aircraft maintenance & support equipment property of … · 2018-12-03 · malabar...

MALABARINTERNATIONAL

Date: April 22, 2016

OWNER’S MANUAL FOR MALABAR MODEL

AIRCRAFT MAINTENANCE & SUPPORT EQUIPMENT

8864

TWO STAGE FIXED HEIGHT HYDRO - MECHANICAL

AVIATION TRIPOD JACK

* GENERAL DESCRIPTION * OPERATION * SERVICE * PARTS BREAKDOWN

For Service & 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: [email protected] 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.

READ AND

SAVE

THIS INSTRUCTION

MANUAL

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RECOMMENDED SPARE PARTS:

The following spare parts are recommended and available upon request.

Part No. Description Qty Standard Spare Parts

8864PK Repair parts kit -------------------------------------------------------------------------------------------------- 1 56010-1 Valve block assembly---------------------------------------------------------------------------------------- 1 79366 Release valve knob ------------------------------------------------------------------------------------------ 1 79365 Release valve stem------------------------------------------------------------------------------------------- 1 65228 Release valve lockscrew ----------------------------------------------------------------------------------- 1 55155 Safety pop-off valve assembly -------------------------------------------------------------------------- 2 79571-1 Hand pump assembly --------------------------------------------------------------------------------------- 1 55762-7 Pump handle ---------------------------------------------------------------------------------------------------- 1 76347 Reservoir gasket ----------------------------------------------------------------------------------------------- 1 79562 Filler cap with dipstick---------------------------------------------------------------------------------------- 1 424-005 Drain cock valve ------------------------------------------------------------------------------------------------ 1

79596 55991-7 55994 55998 75940 876009 876012 876019 876020 51580 79595

Placard, instruction ------------------------------------------------------------------------------------------- 1 Placard, tonnage, 30 ton ---------------------------------------------------------------------------------- 1 Sticker, fluid ------------------------------------------------------------------------------------------------------ 1 Sticker, Malabar ------------------------------------------------------------------------------------------------ 2 Sticker, towing -------------------------------------------------------------------------------------------------- 1 Inner lower bearing ------------------------------------------------------------------------------------------- 1 Outer lower bearing ------------------------------------------------------------------------------------------ 1 Inner stop ring -------------------------------------------------------------------------------------------------- 1 Outer stop ring -------------------------------------------------------------------------------------------------- 1 Ship adapter----------------------------------------------------------------------------------------------------- 1 Rain hat ------------------------------------------------------------------------------------------------------------ 1

Air Pump Kit Spare Parts 441-001 441-030 421-004 471-001 499-001 425-001 481-001

876015 424-001

75941 79225

Air pump ----------------------------------------------------------------------------------------------------------- 1 Air pump seal kit ----------------------------------------------------------------------------------------------- 1 Air valve ------------------------------------------------------------------------------------------------------------ 1 Lubricator --------------------------------------------------------------------------------------------------------- 1 Muffler -------------------------------------------------------------------------------------------------------------- 1 Air relief valve --------------------------------------------------------------------------------------------------- 1 Oil screen --------------------------------------------------------------------------------------------------------- 1

Load Gauge Kit Spare Parts Load gauge ------------------------------------------------------------------------------------------------------ 1 Shutoff valve ---------------------------------------------------------------------------------------------------- 1

Adjustable Foot Kit Spare Parts Sticker, footpad ------------------------------------------------------------------------------------------------ 3 Level assembly ------------------------------------------------------------------------------------------------- 1

Hydraulic Caster Kit Spare Parts 8818PK 881801-1 881801-2 483-006 79366 79365 65228 881816

490-029 MS28778-6

76378

Hydraulic caster repair parts kit -------------------------------------------------------------------------- 3 Swivel caster----------------------------------------------------------------------------------------------------- 1 Swivel caster with swivel lock----------------------------------------------------------------------------- 2 Breather ----------------------------------------------------------------------------------------------------------- 3 Release valve Knob ------------------------------------------------------------------------------------------ 3 Release valve stem------------------------------------------------------------------------------------------- 3 Release valve lockscrew ----------------------------------------------------------------------------------- 3 Safety pop-off valve assembly -------------------------------------------------------------------------- 3

Shock Absorber Kit Spare Parts Shock Absorber ------------------------------------------------------------------------------------------------ 3 O-ring --------------------------------------------------------------------------------------------------------------- 6

Ladder Assembly Kit Spare Part Safety chain assembly -------------------------------------------------------------------------------------- 1

