Malabar 795 Owner's Manual

Single stage fixed height hydro-mechanical aviation tripod jack

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MALABAR

AIRCRAFT MAINTENANCE & SUPPORT EQUIPMENT

READ

AND

SAVE

THIS

INSTRUCTION

MANUAL

INTERNATIONAL

OWNER'S MANUAL FOR MALABAR MODEL

SINGLE STAGE FIXED HEIGHT

HYDRO - MECHANICAL

AVIATION TRIPOD JACK

For Service & Spare

Parts, Please Contact:

OVER 65 YEARS OF SERVICE & EXPERIENCE

795

* GENERAL DESCRIPTION

* OPERATION

* SERVICE

* PARTS BREAKDOWN

Malabar International

220 W. Los Angeles Avenue

Simi Valley, California 93065

Phone: (805) 581-0116

Fax: (805) 584-1624

E-mail: sales@malabar.com

Web site: http://www.malabar.com

Date: June 7, 2006

Table of Contents

Summary of Contents for Malabar 795

Page 1 Simi Valley, California 93065 Phone: (805) 581-0116 Fax: (805) 584-1624 E-mail: sales@malabar.com Web site: http://www.malabar.com OVER 65 YEARS OF SERVICE & EXPERIENCE 2002 Malabar International. All rights reserved. Permission to reproduce all or part of this material must be obtained from Malabar International.
Page 2: Valve Block Assembly
GENERAL DESCRIPTION: The Malabar Fixed Height Tripod Jack Model 795 is a 100 ton capacity single stage hydraulic jack designed primarily for use in aircraft maintenance. It consists of a tripod structure, hydraulic cylinder assembly, reservoir, valve block assembly, hand pump assembly, tow handle, swivel casters and the...
Page 3: Pump Handle
pads have adjustable leveling feet for slightly uneven or sloping floors. On jacks equipped with hydraulic casters, leveling of the jack is faster and easier by selectively extending or retracting the caster plungers utilizing the caster hand pump or release valve. Extending the casters also increases the towing ground clearance.
Page 4 PRE-OPERATION INSPECTION: Each time the jack is to be used, inspect the following: 1. Check the tripod structure for rigidity. Make sure all bolts are tightened. 2. Check hydraulic line connections for leaks. Tighten as required. 3. Check for hydraulic fluid leaks around the base, reservoir, tripod head, hand pump, air pump (if so equipped), hydraulic casters (if so equipped) and shock absorber (if so equipped).
Page 5 6. To raise the load manually: a. The jack is equipped with an adjustable hand pump. The hand pump handle length can be varied by inserting the quick release pin through the clamp and appropriate hole along the handle (see figure 4).
Page 6 LOCATED IN THE HYDRAULIC CASTER VALVE BLOCK ASSEMBLIES, SHOULD NOT BE REMOVED UNLESS ABSOLUTELY NECESSARY. THE HYDRAULIC CASTER RELIEF VALVES ARE SET TO BY-PASS HYDRAULIC FLUID BACK TO THE RESERVOIRS AT 900 ± 20 psig (63.3 ± 1.4 kg/sq cm) IF ADJUSTMENT IS REQUIRED, SEE PROCEDURE UNDER TESTING (SEE SHEET 5).
Page 7 3. While operating the hand pump, adjust set screw (figure 3, item 9) until the thermal relief valve by- passes hydraulic fluid back to the reservoir at 120.0 to 125.0 tons. 4. Replace plug (figure 3, item 8). Once more operate hand pump to verify correct setting. 5.
Page 8: Table Of Contents
