Jack Tester Info.PDF

TO 33AA14-2-11

TECHNICAL MANUAL

WORK PACKAGE

OPERATION AND MAINTENANCE WITH ILLUSTRATED PARTS

BREAKDOWN

UNIVERSAL JACK TESTER

NSN 1730-01-329-6355

PN 7186-010

SUNBELT DESIGN & DEVELOPMENT INC.

FA8532-12-C-0018

This manual supersedes TO 33AA14-2-11, dated 2 August 2013, Change 1 dated 25 February 2015.

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government Agencies and their contractors (Administrative or Operational Use) (2 August 2013). Other requests for this document shall be referred to 406 SCMS/GUEE, Robins AFB, GA 31098. Questions concerning technical content shall be referred to AFLCMC/WNZABA.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of contents or reconstruction of the document.

Published Under Authority of the Secretary of the Air Force

20 FEBRUARY 2016

Dates of issue for original and changed pages are:

Original. . . . . . . .0 . . . . 20 February 2016

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 104, CONSISTING OF THE FOLLOWING:

Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

Title A i ii Blank iii - vii viii Blank

TO 33AA14-2-11

LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

NOTE The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.

* Zero in this column indicates an original page.

A USAF

NUMERICAL INDEX OF EFFECTIVE WORK PACKAGES

NOTE

Only those work packages and subordinate work packages assigned to this manual are listed in this index, therefore WP/SWP numbers may not be sequential.

WP/SWP

No.

Change No.

Model Application Title

001 00 0 Alphabetical Index 002 00 0 Foreword 003 00 0 Master List of Special Tools, Test Equipment, and Consumables 004 00 0 Preparation for Use and Shipment 005 00 0 Operation 006 00 0 Testing and Troubleshooting 007 00 0 Maintenance 008 00 0 Diagrams 998 00 0 Illustrated Parts Breakdown i/(ii blank)

SAFETY SUMMARY

1 GENERAL SAFETY INSTRUCTIONS.

This manual describes physical and chemical processes which may cause injury or death to personnel, or damage to equipment if not properly followed. This safety summary includes general safety precautions and instructions that must be understood and applied during operation and maintenance to ensure personnel safety and protection of equipment. Prior to performing any task, the WARNINGs, CAUTIONs, and NOTEs included in that task shall be reviewed and understood.

2 WARNINGS, CAUTIONS AND NOTES.

WARNINGS and CAUTIONS are used in this manual to highlight operating or maintenance procedures, practices, condi-tions or statements which are considered essential to protection of personnel (WARNING) or equipment (CAUTION).

WARNINGS and CAUTIONS immediately precede the step or procedure to which they apply. NOTES are used in this manual to highlight operating or maintenance procedures, practices, conditions or statements which are not essential to protection of personnel or equipment. NOTES may precede or follow the step or procedure, depending on the information to be highlighted. The headings used and their definitions are as follows:

A WARNING appears in this form for an operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed, could result in injury to or death of personnel.

A CAUTION appears in this form for an operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed, could result in damage to or destruction of the equipment.

NOTE

A NOTE appears to provide important information about the equipment or a maintenance or operating procedure.

3 HAZARDOUS MATERIALS WARNINGS..

Hazardous Materials Warnings in this manual are provided through use of the Hazard Symbols listed below. Consult the HAZARDOUS MATERIALS DESCRIPTION below or Safety Data Sheets (SDS) (Occupational Safety and Health Admin-istration (OSHA) Form 20 or equivalent) for specific information on hazards, effects, and protective equipment requirements.

If you do not have an SDS for the material involved, contact your supervisor, or the base Safety or Bioenvironmental Engineering Offices.

3.1 Hazardous Materials Icons. The following icons are used throughout Air Force technical manuals to indicate the use of hazardous materials:

The abstract symbol shows a material that may contain bacteria or viruses that present a health hazard.

The symbol of drops of a liquid burning a hand shows a material that causes burns to human skin or tissue.

iii

The rapidly expanding symbol shows that the material may explode if subjected to high tem-perature, sources of ignition, or high pressure.

The symbol of a person wearing goggles shows a material that can injure your eyes.

The symbol of a fire shows that a material can ignite and burn you.

The symbol of a skull and crossbones shows a material that is highly toxic and can be a dan-ger to life and health.

The symbol of three circular wedges shows that the material emits radioactive energy and can injure human tissue or organs.

The symbol of a human figure in a cloud shows that breathing this material can present a health hazard.

3.2 Hazardous Materials Description. The following detailed HAZMAT warnings pertain to materials or substances used in connection with procedures called out or described in this technical manual. Use these advisory warnings and their associated precautions in conjunction with the current SDS for each material or substance. If there is conflict between this safety summary and the SDS, the SDS takes precedence.

OIL, MACHINE, TBP 1

Machine Oil, TBP, is a skin and eye irritant. Store away from heat, sparks, and other ignition sources. Provide local exhaust ventilation. Protection: organic vapor mask, oil-resistant gloves, splash-proof goggles or face shield, chemical resistant apron.

OIL, LUBRIPLATE BAR AND CHAIN, PN 10-R 2

Lubriplate Bar and Chain Oil, PN 10-R, is a skin, eye, and lung irritant. May be harmful if swallowed. Avoid heat, flames, sparks and other sources of ignition. Avoid contact with strong oxidants like liquid chlorine, concentrated oxygen. Provide local exhaust ventilation system. Ensure compliance with applicable exposure limits. Protection: splash-proof chemical goggles, nitrile gloves, chemical resistant clothing, self-contained breathing apparatus, adequate masks and filters.