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16 1 363-00617 14 351-00318 1 351-00419 2 5599820 1 7594021 1 7891522 1 717-00123 1 87606024 1 MS28778-625 12 325-00126 1 881801-127 1 87606828 1 88181829 6 84292530 2 362-007

CYLINDER ASSEMBLYTRIPOD HEAD TEST PINWASHERVALVE BLOCK ASSEMBLYRESERVOIRSTRAPTOW HANDLESPACERELBOW, 3/8 TUBE x 3/8 SAETUBE, 3/8 O.D. x .065 WALLHHCS, 1/2-13 x 1" LGHHCS, 1/2-13 x 1 1/2 LGHHCS, 3/4-10 x 4 1/2 LGFLAT WASHER, 1/2 SAESPLIT LOCKWASHER, 1/2

MODEL 8864 JACK ASSEMBLY

FIGURE 1A

NO. QTY PART NO. DESCRIPTION

- 11 -

1 1 8864992 3 8429223 6 8336074 1 56010-15 1 8760306 1 8760317 1 795358 1 789859 1 722-018

10 A/R 732-01011 6 321-05112 4 321-01413 1 321-30614 18 362-00515 22 363-004


22

10

8121415

924 ♦

SPLIT LOCKWASHER, 3/4HEX NUT, 1/2-13HEX NUT, 3/4-10STICKER, MALABARSTICKER, TOWINGAIR PUMP KITPLUG, USED w / NO GAUGELADDER ASSEMBLY KITO-RING (PART OF ITEM 9)FSHCS, 1/2-13 x 1 1/2 LGSWIVEL CASTERADJ FOOT KIT w/ HYD CASTSHOCK ABSORBER KITBUSHINGFLAT WASHER, 3/4 SAE

26

14151725

13161830

23

111529

4

21

5

55998

6

12141517

19

23

1

28

27

20

7

♦ PART OF REPAIR PARTS KIT

19

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4


FIGURE 1B

MODEL 8864 JACK ASSEMBLY

BRACERESERVOIR GASKETRESERVOIR COVERFILLER CAP WITH DIPSTICKDRAIN COCK VALVEHHCS, 3/8-16 x 1 1/4 LGHHCS, GR 5, 1"-8 x 4" LGFLAT WASHER, 3/8 SAESPLIT LOCKWASHER, 1"HEX NUT, 1"-8

- 12 -

11 10 397-00512 1 55991-713 1 7959614 1 5599415 1 7959516 1 87601417 6 363-00318 2 881801-219 1 7922520 24 361-013

79

1020

18

1 6 8760242 1 763473 1 763464 1 795625 1 424-0056 6 321-0087 12 321-1018 6 362-0039 12 363-008

10 12 351-005


18

19

23

6817

791020

1

SELF TAPPING SCREW, #4PLACARD, TONNAGE, 30 TONPLACARD, INSTRUCTIONSTICKER, FLUIDRAIN HAT (NOT SHOWN)LOAD GAUGE KITSPLIT LOCKWASHER, 3/8SWIVEL CASTER W/ LOCKLEVEL ASSEMBLYFLAT WASHER, 1" SAE

1614

12115

1311

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12

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CYLINDEROUTER PLUNGERINNER PLUNGEREXTENSION SCREWEXTENSION SCREW NUTSHIP ADAPTERTRIPOD HEADOUTER LOCKNUTINNER LOCKNUTOUTER STOP RINGINNER STOP RINGOUTER LOWER BEARINGINNER LOWER BEARING

FIGURE 2

886499 CYLINDER ASSEMBLY

14 1 55925-44415 1 55929-44416 1 55931-44417 1 55932-26318 1 55924-75019 1 55925-43020 1 55929-43021 1 55931-43022 1 55932-24623 1 55924-47524 1 331-00125 1 331-002

NO. QTY PART NO. DESCRIPTIONNO. QTY PART NO. DESCRIPTION

1 1 8760052 1 8864113 1 8864104 1 8864085 1 8864166 1 515807 1 8760138 1 8760189 1 876017

10 1 87602011 1 87601912 1 87601213 1 876009

17

14

18

19

O-RINGBACK-UP RINGO-RINGO-RINGRETAINING RINGO-RINGBACK-UP RINGO-RINGO-RINGRETAINING RINGSHSS, 1/2-20 x 1/2 LGSHSS, 3/8-16 x 1/2 LG

