Malabar 832R User Manual
Contents
1. Swivel Wheel Valve block and hand pump assembly FU CUM rr a Plunger 7 16 dia Body 7 16 dia Plunger 13 16 dia Body 13 16 Pump handle Hydraulic hose Oil return Breather amp dipStiCk Extension 8 renace Stop ring Inner bearing Center bearing Outer bearing Placard tonnage 35 ton2. Nameplate Sticker Malabar 2 2 522 Sticker fluid ci Sticker towing pUMp Air drive seal kit air pump Hydraulic seal kit air pUMp Air valve ic ii Air relief Load gauge Cross check valve Optional equipment These parts required only when supplied with jack PNEUMATIC HYDRAULIC DIAGRAM RESERVOIR AIR RELIEF VALVE OIL SCREEN AIR VALVE CROSS CHECK VALVE AIR PUMP LOAD GAUGE VALVE BLOCK CYLINDER ASSEMBLY SAFETY POP OFF VALVE RELEASE VALVE HAND PUMP PNEUMATIC HYDRAULIC DIAGRAM WITH AIR OPERATED VACUUM RETRACT KIT A 3 D AIR INLET RESERVOIR FOUR WAY VALVE CROSS CHECK VALVE AIR RELIEF VALVE LOAD GAUGE AIR VALVE CYLINDER ASSEMBLY AIR PUMP RELEASE VALVE VALVE BLOCK FILTER BREATHER SAFETY POP OFF VALVE VACUUM P
3. BASE CYLINDER ASSEMBLY REF FIGURE 7 83247 RAIN HAT KIT RAIN 512 HHCS 3 8 16 7 8 LG RAIN HAT BRACKET SPLIT LOCKWASHER 3 8 STICKER CLOSE COVER HEX LOCKNUT 5 16 18 HHCS 5 16 18 x 1 1 2 LG HEX NUT 3 8 16 PART NO DESCRIPTION
4. pumps Close release valve and operate hand pump to raise plungers approximately 1 inch Open release valve to retract plungers fully to bleed all air trapped under jack plungers Close release valve PRE OPERATION INSPECTION Each time the jack is to be used inspect the following 1 Check jack structure for rigidity Make sure all bolts are tightened 2 Check hydraulic line connections for leaks Tighten as required OO Check for hydraulic fluid leaks around the cylinder assembly reservoir air pump and hand pumps Check hand pumps for proper operation Check caster wheels for proper operation Check reservoir fluid level with jack plungers fully retracted OPERATION 1 Position the jack under the appropriate jacking pad of the aircraft CAUTION DONOT EXTEND EXTENSION SCREW AGAINST AIRCRAFT JACK 2 3 PAD WITH THE PLUNGERS FULLY RETRACTED Raise the extension screw by turning counterclockwise until the ship adapter is 1 2 to 1 from aircraft jacking pad or as far as the screw will travel 3 inches maximum Close the release valve located in front of the frame reservoir assembly CAUTION ON JACK EQUIPPED WITH AIR PUMP AIR RELIEF VALVE MUST BE INSTALLED ALL TIMES IF AIR RELIEF VALVE IS REMOVED IT IS POSSIBLE TO OVER PRESSURIZE THE PNEUMATIC SYSTEM WHICH COULD CAUSE EQUIPMENT FAILURE AND POSSIBLE BODILY INJURY On jack equipped with air pump connect air supply 90 1
5. 86367 CROSS CHECK VALVE TUBE 3 8 O D x 065 WALL 14 721 009 CONN 3 8 T x 1 4 MPT ADAPTER 3 8 SAE x 1 4 FPT 15 323 071 SHCS ASHCROFT GAUGE NIPPLE 3 8 MPT x 1 4 MPT 16 MS28778 6 O RING FOR ITEMS 7 amp 12 0 100 00 9 PART OF REPAIR PARTS KIT 5 AIR INLET FIGURE 5 80218 PUMP KIT AIR PUMP 425 001 AIR RELIEF VALVE MOUNT PLATE 732 010 VALVE TUBE 3 8 O D x 065 WALL 722 014 NIPPLE 1 4 MPT x 1 8 MPT ELBOW 3 8 T x 1 4 MPT 55925 016 O RING TEE 1 4 FPT TO AIR CONTROL VALVE INLET EXISTING HAND PUMP Ni 8 VALVE BLOCK FEZ T 1 1 E EXISTING Ga RESERVOIR P N 425 001 FIGURE 6 83260 AIR OPERATED VACUUM RETRACT KIT 83260 AIR OPERATED VACUUM RETRACT KIT NO DESCRIPTION O A Nae gt gt 22 2 4 1 1 1 MOUNTING PLATE HAND VALVE AIR OPERATED VAC PUMP MUFFLER 1 4 FPT DIPSTICK PLACARD INSTRUCTION ELBOW 3 8 T x 3 8 MPT CONN 3 8 T x 1 4 MPT REDUCER 3 8 MPT x 1 8 FPT NIPPLE BRASS 1 8 MPT ELBOW 1 4 T x 1 8 MPT ELBOW 1 4 T x 1 4 MPT REDUCER 3 4 MPT x 1 4 FPT STREET TEE 3 4 NPT HHCS 3 8 16 x 1 LG SHCS 1 4 20 x 1 1 2 LG BREATHER 3 8 MPT TUBE 3 8 O D x 049 WALL TUBE 1 4 O D x 035 WALL SELF TAPPING SCREW 6 SPLIT LOCKWASHER 1 4 NIPPLE 3 8 MPT x 1 4 MPT TEE BRASS 1 4 FPT PLUG 1 4 MPT FRAME REF
