SERVICE MANUAL - Castle Equipment Co.
Contents
1. S 16032 523872 S 16023 S 15694 S 6586 M 1423 S 5096 S 9147 9149 WA 85 Repair Parts List Description Acorn Nut Jam Nut Bearing Cap Upper Bearing Assembly Caster Bracket Lower Bearing Assembly Bearing Retainer Caster Assembly Caster Wheel Hex screw 1 2 x 2 1 2 1 2 Lockwasher 1 2 Nut Cotter Pin Caster Axle Bearing Saddle Shoulder Bolt Saddle Bracket Pin Castle Nut Lifting Arm Saddle Bracket Lift Arm Pin Par Link Lift Arm Spring Spring Retainer Spring Retainer Par Link Pin Saddle Screw Spring Rod Tiecasting Bolt Tiecasting Pin Foot Pedal Pin Axle Crosshead Pin Cover Plate Hex Nut 1 2 Foot Pedal Release Lever Crosshead Pump Bracket or M 2237 Comp Spring Lift Arm Bushing Aluminum Washer Handle Yoke Yoke Return Rod Pin Cotter Pin 3 16 x 1 1 2 Cotter Pin 3 16 x 2 1 2 Inside Hub Washer Release Pull Lever Piston Rod Assembly Name Plate 114 20 Sq Hd Set Screw Piston Cup Rolt Pin Release Lever Pin Tie Casting Grease Fitting Wheel Bearing Cover Inside Wheel Washer Item No 61 62 1863 S 7412 AS 15930 AS 16037 M 1167 11103 S 1877 21050 55173 9 2591 5 1934 55176 AS 21052 S 9786 55261 AS 6660 AS 6550 Part No S 4710 5123 S 2329 AS 6545 21051 S 15047 S 17829 S 1805 S 16196 S 20886 S 5122 S 5355 S 7026 S 5178 S 16022 S 22964 M 2041 M 20422. CARE as the cup passes the filler plug hole not to cut or otherwise damage the cup Then replace the cylinder cap To replace the smali cup on the pump tum the cylinder unit pump end upward in the vise Unscrew the packing nut and pul out the pump plunger Remove the nut that holds cup to end of plunger insert new cup and replace nut Release Group Assembly Function 1 Ameans to manually release jack and safety overload circuit If underloaded jack bleeds down release valve may be out of alignment In release group assembly spring governs load jack will lift When pressure of cylinder overcomes spring tension the release valve floats off seat It is Imperative that the release valve floats freely in release group assembly To check use forefinger and thumb to grasp the release valve when the release cievis pin passes thru and wiggle from side to side There should be a minimum of 002 to 004 Clearance If no movement is noted remove hex nut release valve guide and release spring and place release valve with release valve guide back in release nut Tap end of release spring with Brass hammer Slide release valve guide into position and noting where alignment Is off correct misalignment by tapping welded needie bracket accordingly with Brass hammer Re assemble and set pressure by hydraulic means Note This procedure should only be done by a qualified Authorized Service Depot
3. 5 Aluminum Gasket S 24648 Pump Cup Order part number KJ 109 Service Instructions GET Handie Lock Lever Handle Set Screw Release Lever Lock Lock Rod Valve Plug Eliler Plug amp Reservoir Vent Hole To Assemble 1 Check the handle set screw for tightness 2 Remove and discard the vent filler plug This is very important as the vent hole must always be kept open so the jack can breathe To Operate 1 The jack is easily maneuvered by depressing the Handie Lock Lever until the lock rod engages one of the two handle positions and then pivot ing the jack on its rear casters 2 Place the jack In position so that the saddle will engage an approved lifting area of the vehicle The saddle is raised to the contact point by the foot pedal Light loads may be raised by the foot pedal alone On low clearance vehicles It is often advantageous to operate the foot pedal by hand while watching to assure proper saddle contact Surface on which jack rests should be fairly flat to prevent twisting of frame Load should be centered In saddle 3 Pump with handle for easy lifting Do not attempt to raise jack beyond Its travel stops 4 To lower the load pull back gently on the release lever 5 Be certain that area beneath vehicle is clear before lowering vehicle Always use the release lever lock to prevent unintentional operation of the release lever To Refill Remove the filler plug and with the saddie DO