LUBRICANT, MOLYDISULPHIDE, MIL-L-24478 OR EQUIVALENT 3

Molydisulphide Lubricant, MIL-L-24478 or equivalent, is a skin and eye irritant. Dust or vapors may be irritating to nose and throat if inhaled. May be harmful if swallowed. Keep away from heat, sparks, and open flame. Use adequate ventilation.

Empty containers containing residue may cause a hazard. Avoid contact with eyes, skin and clothing. Observe all safety precautions. Avoid breathing vapors or mists. Ground all containers during transfer. Wash thoroughly after using, particularly iv before eating or smoking. Store away from all sources of heat and ignition. Store in a cool and well ventilated area. Keep out of direct sunlight. Keep container closed. Store at ambient temperatures. Store away from oxidizers. Protection: impervious gloves, NIOSH-approved air-supplied respirator, splash-proof chemical goggles, protective clothing.

GREASE, PN 6283 4

Grease, PN 6283, is a skin and eye irritant. Risk of serious damage of eyes. Contain spills and absorb with an inert material.

Collect. Dispose of contaminated product via an approved chemical waste disposal firm and in accordance with all federal, state and local regulations. Wear a face shield and avoid all skin contact. Handle an open container with care. Store in a tightly sealed container. Store in a cool and well-ventilated area. Protection: suitable gloves, face shield, protective clothing.

SOLVENT, DRY CLEANING, MIL-PRF-680, TYPE II OR III 5

Dry cleaning solvent, MIL-PRF-680, Type II or III, is toxic and flammable. Avoid contact with skin and eyes. Avoid breathing vapors. Use with adequate ventilation. Keep away from heat, sparks, and flame. Avoid contact with strong oxidizing agents. Protection: butyl gloves and chemical goggles; faceshield and protective clothing is required when splash-ing is possible or expected; half-mask respirator with organic vapor cartridge is required in poorly ventilated areas.

4 SAFETY PRECAUTIONS.

The following are general safety precautions that are not related to any specific procedures and therefore do not appear elsewhere in this manual. These are recommended precautions that personnel must understand and apply during all phases of operation and maintenance to ensure personal safety and health and the protection of Air Force property.

• Keep Away From Live Circuits. Operating personnel must observe all safety regulations at all times. Do not replace components or make adjustments inside equipment with the electrical supply turned on. Under certain conditions, danger may exist even when the power control is in the off position due to charges ground a circuit before touching

it. Adhere to all lock out/tag out requirements.

• Resuscitation. Personnel working with or near dangerous voltage shall be trained in modern methods of resuscita-tion. Information and training sources may be obtained from the Director of Base Medical Services.

• Finger Rings/Jewelry. Finger rings have caused many serious injuries. Remove rings, watches and other metallic objects which may cause shock or burn hazards. Unless specifically allowed by shop safety procedures, remove finger rings during all maintenance activity.

• Compressed Air. Use of compressed air can create an environment of propelled particles. Do not direct air streams towards self or other personnel. Air pressure shall be reduced to less than 30 Poundforce per Square Inch, Gauge (PSIG) and used with effective chip guarding and personal protective equipment.

• Dangerous Pressures. Care must be taken during testing to ensure that all test connections are proper and tight. All system components must be compatible with pressure applied. Personnel must be protected by a safety shield or located at a distance sufficient to prevent injury.

• Personal Protective Equipment (PPE). If unique local conditions make compliance with the protective clothing or other occupational health requirements specified in this manual unnecessary or impractical, obtain an evaluation of the operation from the Bioenvironmental Engineer. The Bioenvironmental Engineer and Base Safety Office will determine the required precautions.

• Cleaners/Chemicals/Paints/Primers. Some cleaners, chemicals, paints, and primers are toxic and produce adverse effects on skin, eyes, and respiratory tract. Therefore, to preclude or minimize potential exposure, follow manufac-turer’s Warning Labels; Material Safety Data Sheets (MSDS) instructions for proper handling, storage, and dis-v posal; and current safety directives. Use only in authorized areas. Unless otherwise indicated in the text, use as described in this TO should not result in any immediate health concerns. Consult the local Bioenvironmental Engineer and Base Safety Office for specific protection equipment and ventilation requirements.

• Electrostatic Discharge Sensitive (ESDS). ESDS is applied to low power solid state parts which could be damaged or destroyed when exposed to discharges of static electricity. Maintenance personnel are often not aware that the ESDS parts have been damaged or destroyed because electrostatic discharges at levels less than 4,000 volts cannot be seen, felt, or heard. Maintenance procedures identified by the ESDS symbol shall be in accordance with TO 00-25-234 to prevent damage to or destruction of ESDS parts. When the ESDS symbol appears between a paragraph number and paragraph title the entire paragraph and all subparagraphs shall be considered ESD sensitive.

When the ESDS symbol appears between a step number and the step text, the step shall be considered ESD sensitive.

• Spring-Loaded Mechanism. A spring-loaded mechanism can cause injury if released in an uncontrolled manner.

Always take extra care when disassembling this type of mechanism.

• Do Not Service or Adjust Alone. Do not attempt internal service or adjustment of equipment unless another person capable of rendering aid and resuscitation is present.

• Lifting/Handling. The electric chain hoist weighs 136 pounds. The beam assembly and other universal jack tester components have significant weight. Use adequate number of personnel or appropriately rated lifting and handling devices to move equipment.

• Lockout/Tagout. Personnel shall be aware of the hazards associated with unguarded machinery parts, capacitors, gaseous and wet pipe systems, spring loaded devices, etc. Lockout/tagout the energy source prior to performing maintenance, adjustments, or other procedures that would bypass safety guards, barriers, or otherwise expose personnel to hazardous energy sources. Any equipment, machine, or process that could unexpectedly energize, start-up, or release energy will be equipped with a means to lockout/tagout the energy source(s).