6. and freedom of rust pits and excessive wear Check extension screw cylinder plungers etc for corrosion wear and condition of threads Verify that the extension screw has a positive stop to prevent it from being extended beyond its safe thread engagement Inspect packings seals gaskets and wipers in the cylinder assembly and hand pumps for cuts scratches deterioration and distortion Inspect stop ring for excessive scoring and or wear Check hand pump oil screens by removing valve block and verifying cleanliness Inspect valves and valve seats in the valve block for scratches dents and proper seating of the balls Inspect all pivot pins for wear cracks pits or evidence of damage or pending damage Inspect all areas for excessive dirt oil dust and chips al RON O gt OVERHAUL INSTRUCTIONS No definite time schedule can be established for the overhaul of the jack for replacement of the various moving parts The number of times the jack is raised and lowered and the amount of load raised at each operation materially affect the life of the working parts Do not overload the jack Overloading is dangerous will hasten the need for overhaul and may damage the jack During overhaul replace all parts that do not pass disassembly inspection requirements Regardless of apparent condition replace all parts marked with 4 in the parts breakdown A repair parts kit P N 832RPK which contains all of th
7. following optional equipment Air pump Load gauge Air retract Rain hat The jack is mounted on two swivel casters at the rear and a spring loaded wheel at the front to provide portability The cylinder assembly is raised off the ground by the spring loaded wheel when it is under no load The wheel retracts and the base of the cylinder assembly rests on the ground when load is applied A tow handle readily connects to tow vehicle for ease of transport The jack is rated at 5 mph 8 km h towing speed Excessive speed may cause excessive wear and or damage to the jack PROTECTION DEVICES 1 A safety pop off valve is incorporated in the jack located in the valve block to prevent lifting of loads in excess of 38 5 tons 34 9 m tons 2 The extension screw has a positive stop to prevent it from being extended beyond its safe thread engagement 3 An optional load gauge can be installed in order to monitor the approximate load being raised PREPARATION FOR USE 1 The jack is shipped without hydraulic fluid in the reservoir Do not operate air or hand pumps until reservoir is filled will hydraulic fluid MIL H 5606 or approved equivalent Remove filler cap and fill reservoir to mark on dipstick reservoir capacity is approximately 2 gallons 7 6 liters Plungers must be fully retracted before filling reservoir Replace filler cap Open release valve and operate hand pumps a few strokes to bleed all air trapped under hand