4. S 15969 S 24497 S 7075 AS 22107 S 24648 7413 8 1863 S 3282 5 5652 2 M 1157 S 3010 15968 M 2167 S3 S4 AS 15962 AS 15961 AS 15965 S 23689 S5098 AS 12588 AS 24498 543 25661 Description Release Lever Pin Release Yoke 5 16 24 Jam Nut Packing Frame Assembly Center Wheel Packing Nut Front Roller Bearing 1 4 x 3 4 Cap Screw Hx Hd Release Valve Valve Guide Release Spring Lock Nut 3 8 Release Packing Nut Packing House Assembly Comp Spring Release Rod Handle Shell Lock Rod Lock Rod Return Spring Handle Assembly O Ring Housing O Ring O Ring Pipe Plug Ball Chamber Plug Handle Grip 5 8 Ball Bal Weight Vent Plug Pipe Plug Piston Packing Cylinder Cap Gasket Cylinder Cap Packing Nut Piston Rod Pump Piston Rod Release Lock Release Lever Assembly Pump Cup Pump Cup Washer Hex Nut 7116 Ball 3 8 Pipe Plug Line Connector Release Lever 3 4 Int Lockwasher Ram Cup Washer Ram Head Return Line Line Connector Elbow Cylinder Shell Cylinder Complete Ram Head Assembly Roll Pin 1 4 x 1 2 1 4 20 Sq Hd Set Screw Front Wheel Pump Rod Assembly 1 4 Lock Washer Bearing Spacer KJ 109 Seal Kit For Weaver WA 85 20 Ton Jack Contains 5122 Ball S 3282 Ball S 15047 O Ring S 17829 O Ring S 16022 Piston Rod Packing 3 S 16023 Piston Cup S 22964 Cylinder Cap Gasket S 7412 Packing 3 S 3083 Cotter Pin S 512
5. WEAVER jack con MopeL WA 85 PARTS BREAKDOWN SERVICE MANUAL For Parts PLEASE Contact Tou Faes 888 274 8490 c WEST T Since P 9 NY ze ps pj P O Box 3 BraiowooD IL 60408 Parts List WA 85 WEAVER SUPER GIANT LO Hi DRAULIC JACK 20 TON Order All Parts by Number FRAME AND LIFTING ARM ASSEMBLIES E NEL TEEN e AN a pnan Wat H ga i i DCH KENG rat KR kte i U 28 K No 3 q d E gt AFA d SM ZK Qe ORY E je D d 68 HANDLE ASSEMBLY 79 WA 85 WEAVER SUPER GIANT LO HI DRAULIC JACK Continued MISCELLANEOUS CASTINGS AND STEEL PARTS CUP LEATHERS PACKING GASKETS AND FOLLOWERS CASTER a ASSEMBLY AV A Va O 8 gt gt 8 p A 46 P 70 74 Ze 3 eee P L hk NGA G s Sr 19 Cylinder shell 67 AAA olla lo 6 13 Cylinder complete 14 Includes 96497 S ONDA P Part No S 6605 2232 S 24650 AS 15814 M 2028 AS 15815 5 15429 AS 15957 L M 1152 5 4594 8 1571 5 9522 293 515971 S 15398 M 2043 S 15975 S 15973 5 15987 AS 15944 AS 15950 S 15974 AS 15954 S 16061 S 16059 S 16058 S 15972 S 16098 S 27384 S 7394 56551 6552 S 15978 S 15976 AS 16051 s 508 M 1416 M 1148 M 2045 AS 16039 S 1365 15996 8 5125 M 1414 AS 20495 5 6549 S 794 S 3234 S 5200 5 16070 AS 16054
6. WN put in MIL F 17111 Oil until the level comes up to within 1 4 to 3 8 below filter hole Overfilling causes oll to spurt out the vent hole as jack is lowered or may prevent jack from lowering properly Insufficient oil causes jack to lift only part way Always be sure to put In oll only when the saddle is down Be careful not to let any dirt get into the reservoir while the Filler Plug Is out To Service 1 Keep all working parts thoroughly lubricated 2 Packing nuts at the piston and pump plunger should be kept moderately tight These packings are NOT under high pressure and should only be tight enough to prevent leakage 3 Ball valve may be removed for inspection and cleaning by removing the Ball Chamber Plug and turning the jack on Its side allowing the ball to roll out IMPORTANT Whenever it is necessary to loosen or remove the Ball Chamber Plug the gasket should be replaced with a new one Oil leakage at this point is usually caused by trying to use an old gasket over again 4 If pumping falls to raise the rated load the lower ball valve is leaking and It should be inspected for dirt or other obstruction Also check for proper oil level 5 if the load raises on the down stroke of the handle and immediately settles back forcing the handle up it shows the upper ball valve is leaking WARNING Always use stands to support vehicle before attempting under vehicle repairs or inspections To Relieve When Al
7. r Bound 1 Should the oll supply run too low the jack may become air bound and work on only a half stroke of the handle Fill the jack with oil raise the saddle and then lower the saddle while holding the foot pedal depressed This will flush out any air In the system and excess oil may run out of the vent Be sure jack Is properly filled with oll before putting it back In service Oil should cover piston rod To Remove Cylinder 1 Remove the cotter In the cross head 2 Remove the cotter and pin in the pump 8 4 Remove the cotter and pin in the release yoke Place cotter key in while depressing foot pedal This allows for easy removal and reassembly if spring is left on return rod Raise the lifting arm by means of the saddle and place a block of wood between the arm and frame to hold up the arm This releases the cylinder at the forward end so that It may be removed as a complete unit for service To Replace Cup 1 After removing the cylinder unit as described above place It in a vise Note that the vise jaws should grip the steel block not the steel cylinder Set the unit In the vise with the steel cylinder and piston up Remove the vent plug Unscrew the cylinder cap and lift the piston out of the cylinder Remove the nut and washer which holds the cup at the end of the piston put In the new cup and replace nut and washer In fitting the new cup Into the cylinder USE GREAT
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