• Cleaning Solvent. Cleaning solvent is toxic to skin, eyes, and respiratory tract. Skin and eye protection are required.

Avoid repeated or prolonged contact. Good general ventilation is normally adequate. Observe manufacturers warn-ing labels; Material Safety Data Sheets (MSDS) instructions for proper handling, storage, and disposal; and current safety directives.

• Spilled Hydraulic Fluid. Spilled hydraulic fluid can cause personnel to slip and fall. Clean up all hydraulic fluid spills immediately. Dispose of hydraulic fluid in accordance with local regulations.

• Do Not Place Tools on Support. Do not place tools or other objects on the top column support. Do not allow persons to sit on, stand on, or hang from the top column support. Such actions can result in personnel injury.

• Do Not Place Tools on Beam. Do not place tools or other objects on the beam assembly during lifting or lowering.

Do not allow persons to sit on, stand on, hang from, or interfere with the beam assembly during lifting or lowering.

Such actions can result in personnel injury. Ensure personnel and obstacles are clear of the beam assembly and load chain during lifting or lowering.

• Worn Load Chain. A worn load chain can break without giving an indication of failure, causing injury to personnel.

Measure chain wear periodically in accordance with instructions in this TO. Dispose of worn load chain by cutting into small pieces. Do not use worn load chain for other tasks.

• Cutting Load Chain. Cutting the load chain can cause flying particles. Make sure you wear eye protection. Put a shield over the chain to prevent flying particles.

• Disconnect Main Power. Always disconnect/deenergize the main power supply from the electric chain hoist before attempting any maintenance or repair procedures, or working with the hoist electrical connections. Failure to do so can result in severe electrical shock.

• Power Supply Rating. Ensure the electrical power supply is the correct rating as specified in this TO. An improper electrical power supply can cause damage to the hoist and may result in a fire.

vi

• Approved Lubricants. Use only approved lubricants for the hoist and load chain. Other lubricants are inadequate and can cause failure of hoist components, resulting in personnel injury and damage to equipment. Do not lubricate the load chain with used motor oil. Used motor oil can contain unknown carcinogenic materials, causing long-term health hazards to personnel.

• Operator Training. Operators must be trained in general hoisting/rigging procedures before performing any opera-tion or maintenance on the universal jack tester. Operators must be familiar with all controls, indicators, and component parts of the equipment and all Warnings and Cautions before performing any operation or maintenance on the universal jack tester.

• Load Chain Tension. You must always permit the load chain to be loose in the area between the liftwheel and the loose end. If the load chain is tight in this area, it can cause a failure of the hoist, resulting in injury to personnel and/or damage to equipment.

• Approved Replacement Parts. Do not use replacement parts for the hoist that are not listed in the Illustrated Parts List. Use of substitute parts that are not approved can cause failure of the hoist, resulting in severe injury to personnel and/or damage to equipment.

• Load Chain Connection. Do not connect the hoist/load chain to loads other than the beam assembly. Doing so can cause failure of the hoist and/or load chain, resulting in personnel injury and damage to equipment.

• Load Chain Runout. The loose end of the load chain is not connected to the hoist. Do not allow the loose end of the load chain to run out of the hoist by accident. Doing this can cause injury to persons or damage to equipment. Make sure the lower limit switch is set correctly to prevent this problem.

• Limit Switch Setting. Do not permit the hook block to hit the hoist or the chain bucket as this will damage these components. Make sure the upper limit switch is set correctly to prevent this problem.

• Avoid Damage to Parts. Handle equipment carefully to avoid damage to threads and sealing surfaces. Do not tighten vise or place wrench on other than wrench flats. Damage to unit may result.

• Head Protection. Head protection must be used during inspection, operation, adjustment, and maintenance of this unit. Failure to do so can result in serious injury or death.

• Dangerous voltages are present at system connectors. Ensure power is OFF prior to connecting or disconnecting cables.

• Do not wear metal frame glasses, rings, watches, or other metal jewelry while working on electronic equipment.

• Some cleaning materials specified herein are flammable and/or toxic. Keep away from open flame or other ignition sources. Provide adequate ventilation and avoid skin/eye exposure.

• Cleaning with compressed air can create airborne particles that may enter eyes or penetrate skin. Pressure shall not exceed 30 PSIG. Wear goggles. Do not direct compressed air against skin.

vii/(viii blank)

WORK PACKAGE

ALPHABETICAL INDEX

UNIVERSAL JACK TESTER

EFFECTIVITY: ALL

LIST OF EFFECTIVE WP PAGES

Total Number of Pages in this WP is 2 consisting of the following:

* Zero in this column indicates an original page.

Page *Change Page *Change Page *Change No. No. No. No. No. No.

1. . . . . . . . . . . . . . . . . . . . . . . . . 0 2 Blank

ALPHABETICAL INDEX OF EFFECTIVE WORK PACKAGES

NOTE

Only those work packages and subordinate work packages assigned to this manual are listed in this index.

Subject WP/SWP

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 001 00 DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 008 00 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 002 00 ILLUSTRATED PARTS BREAKDOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 998 00 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 007 00 MASTER LIST OF SPECIAL TOOLS, TEST EQUIPMENT AND CONSUMABLES . . . . . . . . . . . . . . . . . . 003 00 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 005 00 PREPARATION FOR USE AND SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 004 00 TESTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 006 00

TO 33AA14-2-11

WP 001 00

1/(2 blank)

FOREWORD

UNIVERSAL JACK TESTER

EFFECTIVITY: ALL

LIST OF EFFECTIVE WP PAGES

Total Number of Pages in this WP is 8 consisting of the following:

* Zero in this column indicates an original page.

Page *Change Page *Change Page *Change No. No. No. No. No. No.