8. intake valve Remove pump and clean valve block Handle snaps back Sticking intake valve Open release valve Pump rapidly several times close valve Clogged screen 8 E Y 0 lt o lt o O E lt o E MAX TOWING SPEED 5 Je FIGURE 1 MODEL 8328 35 TON AXLE JACK 1 2 3 4 5 6 7 8 N S N N A N 2 8 2 4 4 8 8 1 1 1 3 2 3 12 1 1 1 1 8 1 1 1 1 1 1 1 1 1 1 80215 83282R 83565 86399E 80204 80205 80208 80207 80206 83597 394 003 83295R 83294R 86339 83298 83596 331 011 321 021 363 003 355 009 321 042 321 036 363 001 351 001 321 011 351 002 717 007 321 039 351 003 363 004 321 072 362 001 362 003 55998 55991 8 55997 2 55994 397 005 75940 717 006 717 035 80218 722 007 80216 83519 MS28778 6 83260 83247 MODEL 35 TON AXLE JACK 832R 35 TON AXLE JACK QTY PART NO DESCRIPTION ___________ wo oty PART NO DESCRIPTION FRAME SWIVEL CASTER WHEEL VALVE BLOCK amp HAND PUMP TOW HANDLE TOW HANDLE SPACER LEAF SPRING WHEEL BRACKET SHAFT GUIDE KNOB PIPE CLIP HOSE ASSEMBLY OIL RETURN LINE BREATHER CAP 8 DIPSTICK CYLINDER ASSEMBLY SHAFT ASSEMBLY SHSS 1 4 20 x 1 4 LG HHCS 5 8 11 x 5 1 2 LG SPLIT LOCKWASHER 3 8 HEX LOCKNUT THIN 5 8 11 HHCS 3 8 16 x 3 4 LG HHCS 1 4 20 x 3 4 LG SPLIT LOCKWASHER 1 4 HEX NUT 1 4 20 HHC
9. of lowering is controlled by the amount the release valve is open Note Do not open release valve more than one and one half turns counter clockwise 10 Fully lower jack plungers Lower extension screw Close release valve Cover jack when not in use SERVICING Servicing the jack consists primarily of the following 1 When in use the reservoir should be kept at the proper hydraulic fluid level Check with plungers fully retracted Grease casters and wheel as required Lubricate hand pump pivot pins and tow handle linkage If the jack has been put into storage or has not been used the plungers must be fully extended and retracted every 90 days to exercise the seals A portion of the lift should be operated by the air pump and a portion by the hand pumps RON DISASSEMBLY INSPECTION CAUTION THE SAFETY POP OFF VALVE LOCATED IN THE VALVE BLOCK SHOULD NOT BE REMOVED UNLESS ABSOLUTELY NECESSARY THE VALVE IS SET AND SEALED AT THE FACTORY TO BY PASS HYDRAULIC FLUID BACK TO THE RESERVOIR AT 5 10 ABOVE THE RATED CAPACITY OF 35 TONS IF ADJUSTMENT IS REQUIRED SEE PROCEDURE UNDER TESTING SEE SHEET 4 When necessary to disassemble the jack drain all hydraulic fluid from reservoir and carefully inspect the following 1 Inspect interior walls of jack cylinder plungers and hand pump cylinders for smoothness and freedom from rust nicks scratches and excessive wear Inspect exterior walls of jack plungers for smoothness
10. parts with clean solvent and dry with compressed air Lubricate all threads Use teflon tape carefully on all pipe threads Remove excess tape because it can clog valves and passages If ball valves located in valve block do not seat properly they may be reseated by tapping the ball into the valve seat with a brass rod cupped at one end TESTING Place jack in a load indicating test fixture Make sure the test adapter is 3 4 inch male spherical radius Operate hand pump to extend outer plunger fully and inner plungers partially Make sure ship adapter and test adapter are correctly mated Load test the jack at rated capacity of 35 tons If the jack fails to operate properly check for trouble as indicated in the Trouble Shooting Chart see sheet 8 With plungers extended and supporting the capacity load allow