, Storage or Shipment Preparation for Storage or Shipment Preparation for Use

Principles of Operation Troubleshooting

Record of Applicable Technical Directives

Type/No. Date Title and ECP No. Date Inc. Remarks

SEB 438

Rev. A

11-28-84 Aircraft Jacks, Stenciling and Marking of Maximum Extension Screw Lengths

12-01-89 –

1. INTRODUCTION.

2. This work package has been prepared as the basic operation and maintenance procedure for the 5-ton Hydraulic Aircraft Axle Jack, Model No. A5-1HC, Part No. 53D22020, hereafter referred to as the jack.

3. Procedures and data covered in this work package are intended for use by operation and maintenance personnel at organizational and intermediate levels.

4. LEADING PARTICULARS. Leading particulars of the jack are shown below.

Item Characteristics

Use Vertical Load Lift Rated Load 5 tons (10,000 Ibs) Maximum Allow. Load 5.5 tons (11,000 Ibs) Operating Force (at rated load) 75 pounds (approx.)

Operating Fluid Specifications MIL-PRF-83282 Hydraulic System Fluid Capacity 1.3 pt Pump Handle Length 18 in Hydraulic Lift (rams extended) 9 in Extension Screw (fully extended) 3 in Height Overall:

Collapsed 5.5 in Fully Extended 17.5 in Weight (with fluid) 26 lbs Width 3 in Length 11.375 in

5. DESCRIPTION.

6. The jack (Figure 1) is a portable, self-contained unit with a single speed, manually operated pump.

The lift consists of three rams and an extension screw, all encased within an outer cylinder which is integrated with the base. A rectangular tank is welded to the base, forming the fluid reservoir. The jack is used for vertical lifting of loads up to 5 tons (10,000 pounds). At the maximum allowable load of 5.5 tons (11,000 pounds) the hydraulic operating fluid is bypassed within the jack by an automatic valve and the jack will not continue to lift.

7. PRINCIPLES OF OPERATION.

8. The valve assembly is located beneath the pump actuating cylinder (Figure 2). The valve assembly contains a gravity check valve, a spring-loaded check valve and a safety bypass valve (4). On the upstroke the pump piston draws hydraulic fluid from the reservoir. The downstroke forces fluid under pressure through the spring-loaded check valve and into the base assembly cylinder and rams. This fluid pressure is retained by the spring-loaded check valve.

Pressure is released and the fluid returned to the reservoir by opening the release valve. The safety bypass valve is operative when load to the rams exceeds the maximum allowable load of 5.5 tons (10 percent greater than rated load).

9. PREPARATION FOR USE, STORAGE OR

SHIPMENT.

Materials Required

Nomenclature Specification or P/N

Fluid, Hydraulic MIL-PRF-83282 Oil, Lubricating MIL-PRF-7870

10. PREPARATION FOR USE.

a. If the jack is crated, uncrate and inspect for physical damage and missing parts.

Hydraulic Fluid, MIL-PRF-83282 1

b. Ensure that rams are fully collapsed prior to adding fluid. Fill reservoir to within 1/4 to 1/2 inch of filler hole with hydraulic fluid, MIL-PRF-83282.

c. Complete fluid change is required every three years, in accordance with NAVAIR 19-600-135-6-2.

004001

Figure 1. A5-1HC Aircraft Axle Jack

004002

Figure 2. A5-1HC Aircraft Axle Jack Flow Diagram

Change 1 Page 4

Damaged, defective or suspect parts shall be repaired or replaced before attempting to operate the jack. Defective parts or weak structural points may cause sudden jack failure and/or loss of lift load with potential danger or injury to personnel.

d. Perform preoperational check in accordance with NAVAIR 19-600-135-6-1.

11. PREPARATION FOR STORAGE OR SHIP-

MENT.

Lubricating Oil, MIL-PRF-7870 2

a. Apply a light film of lubricating oil to outer bearing surfaces of rams.

b. Fully collapse rams, close release valve, and close air vent screw.

c. Stow jack in a sheltered area. To prolong efficiency and useful life, use a water repellant cover.

Hydraulic Fluid, MIL-PRF-83282 1

d. For shipment, drain all hydraulic fluid from jack. Turn jack in to supply activity for packing.