1 - 8

TABLE OF CONTENTS

Paragraph Page

1 ABBREVIATIONS

2 RELATED PUBLICATIONS

3 PURPOSE

4 SCOPE

5 MANUAL STRUCTURE

6 WORK PACKAGE BREAKDOWN

7 LOCATING INFORMATION

8 LEADING PARTICULARS

9 MAINTENANCE CONCEPT

10 GENERAL INFORMATION

10.1 Purpose

10.2 System

10.3 Control Box

10.4 Electric Chain Hoist

LIST OF ILLUSTRATIONS

Number PageTitle

1 Universal Jack Tester 2 Control Box 3 Electric Chain Hoist

TO 33AA14-2-11

WP 002 00

LIST OF TABLES

Number PageTitle

1 Leading Particulars

TO 33AA14-2-11

1 ABBREVIATIONS.

All abbreviations used in this manual are in accordance with ASME Y14.38, Abbreviations and Acronyms for Use on Drawings and Related Documents:

AF Air Force AFTO Air Force Technical Order AP Attaching Parts AR As Required ASSY Assembly AWG American Wire Gage AWS American Welding Society CAGE Commercial and Government Entity CFE Contractor Furnished Equipment DLA Defense Logistics Agency DoD Department of Defense ESDS Electrostatic Discharge Sensitive GFE Government Furnished Equipment Hz Hertz IPB Illustrated Parts Breakdown MPL Maintenance Parts List NHA Next Higher Assembly NI Numerical Index NOVRAM Non-Volatile Random Access Memory PN Part Number PSI Poundforce per Square Inch PSIG Poundforce per Square Inch, Gauge RDI Reference Designator Index REF Reference SDS Safety Data Sheets SMR Source, Maintenance, and Recoverability SWP Subordinate Work Package TO Technical Order UOC Usable on Code VIN Value of the Input Voltage VAC Volts Alternating Current VREF Value of the Reference Voltage WP Work Package

2 RELATED PUBLICATIONS.

NOTE

When searching technical order (TO) numbers in the Enhanced Technical Information Management System (ETIMS) catalog, please use the wildcard (*) after typing in the TO number. Many TOs are not available in paper format, (i.e., digital (WA-1) or Compact Disk (CD-1)). This ensures TOs in all media formats will populate the search.

The following publications, contain information in support of this technical manual.

TO 33AA14-2-11

List of Related Publications

Number Title AFOSH 91-501 Air Force Occupational Safety and Health Standards AWS D1.1 American Welding Society (AWS) Structural Welding Code - Steel MIL-STD-2073-1 DOD Standard Practice for Military Packaging MIL-STD-129 Military Marking for Shipment and Storage MIL-STD-162 Materials Handling Equipment: Preparation for Shipment, Storage, Cyclic Mainte-nance, Routine Testing and Processing MIL-STD-281 Automobiles, Trucks, Truck-Tractors, Trailers and Trailer TO 00-25-234 General Shop Practice Requirements for the Repair, Maintenance, and Test of Elec-tronic Equipment Dollies; Preservation and Packaging of TO 35-1-3 Painting and Marking of USAF Aerospace Ground Support Equipment

3 PURPOSE.

The Universal Jack Tester, part number 7186-010, hereafter referred to as the Jack Tester, is made by Sunbelt Design & Development Inc. of San Antonio, TX, Commercial and Government Entity (CAGE) Code 0FC01. This manual and its accompanying Illustrated Parts Breakdown (IPB) are applicable to the Jack Tester.

4 SCOPE.

This manual is intended for use by operator, support and intermediate depot maintenance personnel in the operation, maintenance, and repair of the Jack Tester.

5 MANUAL STRUCTURE.

Work Package manuals are divided into Work Package (WPs) and Subordinate Work Packages (SWPs) (when used). Each WP is an independent, task-oriented unit. Only essential information is provided. WPs cover the subjects of alphabetical index, foreword, packaging and shipping, necessary tools, operating instructions, maintenance instructions, a troubleshooting guide and an illustrated parts breakdown.

6 WORK PACKAGE BREAKDOWN.

The work packages are arranged to establish a complete progressive program of operation and maintenance of the Jack Tester. The Alphabetical Index (WP 001 00) provides a complete list of all WPs and SWPs.

7 LOCATING INFORMATION.

The Numerical Index of Effective Work Packages lists in numerical order all WPs and SWPs contained in this manual and provides the model application for each WP/SWP. The Alphabetical Index WP lists in alphabetical order all WPs and SWPs contained in this manual. Each WP/SWP contains a table of contents which lists all procedures contained in that WP/SWP.

References to paragraphs, tables, or figures within a WP are made by number. For example: Paragraph 7, Table 2 or Figure

3. A reference to another WP merely includes the WP or SWP number: WP 998 00 or SWP 006 01. To find a particular procedure or topic, it is necessary to refer to that WP or SWP.

8 LEADING PARTICULARS.

Table 1 lists the leading particulars, main features, and technical characteristics of the jack tester.

Table 1. Leading Particulars

Data Description Height 245 inches Foundation width 168 inches

TO 33AA14-2-11

Table 1. Leading Particulars - Continued

Data Description Foundation length 180 inches Upper limit of load cell travel 157.46 - 161.46 inches above ground level Lower limit of load cell travel 7.46 - 9.46 inches above ground level Weights:

Beam Assembly 3000 lbs.

Column 1200 lbs.

Top Column Support 300 lbs.

Load Cell 130 lbs.

Hoist:

Electrical power requirements 115 VAC, single phase, 50/60 Hertz (Hz) Lifting capacity 2 tons Weight 136 lbs.