the jack to stand for 10 minutes Any excess settling indicates leakage in the hand pump check valves or jack packing seals Check for hydraulic fluid leaks and replace all defective parts If adjustment is required for the safety pop off valve perform the following procedure 4 2 3 Place jack in a load indicating test fixture Make sure the test adapter is 3 4 inch male spherical N OU Cut remove and discard lead amp wire seal figure 3 item 38 Remove plug figure 3 item 35 Close release valve figure 1 item 10 radius Operate hand pump to extend plungers against the test adapter Make sure ship adapter and
11. 25 psig to the 1 4 NPT air inlet located near the air valve A minimum of 17 scfm is required for the air pump Air relief valve must be properly installed Do not attempt to remove air relief valve The jack is equipped with two hand pumps One with 3 4 inch diameter pump plunger for rapid raising of jack plungers under low pressure and one with 7 16 inch diameter pump plunger for high pressure operation The hand pumps can be operated by placing pump handle over the end of the pump fulcrum and operating either the low or high pressure hand pump Operate air valve or either hand pump to raise plungers until the ship adapter contacts the jacking pad Note A small amount of fluid wetting is normal on manual hand pump plungers Periodically clean to remove accumulated grease or foreign material Insure ship adapter and jacking pad are correctly mated To raise the load a Operate the air valve or either hand pump as required b Do not lift a load greater than the rated capacity of 35 tons 31 8 m tons The approximate load being lifted can be read in tons on the load gauge Read load on lower stage scale when only outer plunger is extended Read load on center stage scale when center plunger is extended 2 Read load on upper stage scale when inner plunger is extended Fluid pressure in psig may be read on outer scale for gauge calibration 9 To lower the load a Slowly open the release valve to lower the load The speed
12. Date July 29 2010 MALABAR AIRCRAFT MAINTENANCE 8 SUPPORT EQUIPMENT OWNER S MANUAL FOR MALABAR MODEL 832R THREE STAGE HYDRAULIC AVIATION AXLE JACK READ S N 929 AND UP AND SAVE GENERAL DESCRIPTION OPERATION THIS SERVICE INSTRUCTION PARTS BREAKDOWN MANUAL For Service amp Spare Parts Please Contact Malabar International 220 W Los Angeles Avenue Simi Valley California 93065 Phone 805 581 0116 Fax 805 584 1624 E mail sales O malabar com Web site http www malabar com OVER 65 YEARS OF SERVICE amp EXPERIENCE O 2002 Malabar International All rights reserved Permission to reproduce all or part of this material must be obtained from Malabar International GENERAL DESCRIPTION OPERATION SERVICE AND PARTS BREAKDOWN MALABAR MODEL 832R THREE STAGE HYDRAULIC AVIATION AXLE JACK CAUTION AIRCRAFT MANUFACTURER S SPECIFICATIONS AND INSTRUC TIONS MUST BE FOLLOWED IN THE EVENT OF CONTRADICTION BETWEEN AIRCRAFT MANUFACTURER S SPECIFICATIONS AND 5 AIRCRAFT MANUFACTURER S SPECIFICATIONS WILL PREVAIL SPECIFICATIONS Rated 35 tons 31 8 m tons Low 7 inches 178 mm Hydraulic Lift 12 inches 305 mm Extensi