55991-14 Placard, tonnage, 100 ton ---------------------------------------------------------------------------- 79596 Placard, instruction ------------------------------------------------------------------------------------- 55998 Sticker, Malabar ----------------------------------------------------------------------------------------- 55994 Sticker, fluid ---------------------------------------------------------------------------------------------- 75940 Sticker, towing ------------------------------------------------------------------------------------------- 79536A Spring loaded swivel caster with swivel lock---------------------------------------------------- 79307 Lower bearing-------------------------------------------------------------------------------------------- 79619 Upper bearing-------------------------------------------------------------------------------------------- 79386 Ship adapter---------------------------------------------------------------------------------------------- 79595...
Page 9 PNEUMATIC / HYDRAULIC DIAGRAM AIR INLET RESERVOIR - AIR RELIEF VALVE - SYSTEM RELIEF VALVE - AIR VALVE - THERMAL RELIEF VALVE - LUBRICATOR - CYLINDER ASSEMBLY - AIR PUMP - LOAD GAUGE - MUFFLER - SHUTOFF VALVE - OIL SCREEN - RELEASE VALVE - VALVE BLOCK - HAND PUMP...
Page 10 PNEUMATIC / HYDRAULIC DIAGRAM WITH REMOTE CONTROL AIR INLET RESERVOIR - AIR RELIEF VALVE - SYSTEM RELIEF VALVE - AIR VALVE - THERMAL RELIEF VALVE - LUBRICATOR - CYLINDER ASSEMBLY - AIR PUMP - LOAD GAUGE - MUFFLER - SHUTOFF VALVE - OIL SCREEN - RELEASE VALVE - VALVE BLOCK...
Page 11 PNEUMATIC / HYDRAULIC DIAGRAM WITH ELECTRIC MOTOR RESERVOIR - MOTOR / PUMP ASSEMBLY - CYLINDER ASSEMBLY - HAND PUMP - LOAD GAUGE - HYDRAULIC PUMP - SHUTOFF VALVE - OIL SCREEN - RELEASE VALVE - VALVE BLOCK - ELECTRIC MOTOR - SYSTEM RELIEF VALVE - COUPLING - THERMAL RELIEF VALVE...
Page 12 HYDRAULIC CASTER HYDRAULIC DIAGRAM RESERVOIR - VALVE BLOCK - CYLINDER ASSEMBLY G - SHOCK ABSORBER - HAND PUMP - RELEASE VALVE - RELIEF VALVE - METERING ORIFICE - 11 -...
Page 13 TROUBLE SHOOTING CHART TROUBLE PROBABLE CAUSE REMEDY Release valve open. (Oil Close valve firmly. ack will not raise. passing back into reservoir.) Intake valve open. (Oil passing Pump rapidly to flush dirt off. back into reservoir.) Discharge valve open. (Oil Pump rapidly to flush dirt off.
Page 14 PART OF REPAIR PARTS KIT DRAIN 55998 6 (REF) FIGURE 1A MODEL 795 JACK ASSEMBLY NO. QTY PART NO. DESCRIPTION NO. QTY PART NO. DESCRIPTION 79599 CYLINDER ASSEMBLY 19 A/R 732-010 TUBE, 3/8 O.D. x .065 WALL 79391 RESERVOIR (NO R/C KIT)
Page 15: Placard, Instruction
FIGURE 1B MODEL 795 JACK ASSEMBLY NO. QTY PART NO. DESCRIPTION NO. QTY PART NO. DESCRIPTION 79552 BRACE 12 12 351-005 HEX NUT, 1"-8 79546 LOAD GAUGE KIT 13 10 397-005 SELF TAPPING SCREW, #4 76346 RESERVOIR COVER 55994 STICKER, FLUID...
Page 16: Lower Bearing
PART OF REPAIR PARTS KIT FIGURE 2 79599 CYLINDER ASSEMBLY NO. QTY PART NO. DESCRIPTION NO. QTY PART NO. DESCRIPTION 79503 CYLINDER 55925-446 O-RING 79307 LOWER BEARING 55929-446 BACK-UP RING 79306 PLUNGER 55932-266 O-RING 79313 TRIPOD HEAD 55931-446 TEFLON O-RING W / GROOVE 79619 UPPER BEARING 55925-438...
Page 17 PART OF REPAIR PARTS KIT (THERMAL RELIEF VALVE) CYLINDER PORT GAUGE PORT AIR PUMP PORT (SYSTEM RELIEF VALVE) FIGURE 3 56010-1 VALVE BLOCK ASSEMBLY NO. QTY PART NO. DESCRIPTION NO. QTY PART NO. DESCRIPTION 717-048 PLUG, FLUSH, 1/16 NPT 55568 OIL SCREEN 79366 RELEASE VALVE KNOB...