12. OPERATION INSTRUCTIONS.

13. PREOPERATION. Perform preoperational check in accordance with NAVAIR 19-600-135-6-1.

14. LIFTING.

Do not attempt to lift loads exceeding 5 tons (10,000 Ibs) with this jack. Over-loading may result in lift failure and/or load loss hazard to personnel.

a. Close release valve fully, and unscrew air vent screw two turns.

b. Ensure jack rests on a firm and level foundation. If necessary, place a flat metal plate under the jack base to provide secure footing for the jack.

c. Operate jack handle to lift rams partially.

Do not attempt to unscrew extension screw more than 3 inches; an internal stop pin limits screw extension to prevent unstable load support and extension screw loss or damage. Forcible loosening of extension screw post beyond its internal stop pin will damage or shear the pin, necessitating extension screw removal and repair.

d. Position jack under load and, if necessary, partially unscrew extension screw to contact the load and to provide additional lift. Operate handle to lift rams to contact the load if maximum extension screw is insufficient.

If jack lifting stops before rams are fully extended, an overload is indicated. In this event use a jack with a greater capacity to lift the load.

e. After jack is firmly positioned under load, operate jack handle using long, smooth strokes until jack has lifted load.

15. LOWERING.

NOTE

Do not open release valve more than two complete turns when lowering.

a. Allow vent assembly air vent screw to remain open. Open release valve slowly, using slotted end of handle, until jack begins to lower. The rate of load descent is in proportion to the amount of release valve opening.

b. With release valve open, rams will lower load supports itself. Withdraw jack. Lower extension screw, and manually press rams until they are flush with base cylinder.

c. Fully close and tighten release valve. If jack is to be stowed, close air vent screw.

Table 1. Troubleshooting

Trouble Probable Cause Remedy

Rams (see fig. 3) fail to lift when jack is operated, or jack fails to lift rated load.

Release valve not closed or leaking.

Obstructed fluid suction passage.

Tighten release valve securely.

Disassemble jack. Blow passages clear with compressed air. Reassemble jack, flush and fill with clean fluid.

Low fluid level. Inspect and fill to correct fluid level if necessary.

Bypass valve improperly adjusted. Adjust bypass valve as directed by paragraph 31.

Broken bypass valve spring. Replace bypass valve. Test as directed by paragraph 31.

Rams will not fully elevate.

Low fluid level.

Leaking discharge valve.

Inspect and fill to correct fluid level. Refer to paragraph 10.b.

Remove valve assembly. Inspect ball and ball seating surfaces of valve body. Replace ball if defective; reseat if necessary.

Rams will not support load.

Defective packing. Worn rams. Remove rams. Replace rings, gaskets and packings. Inspect bearings and bushing for damaged grooving or uneven wear. Replace defective parts.

Leaking discharge or release valve.

Remove valve assembly. Inspect ball and ball seating surfaces of valve body. Replace ball if defective. Reseat if necessary.

Rams rise and fall each stroke.

Incomplete closure of release valve.

Leaking discharge or release valve.

Tighten release valve securely.

Remove valve assembly. Inspect ball and ball seating surfaces of valve body. Replace ball if defective. Reseat if necessary.

Pump inoperative or difficult to operate.

Vacuum created in reservoir due to closed vent assembly vent screw.

Unscrew air vent assembly two turns.

Pump operates, and fluid pressure fails to bypass at maximum ram extension or with overload applied.

Bypass improperly adjusted.

Defective bypass spring or ball.

Remove screw. Adjust screw as outlined in paragraph 31.

Remove screws, replace valve assembly.

Adjust screw as outlined in paragraph 31.

Rams will not lower. Loose retaining ring lodged beneath rams.

Relieve load with another jack. Remove rams.

Inspect and replace retaining rings if necessary.

Excessively worn rams or jammed. Relieve load with another jack. Remove, inspect and replace rams if necessary.

16. TROUBLESHOOTING.

17. To troubleshoot the jack in the event of abnormal operation or deterioration of performance refer to Table 1.

18. MAINTENANCE.

Support Equipment Required

Nomenclature Part Number

Caliper, Dial 0-6 in 120Z-6 Caliper, Micrometer 2-3 in GGG-C-105 Caliper, Micrometer 3-4 in MT-308 Caliper, Micrometer 4-5 in MT-310 Caliper, Micrometer 5-6 in 436FL Caliper, Micrometer 6-9 in 224B Caliper, Micrometer Inside 41C22