13. EEL BALL 3 8 CHROME STEEL BALL 5 16 FITTING 3 8 37 x 3 8 SAE SPRING DRIVE PIN O RING PART OF ITEM 23 CENTER BEARING OUTER BEARING 9 PART OF REPAIR PARTS FIGURE 3 86399E VALVE BLOCK amp HAND PUMP ASSEMBLY 86399E VALVE 86399E VALVE BLOCK 8 HAND PUMP ASSEMBLY 8 HAND PUMP ASSEMBLY NO DESCRIPTION ba N N N OI N N N N O O HW AH AH AH AHN ao py py 55001 FULCRUM 886659 PLUNGER 7 16 DIA 886658 BODY 7 16 DIA 55922 9 BACK UP RING 55925 111 755 018 WIPER 886657 PLUNGER 13 16 DIA 886656 BODY 13 16 DIA 55922 16 BACK UP RING 55925 211 O RING 755 019 WIPER 717 046 PLUG 55925 904 O RING 55925 113 O RING 390 022 LEAD amp WIRE SEAL 55002 FLAT HEAD PIN 5 16 DIA 372 028 BOW TIE COTTER 55615 LINK 55011 ANCHOR 352 004 HEX JAM NUT 5 8 18 55024 GASKET 412 004 STEEL BALL 1 4 DIA 86376 PUMP HANDLE 55621 SPRING 55620 PLUG 55925 903 O RING 55153 GUIDE 55154H SPRING 55148 SET SCREW 55568 OIL SCREEN 85425 VALVE BLOCK 722 009 ELBOW 45 3 8 37 x 1 4 717 010 PLUG HEX SOC 1 16 NPT 323 009 SHCS 3 8 24 x 3 LG PART OF REPAIR PARTS KIT FIGURE 4 83219 LOAD GAUGE KIT 9 RESERVOIR w GAGE MOUNT 717 006 PLUG 1 4 MPT GAUGE 10 412 001 BALL 3 8 DIA SHCS MARSH GAUGE 11 79367 SPRING SPLIT LOCKWASHER 10 12 722 003 ELBOW 3 8 SAE x 3 8 ELBOW 3 8 T x 1 2 FPT 13
14. S 3 8 16 x 1 LG HEX NUT 3 8 16 PIPE PLUG 3 8 NPT 1 2 13 x 3 LG HEX NUT 1 2 13 SPLIT LOCKWASHER 1 2 HHCS 1 2 20 x 1 LG FLAT WASHER 1 4 SAE FLAT WASHER 3 8 SAE STICKER MALABAR PLACARD TONNAGE 35 TON NAMEPLATE STICKER FLUID SELF TAPPING SCREW 4 STICKER TOWING PLUG 1 4 NPT PLUG HEX 1 4 NPT AIR PUMP KIT ELBOW 45 3 8 37 x 3 8 SAE RESERVOIR LOAD GAUGE KIT O RING PART OF ITEM 43 AIR RETRACT KIT RAIN HAT KIT PART OF REPAIR PARTS KIT A 87 Z W K J A 222 Z j Tel SECTIONS B B amp C C SECTION A A FIGURE 2A oc O LL m N LL 7 83298 CYLINDER ASSEMBLY 119 124 P N 83294R P N 83295R 83207R 83217R 83252R 83210R 83230R 83250R 55925 339 55902 42 55925 347 55902 50 55925 431 55903 58 83208R 83209R SECTION B B BASE STOP RING INNER BEARING OUTER PLUNGER CENTER PLUNGER INNER PLUNGER O RING BACKUP RING O RING BACKUP RING O RING BACKUP RING EXTENSION SCREW EXTENSION SCREW P N 83596 FIGURE 2B 83298 CYLINDER ASSEMBLY PART NO DESCRIPTION PART NO DESCRIPTION NUT PART OF REPAIR PARTS KIT SECTION 331 004 83214R 83234R 55925 011 412 001 412 002 83514 83515 390 001 MS28778 6 83232R 83212R SHSS 5 16 24 x 5 16 LG SNAP RING SNAP RING ELBOW 45 3 8 37 x 1 4 STEM O RING CHROME ST
15. UMP HAND PUMP MUFFLER OIL SCREEN TOTMUOOU gt TROUBLE SHOOTING CHART Jack will not raise Release valve open Oil Close valve firmly passing back into reservoir Intake valve open Oil passing back into reservoir Discharge valve open Oil Pump rapidly to flush dirt off chamber Sticking intake valve Remove pump from jack base PE Unscrew valve block Clean or replace valve Clogged screen Remove and clean Lack of oil Air under plunger Refill Check for leaks Bleed air out by opening release valve Pump rapidly a few times and close release valve Jack will not raise to full Lack of oil Refill check for leaks height Sticking intake valve Remove pump from jack base Unscrew valve block Clean or replace ball valves Re tighten or repair Jack will not raise capacity High pressure leaks At pump load or release valve block each stroke packing Jack will not hold up load Leaky release valve Defective O ring and back up Remove plunger and replace ring O ring and back up ring Jack will not lower the load Damaged release valve Remove and replace parts as needed Jack will not close Air under plunger Bleed air out Open release completely valve and pump rapidly several times Close valve Handle stroke only partly Open release valve and pump effective rapidly several times Close valve block Clogged screen Remove and clean Handle raises without effort Leaky