Page 18 PART OF REPAIR PARTS KIT FIGURE 4 79571-1 HAND PUMP ASSEMBLY NO. QTY PART NO. DESCRIPTION NO. QTY PART NO. DESCRIPTION 55738 PISTON 55925-220 O-RING 55925-213 O-RING 55761 FULCRUM 55922-18 BACK-UP RING 55745 PUMP HANDLE CLAMP 55728 SCRAPER RING 55927-43 RETAINING RING 55729 RETAINING RING...
Page 19: Air Valve
PART OF REPAIR PARTS KIT * PARTS ARE LOCATED INSIDE RESERVOIR TANK * 24 * 23 * 21 FIGURE 5 78915 AIR PUMP KIT NO. QTY PART NO. DESCRIPTION NO. QTY PART NO. DESCRIPTION 441-001 AIR PUMP 321-013 HHCS, 3/8 - 24 x 1" LG 392-001 STUD 363-003...
Page 20 RESERVOIR (REF) FIGURE 6 73148 ELECTRIC MOTOR/PUMP KIT - 19 -...
Page 21: Hydraulic Gear Pump
73148 ELECTRIC MOTOR/PUMP KIT PARTS LIST NO. QTY PART NO. DESCRIPTION NO. QTY PART NO. DESCRIPTION 431-010 ELECTRIC MOTOR 431-015 CONDUIT BOX 438-006 PUMP/MOTOR ADAPTER 440-055 HYDRAULIC GEAR PUMP 432-020 FLEXIBLE COUPLING 450-156 STARTER BOX 721-024 CONN., 1/2 T x 1/2 SAE 722-018 ELBOW, 3/8 T x 3/8 SAE 722-013...
Page 22: Shutoff Valve
PART OF REPAIR PARTS KIT FIGURE 7 79546 LOAD GAUGE KIT NO. QTY PART NO. DESCRIPTION NO. QTY PART NO. DESCRIPTION 79368 LOAD GAUGE 714-001 REDUCER, 1/2 FPT x 1/4 MPT 323-072 SHCS, 10-32 x 3 1/2 LG 711-003 NIPPLE, 1/4 MPT 363-009 SPLIT LOCKWASHER, # 10 424-001...
Page 23 FIGURE 8 79543 ADJUSTABLE FOOT KIT NO. QTY PART NO. DESCRIPTION NO. QTY PART NO. DESCRIPTION 79516 TRIPOD LEG 76377 GUIDE SCREW 79515 TRIPOD LEG w/ TOW BRKT 363-005 SPLIT LOCKWASHER, 5/8 79509 TRIPOD LEG w/ HANDLE HLDR 79343 FOOT SCREW LOCKNUT 76376 LONG SPRING PIN 79346...
Page 24 DRAIN FIGURE 9 79574 ADJUSTABLE FOOT KIT WITH HYDRAULIC CASTER NO. QTY PART NO. DESCRIPTION NO. QTY PART NO. DESCRIPTION 79572 TRIPOD LEG 363-005 SPLIT LOCKWASHER, 5/8 79577 TRIPOD LEG w/ TOW BRKT 79343 FOOT SCREW LOCKNUT 79579 TRIPOD LEG w/ HANDLE HLDR 79346 RETAINING RING 76376...
Page 25: Breather
PART OF HYDRAULIC CASTER REPAIR PARTS KIT APPLY LOCTITE NO. 242 ON THREADS DRAIN FIGURE 10 881800 HYDRAULIC CASTER ASSEMBLY NO. QTY PART NO. DESCRIPTION NO. QTY PART NO. DESCRIPTION 881803 PLUNGER 372-009 COTTER PIN, 3/32 x 1/2 LG 881804 CYLINDER 373-005 FLAT HEAD PIN, 3/8 DIA...
Page 26: Release Valve Knob
PART OF HYDRAULIC CASTER REPAIR PARTS KIT FIGURE 11 881808 VALVE BLOCK & HAND PUMP ASSEMBLY NO. QTY PART NO. DESCRIPTION NO. QTY PART NO. DESCRIPTION 55010 VALVE BLOCK 881847 PLUNGER, 3/4 DIA 55024 GASKET 881846 BODY, 3/4 DIA 55295 SPRING 55926-112 RETAINING RING...
Page 27 37° FLARE END OF ITEM 2 TO BE INSERTED INTO ITEM 1 DRAIN HYDRAULIC CASTER ASSEMBLY FIGURE 12 881818 SHOCK ABSORBER KIT NO. QTY PART NO. DESCRIPTION 490-029 DIAPHRAGM ACCUMULATOR 721-040 CONN, 3/8 37° x 3/8 SAE MS28778-6 O-RING (PART OF ITEM 2) - 26 -...
Page 28 FIGURE 13 78567 LADDER ASSEMBLY KIT NO. QTY PART NO. DESCRIPTION 79575 LADDER 76378 SAFETY CHAIN ASSEMBLY 79560 RAIL STRAP 321-011 HHCS, 3/8-16 x 1" LG 321-008 HHCS, 3/8-16 x 1 1/4 LG 361-001 FLAT WASHER, 3/8 363-003 SPLIT LOCKWASHER, 3/8 - 27 -...
Page 29 CYLINDER LADDER LOWER PANEL BRANCH TEE 1/2 NPT TO VALVE BLOCK FIGURE 14 78990 REMOTE CONTROL KIT NO. QTY PART NO. DESCRIPTION NO. QTY PART NO. DESCRIPTION 713-029 TEE, RUN, 1/2 NPT 76158 CAUTION PLACARD 714-003 REDUCER, 1/2 MPT x 1/4 FPT 397-010 SELF TAPPING SCREW, #6 722-013...
Page 30 WIRING DIAGRAM CONNECTED FOR 460V 3 PHASE HEATER HIGH VOLTAGE FUSES CONTACTOR ELECTRIC MOTOR 2 HP MOTOR THERMOSTAT START GREEN PLUG BY OTHERS FUSE CIRCUIT BREAKER TRANSFORMER NOTE: ALL PARTS IN STARTER ENCLOSURE EXCEPT ELECTRIC MOTOR - 29 -...