Lifting speed 8 feet per minute Motor rating 1 horsepower

9 MAINTENANCE CONCEPT.

The information provided in this manual covers both equipment operation and maintenance procedures. Operating proce-dures are intended for the daily operation of the equipment by the end user. Maintenance procedures are written for qualified maintenance personnel in the accomplishment of scheduled and unscheduled maintenance.

10 GENERAL INFORMATION.

10.1 Purpose. The jack tester is a permanently installed fixture used for the static testing of jacks with a lift capacity of 75 tons.

10.2 System.

Only use the ladder to climb on the unit. Never climb on the ladder without using a safety harness that meets AFOSH 91-501 requirements. Failure to comply could result in injury or death to personnel.

The jack tester (Figure 1) has two vertical columns connected together by top column support and installed into a bottom column support in the foundation. The top column support holds a hoist which is connected to the beam assembly. A control box contains electrical controls and indicators for the hoist. A chain bucket is attached to the side of the hoist and contains the load chain when the main beam is raised. A hook block assembly is mounted to the lifting chain. A load cell is installed on the underside of the beam assembly. The beam assembly is locked in place by two pairs of lock pins. A ladder is installed on each column to permit access to the hoist to engage and disengage the lock pins of the beam assembly. The ladder is connected to the column by brackets. A notch rail is attached to each ladder. A sliding sleeve is installed on the notch rail to attach a safety harness that meets AFOSH 91-501 requirements.

TO 33AA14-2-11

Figure 1. Universal Jack Tester

10.3 Control Box. The control box (Figure 2) consists of a metal case which houses controls and indicators. Main control box components include an LED display, printed circuit boards, a transformer, terminal blocks, and switches.

10.4 Electric Chain Hoist. The electric chain hoist (Figure 3) consists of a motor housing, gear housing, backframe, and associated covers. The motor housing contains a rotor, stator, and end bell on one side. The rotor connects to a liftwheel and chain guides on the other side of the motor housing. The liftwheel connects to a series of gears through a hole in the gear case. The backframe contains a limit switch and electric brake. Covers are removable for maintenance. A swivel hook suspension provides attachment to the top support. Lifting capacity of the hoist is two tons.

Figure 2. Control Box

TO 33AA14-2-11

Figure 3. Electric Chain Hoist

MASTER LIST OF SPECIAL TOOLS, TEST EQUIPMENT, AND

CONSUMABLES

UNIVERSAL JACK TESTER

EFFECTIVITY: ALL

LIST OF EFFECTIVE WP PAGES

Total Number of Pages in this WP is 2 consisting of the following:

* Zero in this column indicates an original page.

Page *Change Page *Change Page *Change No. No. No. No. No. No.

1 - 2

TABLE OF CONTENTS

Paragraph Page

1 INTRODUCTION

2 SPECIAL TOOLS

3 TEST EQUIPMENT

4 EXPENDABLE ITEMS AND CONSUMABLE MATERIALS

LIST OF TABLES

Number PageTitle

1 Master List of Special Tools 2 Master List of Test Equipment 3 Master List of Consumable Materials

1 INTRODUCTION.

This work package contains the Master List of Special Tools, Test Equipment, and Consumables used on the Universal Jack Tester.

2 SPECIAL TOOLS.

No special tools (Table 1) are required.

TO 33AA14-2-11

WP 003 00

Table 1. Master List of Special Tools

Part No./Specification No./NSN

CAGE

Code

Figure/ Index No. Nomenclature Use

None

3 TEST EQUIPMENT.

Equipment that may be necessary for maintenance or assembly/disassembly of the jack tester is listed in Table 2. Equivalent substitutes may be used.

Table 2. Master List of Test Equipment

Part No./Specification No./NSN

CAGE

Code

Figure/ Index No. Nomenclature Use

None None None Overhead Hoist, 2 ton capacity or crane

Assembly/Disassembly

None None None Stand, B-17, B-4 Assembly/Disassembly

None None None Jack (any type) Calibration set up

4 EXPENDABLE ITEMS AND CONSUMABLE MATERIALS.

Refer to Table 3 for consumable materials and expendable items necessary for maintenance.

Table 3. Master List of Consumable Materials

Nomenclature Specifications/ Part No./NSN

CAGE

Code Use Reference

Brush, soft bristle None None Cleaning Paragraph 3.8

Cleaning solvent None 81349 None Paragraph 3.8

Cloth, low lint None 81349 None Paragraph 3.8

Container, 5 gal. None None Catch fluids None

Grease 6V084 None Paragraph 3.3.2.5

Lubricant, Molydisul-phide

81349 None Paragraph 3.3.2.3

Oil, Lubriplate bar and chain

73219 None Table 1

Oil, machine 81349 None Table 1

Silicone 81349 None Paragraph 3.5

TO 33AA14-2-11

WP 003 00

TECHNICAL PROCEDURES

UNIVERSAL JACK TESTER

PREPARATION FOR USE AND SHIPMENT

EFFECTIVITY: ALL

LIST OF EFFECTIVE WP PAGES

Total Number of Pages in this WP is 10 consisting of the following:

* Zero in this column indicates an original page.

Page *Change Page *Change Page *Change No. No. No. No. No. No.