16. e parts marked with 4 is available and recommended to keep on hand at your facility 1 To disassemble cylinder assembly figure 2A a Unscrew stop ring item 2 from base CAUTION PLUNGERS ARE FREE TO SLIDE OUT OF CYLINDER DO NOTDROP o p q r a b c d PLUNGERS AND OR CYLINDER Remove plunger assembly from base Remove snap ring item 17 from center plunger item 5 Push assembly out of outer plunger item 4 Remove snap ring item 16 from inner plunger item 6 Push assembly out of center plunger Loosen set screw item 15 Remove extension screw item 13 and extension screw nut item 14 from inner plunger Unscrew outer bearing item 28 from outer plunger Unscrew center bearing item 27 from center plunger Unscrew inner bearing item 3 from inner plunger Remove and discard all O rings and back up rings from plungers To reassemble install O rings back up rings and bearings onto plungers Lubricate all O rings with MIL H 5606 fluid or equivalent Slide extension screw and extension screw nut into inner plunger and tighten set screw Slide center plunger over inner plunger Install snap ring to inner plunger Slide outer plunger over center plunger Install snap ring to center plunger Slide plunger assembly into base Screw stop ring into base When necessary to disassemble the jack Replace all defective parts Clean all metal
17. on 3 inches 76 mm Total Extended Height 22 inches 559 mm Oil Pressure at Rated 6770 psig 476 kg sq Safety Pop off Valve Set at 38 5 tons 34 9 m tons Proof Load 52 5 tons 47 6 m tons Floor Loading at Rated Capacity 651 psi 46 kg sq cm Reservoir 2 gallons 7 6 liters Hydraulic Fluid MIL H 5606 or equivalent Maximum Towing Speed 5 mph 8 km h Approximate Jack Net Weight 360 lbs 163 kg GENERAL DESCRIPTION The Malabar Axle Jack Model 832R is a 35 ton capacity three stage telescoping hydraulic jack designed primarily for use in jacking the landing gear of various aircraft The jack consists of a three stage cylinder and base assembly frame reservoir assembly valve block assembly hand pump assembly and the
18. test adapter are correctly mated While operating the hand pump adjust set screw figure 3 29 until the safety pop off valve by passes hydraulic fluid back to the reservoir at 36 8 to 38 5 tons Replace plug figure 3 item 35 Once more operate hand pump to verify correct setting Install new lead amp wire seal figure 3 item 38 Open release valve to relieve pressure SPECIAL TOOLS The following special tools are necessary to disassemble reassemble the cylinder assembly These tools may be purchased upon request Part No 83220 730826 730827 83221 83224 Description Spanner wrench stop ring Spanner wrench inner bearing Spanner wrench center bearing Spanner wrench outer bearing Lifting tool extension screw RECOMMENDED SPARE PARTS The following spare parts are recommended and available upon request Part No 832RPK 83282R 83565 86399E 55001 886659 886658 886657 886656 86376 83295R 83294R 86339 83208R 83217R 83252R 83232R 83212R 55991 8 55997 2 55998 55994 75940 441 018 441 037 441 092 421 006 425 001 83275 86367 Description Repair parts kit
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