0.2-1 in Caliper, Micrometer Outside T230R

0-1 in Caliper, Micrometer Outside 1942V

1-2 in Gage, Depth 0-0.125 643J Gage, Depth, Micrometer 455B-6RL Portable Aircraft Jack Tester 67A96D101 Rod and Sleeve 1-2 in 241C22TYJCLB Rod and Sleeve 2-12 in 124B Stationary Aircraft Jack Tester 67A294C4-1/

1380AS100-1

Valve Seat Facing Tool —

Materials Required

Nomenclature Specification or P/N

Cleaning Compound, MIL-PRF-85570 Aircraft, Exterior Type II

Cloth, Aluminum Oxide, ANSI B74.18 Very Fine 320 Grit

Cloth, Lint-Free A-A-59323 Fluid, Hydraulic MIL-PRF-83282 Oil, Lubricating MIL-PRF-7870 Paint, Epoxy Polyamide MIL-PRF-85285, Black, Color No. 17038 Type II Paint, Epoxy Polyamide MIL-PRF-85285, Red Color No. 11105 Type II Paint, Epoxy Polyamide MIL-PRF-85285, White Color No. 17925 Type II Paint, Primer Epoxy MIL-PRF-85582

Polyamide Type I Spray, Dykem SP-1100

(Steel Blue Color) Tape, Masking SAE-AMS-T-23397

19. PERIODIC MAINTENANCE. For periodic maintenance, refer to NAVAIR 19-600-135-6-2.

20. Maintenance of the jack consists of disassembly, cleaning, inspection, repair, lubrication, assembly, testing and finishing.

21. During maintenance, the following apply:

a. Replace damaged or defective parts.

b. Replace the following parts if removed from installed position; cotter pins, retainer rings, o-rings, gaskets, backup rings, plunger and spring.

22. DISASSEMBLY.

Handle jack with care to avoid damaging critical, precision machined surfaces.

a. Place base of jack in drain pan.

b. Remove handle (1, Figure 3) and air vent assembly (2).

c. Remove adjusting valve plug screw (3) and gasket (4).

d. Remove release valve lock screw (5) and release valve (6).

e. Remove o-ring (7) and ball (8).

f. Remove plug (9), spring (10) and screen (11).

Hydraulic Fluid, MIL-PRF-83282 1

g. Thoroughly drain jack of hydraulic fluid.

h. Remove cotter pins (12) and pins (13 and 14).

i. Remove links (15) and rocker arm (16).

j. Remove pump piston (17) and packing nut (18).

k. Remove backup ring (19) and o-ring (20).

l. Unscrew and remove pump body (21) from base assembly (47).

m. Remove upper pump valve gasket (22).

NOTE

For service and repair do not disassemble valve assembly (23). Replace valve assembly as necessary for each service or repair action. If valve assembly is defective, it shall be replaced as an entire unit. The new installed valve assembly shall be tested and adjusted as outlined in paragraph 31.

n. Screw a 1-1/2 inch long 1/4-20 UNC-2A screw into threaded hole atop valve assembly (23).

Lift valve assembly (23) from hole in base assembly (47). Remove lower valve gasket (22).

o. Remove cylinder bushing (24) and retainer ring (25).

p. Unscrew extension screw (26). Grasp extension screw and lift ram installation (27 through

44) as a unit from cylinder and base (47). Telescope ram components to “inside out” position to facility disassembly.

q. Remove first stage ram (27) and retainer ring (28).

NOTE

Tap lightly with a soft head mallet at inner bearing circumference to facilitate removal of bearings (29, 35, and 40).

r. Remove first stage bearing (29).

s. Remove o-ring (30) and backup ring (31).

t. Remove retainer ring (32) and second stage ram (33).

u. Remove retainer ring (34) and second stage bearing (35).

v. Remove o-ring (36) and backup ring (37).

w. Remove third stage ram (38) and retainer ring (39).

x. Remove third stage bearing (40); o-ring (41) and backup ring (42).

y. Do not remove extension screw (26) from third stage ram (38) unless screw or ram is damaged.

Forcible extension screw removal will damage or shear plunger (43).

z. If damaged necessitates removal of extension screw, proceed as follows:

NOTE

If extension screw is removed, a new plunger (43) and spring (44) shall be installed in extension screw (26) prior to assembling extension screw into third stage ram (38).

(1) Using wood blocks to protect outer ram surfaces, carefully clamp third stage ram (38) in a vise.