1 - 10

TABLE OF CONTENTS

Paragraph Page

1 INTRODUCTION

2 PREPARATION FOR USE

2.1 Foundation Installation

2.2 Initial Setup

2.3 Wiring/Power Connections

2.4 Hoist Test/Beam Hookup

2.5 Preoperational Inspection

3 PREPARATION FOR SHIPMENT

LIST OF ILLUSTRATIONS

Number PageTitle

1 Fabrication Detail for the Foundation 2 Correct Orientation of Load Cell

LIST OF TABLES

Number PageTitle

1 Foundation Materials 2 Preoperational Inspection

TO 33AA14-2-11

WP 004 00

REFERENCE MATERIAL REQUIRED

Publication Number Publication Title

AWS D1.1 American Welding Society (AWS) Structural Welding Code - Steel

MIL-STD-162 Materials Handling Equipment: Preparation for Shipment, Storage, Cyclic Maintenance, Routine Testing and Processing

MIL-STD-281 Automobiles, Trucks, Truck-Tractors, Trailers and Trailer Dollies; Preser-vation and Packaging of

APPLICABLE TCTOs

NONE

CONSUMABLE MATERIALS

NONE

APPLICABLE SUPPORT EQUIPMENT

Part Number Nomenclature CAGE Code

- Overhead Hoist, 2 ton capacity or crane -

1 INTRODUCTION.

This work package contains instruction for use and shipment of the jack tester.

2 PREPARATION FOR USE.

2.1 Foundation Installation. Install the foundation for the jack tester as follows:

NOTE

• Foundation installation instructions (Figure 1) in this manual are typical of most installations. Drawing number 7186-F provides foundation instructions and may be requested from 642 CBSG/GBEA, Robins AFB, GA 31098.

• The jack tester cannot be installed if the ceiling height is less than the minimum specified below.

a. If the jack tester will be located indoors, you must calculate the ceiling height necessary to permit installation. The minimum height necessary is 23 feet plus the height of the lifting device used to install the components into the foundation. This height is not sufficient to permit installation of pre-assembled columns and top column support, but will permit installation of each part separately. More time is necessary to install components with this procedure.

Pre-assembled columns and top column support may be installed if the available ceiling height is 25 feet plus the height of the hoist.

TO 33AA14-2-11

Figure 1. Fabrication Detail for the Foundation

The foundation drawing shown in Figure 1 is typical of most installations, but soil and topographical conditions at each location are different. It may be necessary to change the configuration of the foundation drawing to adjust to local conditions.

b. Minimum soil bearing pressure for the foundation is 1,500 pounds per square foot. If the soil conditions do not permit this pressure, then the foundation design must be changed. A civil engineer must adapt the design to adjust to local conditions.

c. The materials necessary to make the foundation are found in Table 1.

Table 1. Foundation Materials

Nomenclature Part Number/Size Specification CAGE Code Angle, structural steel 4x4x3/8, x 160 inches long ASTM A36 81346 Angle, structural steel 4x4x3/8, x 180 inches long ASTM A36 81346 Bolt, carriage MS35751-139 NASM35751 80205 Concrete, Portland cement mix 3,000 pounds per square inch minimum - - Rebar, concrete reinforcing Size 8, grade 60 ASTM A615 81346 Support 7186-3 - 0FC01

d. To make the foundation, follow these instructions:

(1) Prepare the foundation area by removing material from a space 180 inches long x 180 inches wide x 48 inches deep as shown in Figure 1.

• If the bottom column support is not installed in the correct position, the location of the ladders and the operator’s station will be incorrect. This can prevent full use of the jack tester. Failure to comply could result in damage to, or destruction of, equipment or loss of mission effectiveness.

• Upright parts of the bottom column support must be vertical to the floor within 0.5 degrees or the jack tester will not operate correctly. Failure to comply could result in damage to, or destruction of, equipment or loss of mission effectiveness.

(2) Install the bottom column support as shown in Figure 1. The word FRONT must point in the direction of the operator. Upright parts of the bottom column support must be vertical to the floor within 0.5 degrees.

(3) Install the rebar (2). Spotweld the rebar to the bottom column support (1) where the pieces touch, in accordance with AWS D1.1.

(4) Weld the stepbolts (3) to the angle pieces (4, 5). Weld the angle pieces (4, 5) together, in accordance with AWS D1.1.

The angle assembly must be level within 0.5 degrees or the jack tester will not operate correctly. Failure to comply could result in damage to, or destruction of, equipment or loss of mission effectiveness.

(5) Install the angle (4, 5) assembly. Angle assembly must be level within 0.5 degrees.

TO 33AA14-2-11

• Do not fill in the drain holes with concrete or moisture will collect at bottom of the support and cause corrosion. Refer to Figure 1 for drain hole location. Failure to comply could result in damage to, or destruction of, equipment or loss of mission effectiveness.

• The concrete floor must be level within 0.5 degrees or the jack tester will not operate correctly. Failure to comply could result in damage to, or destruction of, equipment or loss of mission effectiveness.

• If the concrete does not cure for the specified time, the foundation will be unstable. Failure to comply could result in damage to, or destruction of, equipment or loss of mission effectiveness.

NOTE

• The concrete must have a minimum compressive strength of 3000 Poundforce per Square Inch (PSI).

• If the building has a concrete slab, the foundation must be made flush with the slab. A preformed 3/4 inch expansion joint is necessary around the outer edge of the foundation.

(6) Fill the foundation area with concrete. Fill the bottom column support (1) posts with concrete up to the level of the 1/2 inch drain holes. The concrete must cure for 30 days, minimum.

2.2 Initial Setup. Perform initial setup of the jack tester as follows:

NOTE

Most components of the jack tester are assembled by the manufacturer before shipment. Only primary components must be assembled during initial setup.

2.2.1 25 Foot Ceiling. The subsequent procedure may be used to save assembly time, but only if the ceiling height is 25 feet or more, plus the height of the hoist (Table 2). If the ceiling height is less than this quantity, refer to Paragraph 2.2.2.

NOTE

Ensure pins (WP 998 00, Figure 1, 52) on beam assembly (46) are located to the front. Refer to WP 004 00, Figure 1.

a. Set the beam assembly (WP 998 00, Figure 1, 46) on to the bottom column support (57). Use the hoist. Align the bore holes in the beam assembly and the bottom column support.

b. Install the columns (55, 56) in the top column support (41). Install the screws (42), the lockwashers (43), the washers

(44) and the nuts (45).

c. Attach the hoist (2) to the top column support (41).

NOTE

Top column support is stenciled “FRONT”.

d. Lift the top column support (41) and attached parts (55, 56). Put the columns (55, 56) into the bottom column support (57). Install the screws (42) the lockwashers (43), the washers (44) and the nuts (45). Do not tighten the nuts.

e. Install adjusting screws (62) in the bottom column support (57) and tighten until columns (55, 56) are vertical within

0.5 degrees. Tighten nuts (45).

f. Install the brace (32) and the bracket (35) on the ladder (24) with the screws (25) the washers (26) and the nuts (27).

TO 33AA14-2-11

g. Install the ladder (24) and attached parts (32, 35) on the column (55) with the screws (33, 36) and the washers (34, 37).

Ensure ladder with control box bracket (11) is mounted on front left side.

h. Install the brace (32) and the bracket (38) on the column (56) with the screws (33, 39) and the washers (34, 40).

i. Install the ladder (28) on the brace (32) and the bracket (38) with the screws (29) the washers (30), and the nuts (31).

2.2.2 23 Foot Ceiling. Use the subsequent procedure if the ceiling height is 23 feet or more plus the height of the hoist, but less than 25 feet plus the height of the hoist. If the ceiling height is 25 feet or more plus the height of the hoist, refer to Paragraph 2.2.1 to save time during assembly.

a. Install the columns (WP 998 00, Figure 1, 55, 56) into the bottom column support (57). Install the screws (42), the lockwashers (43), the washers (44), and the nuts (45). Do not tighten the nuts.

b. Install adjusting screws (62) in the bottom column support (57) and tighten until columns (55, 56) are vertical within

0.5 degrees. Tighten nuts (45).

NOTE

Ensure pins (52) on beam assembly (46) are located to the front. Refer to WP 004 00, Figure 1.

c. Install the beam assembly (WP 998 00, Figure 1, 46) on the columns (55, 56) so that it rests on the bottom column support (57). Use the hoist.

NOTE

Top column support is stenciled “FRONT”.

d. Attach the hoist (2) to the top column support (41). Install the top column support (41) on the columns (55, 56). Use the hoist. Install the screws (42) the lockwashers (43) the washers (44) and the nuts (45).

e. Install the brace (32) and the bracket (35) on the ladder (24) with the screws (25) the washers (26) and the nuts (27).

f. Install the ladder (24) and attached parts (32, 35) on the column (55) with the screws (33, 36) and the washers (34, 37).

Ensure ladder with control box bracket (11) is mounted on front left side.

g. Install the brace (32) and the bracket (38) on the column (56) with the screws (33, 39) and the washers (34, 40).

h. Install the ladder (28) on the brace (32) and the bracket (38) with the screws (29), the washers (30), and the nuts (31).

2.3 Wiring/Power Connections. Connect electrical wiring to power source as follows:

a. Install bracket (WP 998 00, Figure 1, 11) on ladder (24) and secure using screws (12), washers (13), and nuts (14).

b. Install arm brace (7) on bracket (11) and secure using bearing (10), washer (9), and cotter pin (8).

c. Install control box (3) on arm brace (7) using screws (4), washers (5), and nuts (6).

Failure to insert flat side of load cell (1) in the beam assembly (54) with the stud (53) can result in death or serious injury to personnel or damage to equipment. Ensure flat side of load cell is fully flush with beam assembly prior to use. Refer to WP 998 00, Figure 2.

d. Install the load cell (1) on the beam assembly (46).

TO 33AA14-2-11

e. Refer to WP 998 00, Figure 1 and connect the cable (15) from the load cell (1) to the control box (3). Secure to beam

(46) and ladder (24) using loop clamps (58), screws (59) washers (60), and nuts (61).

f. Connect the control and power cords (WP 998 00, Figure 2, 108, 112) from the hoist (WP 998 00, Figure 1, 2) to the control box (3). Secure to support (41) and ladder (24) using loop clamps (58), screws (59), washers (60), and nuts (61).

g. Electrical wiring from the power source to the control box (3) is not provided with the jack tester and must be supplied by the user. Make sure the electrical power source is 115 Volts Alternating Current (VAC), single phase, 60 Hertz (Hz).

h. Make sure the door on the control box (3) is closed and locked. Use the clips to lock the door.

TO 33AA14-2-11

Figure 2. Correct Orientation of Load Cell

2.4 Hoist Test/Beam Hookup. Perform initial setup of the jack tester as follows:

• Make sure the area around the jack tester is clear of objects that could hit or catch the load chain or beam assembly during operation. Failure to comply may result in injury to personnel or death.

• Never walk under beam if load pins are not in the locked position. Failure to comply may result in injury to personnel or death.

• Only use the ladder to climb on the unit. Failure to comply may result in injury to personnel or death. Never climb on the ladder without using a safety harness that meets AFOSH 91-501 requirements.

a. Place the ON switch on the control box (WP 998 00, Figure 1, 3) in the ON (up) position. Permit the control box to do a self-check for approximately 3 minutes. It is necessary for the electronic system to be stable before you do a test.

b. Test the electrical connections by operating the UP and DOWN switches on the control box. (3). Make sure the lower hook (WP 998 00, Figure 2, 53) moves in the specified direction. If the hoist (WP 998 00, Figure 1, 2) does not operate correctly, refer to WP 006 00.

c. Operate the DOWN switch on the control box (WP 998 00, Figure 1, 3) until a sufficient length of load chain is available to connect the lower hook to the beam assembly (46).