(2) Unscrew and extend extension screw (26) until plunger (43) engages. Forcibly unscrew and remove extension screw (26), plunger (43) and spring (44).

aa. If necessary remove screws (46) and nameplate (45).

ab. If necessary remove decal (48) from base assembly (47).

23. CLEANING.

a. Periodic cleaning shall be conducted in accordance with NAVAIR 19-600-135-6-2.

Maintenance operation shall be performed in a clean shop environment.

Wear goggles and gloves. Cleaning compound is a skin and eye irritant. If cleaning compound is splashed on bare skin or in eyes, rinse thoroughly with fresh water.

Use care to avoid introduction of solvents, cleaning agents or other contaminants into hydraulic system. Cleaning agents may cause deterioration of o-rings and seal.

b. Each disassembled metal part of the jack shall be cleaned with MIL-PRF-85570, type II, cleaning solution, thoroughly rinsed with clean water, and then thoroughly dried before reassembly. Use low pressure compressed air to blow out all passages in the base and intake screen.

c. Use lint-free cloth to wipe the parts after they have been cleaned. Do not permit lint or dirt to become lodged in any of the valves or oil passages.

24. INSPECTION. Inspect all parts for damage, distortion, corrosion and other faults as outlined in Table 2. Wear tolerances are contained in Table 3.

Table 2. Inspection

Pins Figure/Index No. Inspect For

(Figure 3) Pins 13 and 14 Grooving Links 15 Out-of-round holes.

Arm 16 Out-of-round holes.

Piston 17 Grooving and scoring; out-of-round hole.

Nut, Packing 18 Grooving and scoring at ID; condition of threads Body Pump 21 Grooving and scoring at ID; condition of threads.

Ball 8 Nicks, grooves and flat spots.

Spring 10 Cracks, free length of 1-1/2 inch.

Screen 11 Breaks in wire mesh, buckling, loosen ends.

Bushing 24 Grooves, scoring, gouges, condition of threads.

Rams 27, 33 & 38 Grooves, scoring, and cracks. For cracks, use magnetic particle inspection (MIL-STD-1949).

Bearings 29, 35 & 40 Grooves and scoring.

Screw 26 Cracks (as outlined for rams), condition of threads.

Base Assembly 47 Cracks (as outlined for rams), grooves and scoring at cylinder ID. Condition of threads. Nicks and scratches on ball seat.

Table 3. Wear Tolerance

Part and Index No.

(Figure 3)

Description Tolerance (inches) Max Min

Piston (17) Minor diameter --- 0.496

Nut (18) ID 0.507 ---

Body (21) Minor ID 0.502 ---

Bushing (24) ID 2.518 ---

Ram (27) Outer wear surface diameter --- 2.509

Major inner wear surface diameter 2.117 ---

Minor inner wear surface diameter 2.017 ---

Bearing (29) OD --- 2.606

Ram (33) Outer wear surface diameter --- 2.008

Major inner wear surface diameter 1.617 ---

Minor inner wear surface diameter 1.519 ---

Bearing (35) OD --- 2.106

Ram (38) Outer wear surface diameter --- 1.510

Base assembly (47) Cylinder wear surface ID 2.617 ---

25. REPAIR.

a. Defective ball seat in base assembly (47) shall be refaced using a valve seat-facing tool.

b. Using a brass dowel, a mallet and a ball of the same size used with seat being refaced, form a new seat by tapping lightly on seated ball until a 1/64 inch wide seat is formed.

c. Discard ball used for seating operation.

Wear goggles and gloves. Cleaning compound is a skin and eye irritant. If cleaning compound is splashed on bare skin or in eyes, rinse thoroughly with fresh water.

d. Wash refaced seat with MIL-PRF-85570, type II, cleaning solution. Rinse thoroughly with clean water. Dry thoroughly with low-pressure compressed air.

e. Install a new ball of proper size at each refaced seat.

26. Welding.

All welding must be performed in a well-ventilated area. All closed spaces within the jack shall be certified gas free prior to welding. Personnel injury can occur.

a. Non-critical structural areas of the base assembly may be welded. Ensure that machined areas will be unaffected by the welding. Cracks or breaks at cylindrical machined surfaces require replacement of base assembly. Before welding any portion of base assembly, wash with water and liquid detergent, flush and thoroughly drain.

b. Welding repairs shall be in accordance with

NAVSEA TECH PUB S9074-AR-GIB-010/278.

Replace all…