Make sure that the load chain is tight, with no slack, before releasing the stop pins. Failure to comply may result in injury to personnel or death.

d. Make sure the stop pins (52) on the beam assembly (46) are locked in the disengaged position. Operate the UP and DOWN switches on the control box (3) until the beam assembly is at the necessary height.

e. Release the upper two (spring loaded) stop pins (52) on the beam assembly (46). Operate the UP and DOWN switches on the control box (3) until the upper two stop pins engage the holes in the columns (55, 56). Engage the lower two stop pins (52) in the holes in the columns. Make sure all the stop pins are locked in position.

f. Operate the DOWN switch on the control box (3) for one second to make sure the stop pins (52) fully engage the holes in the columns (55, 56).

g. The control box (3) must be calibrated before initial use. Refer to Paragraph 3.7 (WP 007 00) for instructions.

2.5 Preoperational Inspection. Perform a preoperational inspection as specified in Table 2. Replace or repair any com-ponent that shows wear or damage before operating the hoist. Tighten any component that is loose.

NOTE

A fast visual inspection is sufficient when jack tester components are new. A full inspection is necessary when components show signs of use or damage.

Table 2. Preoperational Inspection

Component Inspect For All jack tester components Obvious damage, loose or missing parts Control box (WP 998 00, Figure 1, 3) AFTO Form 244, Status of Unit, must show current inspection dates

TO 33AA14-2-11

Table 2. Preoperational Inspection - Continued

Component Inspect For Sleeve (23) Damaged hooks or latches, damaged rollers, spring on sleeve body with insufficient pressure to fully lock the latching mechanism

3 PREPARATION FOR SHIPMENT.

a. Foundation components are permanently installed. Other jack tester components must be disassembled before ship-ment. Refer to Paragraph 3.1.1 (WP 007 00) for instructions.

b. Do the preservation and packaging procedures found in MIL-STD-281 for all components.

c. All components must be marked and identified. Refer to MIL-STD-162 for instructions.

d. If the equipment is not used, it must be kept in a location that is clean and dry.

TO 33AA14-2-11

UNIVERSAL JACK TESTER

OPERATION

EFFECTIVITY: ALL

LIST OF EFFECTIVE WP PAGES

Total Number of Pages in this WP is 12 consisting of the following:

* Zero in this column indicates an original page.

Page *Change Page *Change Page *Change No. No. No. No. No. No.

1 - 9. . . . . . . . . . . . . . . . . . . . . . 0 11 10 Blank . . . . . . . . . . . . . . . . . . . 0 12 Blank

TABLE OF CONTENTS

Paragraph Page

1 INTRODUCTION

2 THEORY OF OPERATION

2.1 Jack Tester

2.2 Control Box

2.3 Hoist

2.4 Load Cell

3 OPERATING CONTROLS AND INDICATORS

4 OPERATION INSTRUCTIONS

5 NORMAL SHUTDOWN

6 EMERGENCY SHUTDOWN

LIST OF ILLUSTRATIONS

Number PageTitle

1 Control Box Block Diagram 2 Controls and Indicators

TO 33AA14-2-11

WP 005 00

1 Controls and Indicators 2 Display Indications 3 Beam Heights/Clearances 4 Relief Valve Settings

REFERENCE MATERIAL REQUIRED

NONE

APPLICABLE TCTOs

NONE

CONSUMABLE MATERIALS

NONE

APPLICABLE SUPPORT EQUIPMENT

Part Number Nomenclature CAGE Code

- Jack (any type) -

1 INTRODUCTION.

This work package contains a functional description of the jack tester and a list of controls and indicators.

2 THEORY OF OPERATION.

2.1 Jack Tester. The jack tester uses an electrical chain hoist to lift and lower a beam assembly. The hoist is operated by a control box. A load cell attached to the beam assembly connects to the control box. The beam assembly is positioned over the jack to be tested and locked in position. Then the jack is operated to apply pressure against the load cell. This pressure is indicated on a display on the control box.

2.2 Control Box. When the ON switch is put in the ON position, 115 Volts Alternating Current (VAC) from the main power source goes to the control box, and causes the POWER light to come on. Power will not be provided if the door interlock (S6) is open or if the circuit breaker (S5) is open. The detailed theory of operation for the control box is shown in the block diagram, Figure 1. There are three input sources for the control box: the load cell output signal, a zero reference, and a full scale voltage signal. These three sources go into a multiplex unit and are used each time a weight is calculated. A microprocessor uses the zero and full scale data to correct any change in the amplifier, filter, or analog-to-digital converter signals when a weight is calculated. The strength of these signals is increased by an amplifier to keep background noise to a minimum. A filter is used to decrease any high frequency signals that are more than 10 Hertz (Hz). The filtered signal goes to the analog-to-digital converter. The analog-to-digital converter changes the analog voltage signal from the load cell to a digital value. This is necessary because the microprocessor uses data to calculate the weight, but the load cell output is an analog voltage. The Value of the Input Voltage (VIN) is divided by the Value of the Reference Voltage (VREF). This makes allowance for any internal changes, such as the load cell excitation voltage. The output from the analog-to-digital converter goes to the microprocessor in increments of one bit at a time. This value is compared to a zero value and to the full scale signal value and corrected with a span constant. The zero value is the quantity subtracted from the load cell output to make the scale show zero when no weight is applied against the load cell. The zero value is set using the ZERO switch on the front panel. The span constant controls the proportion of weight shown on the display to the strength of the full scale signal. The span constant is set by applying a known weight to the load cell and writing that known weight value into the microproces-sor. This procedure is done at three weights: 1/3, 2/3, and full capacity. The span constant is then applied automatically during the weighing procedure. The microprocessor selects the correct span constant to use for each weight to be calculated.

The span constant is set with the ZERO (S1) and DIGIT ADVANCE (S2) switches. The value that results from the zero and span calculations is sent to the display driver…