23

13

16

15

21

20

22

9

4

10

65

7

1

2

3

8

11

2524

PART OF REPAIRPARTS KIT

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11

56010-1 VALVE BLOCK ASSEMBLY

FIGURE 3

- 14 -

PLUG, FLUSH, 1/16 NPTRELEASE VALVE KNOBRELEASE VALVE STEMBACK-UP RINGO-RINGSTEEL BALL, 5/16 DIASETSCREW, 5/16-24 x 5/16 LGPLUG, 1/4 SAESAFETY BYPASS SCREWSPRINGSPRING GUIDESTEEL BALL, 1/4 DIAPLUG, 3/8 SAE


1 2 717-0482 1 793663 1 793654 1 55929-0115 1 55925-0116 1 412-0027 1 331-0048 2 717-0019 2 55148

10 2 55154H11 2 5515312 2 412-00413 1 717-003

24(SYSTEM RELIEF VALVE)

826

219

10

OIL SCREENELBOW, 3/8 T x 3/8 SAESPRINGSTEEL BALL, 3/8 DIAO-RINGSHCS, 3/8-24 x 3" LGPLUG, SOC HD, 1/16 NPTVALVE BLOCKHAND PUMP ASSYRELEASE VALVE LOCKSCREWSAFETY POP-OFF VALVE ASSYO-RING (PART OF ITEM 13 &15)O-RING (PART OF ITEM 8)


14 1 5556815 1 722-01816 1 7936717 1 412-00118 4 55925-01419 4 323-00920 1 717-01021 1 7634522 1 79571-123 1 6522824 2 5515525 2 MS28778-626 2 MS28778-4

1920 AIR PUMP PORT

19

1325 14

18

5

2

73

4

1

23

6

12

22

1 18 18

25

19

CYLINDER PORT

19

GAUGE PORT

17

16

(THERMAL RELIEF VALVE)24

PART OF REPAIR PARTS KIT

11

10

12

9

158

26

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79571-1 HAND PUMP ASSEMBLY

FIGURE 4

13 1 55925-22014 1 5576115 1 5574516 2 55927-4317 1 5573918 3 372-03119 1 370-00120 1 MS51861-44C21 3 373-00122 1 7956323 1 55762-7


PISTONO-RINGBACK-UP RINGSCRAPER RINGRETAINING RINGPUMP BODYO-RINGSTEEL BALL, 3/8 DIASTEEL BALL, 5/16 DIASPRINGO-RINGPUMP CYLINDER NUT


1 1 557382 1 55925-2133 2 55922-184 1 557285 1 557296 1 557537 1 55925-2118 1 412-0019 1 412-002

10 1 5575411 1 55925-02112 1 79564

♦ 16

♦ 13

♦ 7♦ 9

♦ 10

♦ 18♦ 21

6

11 ♦

12

8 ♦

16 ♦

O-RINGFULCRUMPUMP HANDLE CLAMPRETAINING RINGLINKCOTTER RING, 7/16 PIN DIAQUICK RELEASE PIN, 1/4 DIASELF TAPPING SCREW, #10 CLEVIS PIN, 7/16 DIACYLINDERPUMP HANDLE

2 ♦

17

22

1

3 ♦

♦ 18♦ 21

♦ 5

♦ 4

14

20

18 ♦21 ♦

3 ♦

15

19 ♦ PART OF REPAIR PARTS KIT

23

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10

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78915 AIR PUMP KIT

AIR PUMPSTUDAIR VALVELUBRICATORMUFFLERNIPPLE, BRASS, 1/2 x 3" LGNIPPLE, BRASS, 1" x 4" LG ELBOW, BRASS, 1" FPTELBOW, 1/2 T x 1/2 MPTTEE, BRANCH, 1/2 NPTELBOW, 1/2 MPT x 3/8 FPTREDUCER, 3/8 MPT x 1/4 FPTAIR RELIEF VALVEALLEN NUT, 5/16-18

FIGURE 5

15 2 321-01316 2 363-00317 1 722-01818 1 722-01519 A/R 732-01020 A/R 732-00121 2 711-00422 1 719-00123 1 481-00124 1 712-01125 2 363-00226 2 361-00127 1 MS28778-6

NO. QTY PART NO. DESCRIPTIONNO. QTY PART NO. DESCRIPTION

1 1 441-0012 2 392-0013 1 421-0044 1 471-0015 1 499-0016 1 711-0067 1 711-0168 1 712-0159 2 722-013

10 1 713-02111 1 712-03212 1 714-009 13 1 425-00114 2 359-001

13

1112

151626

18

19

17 27

HHCS, 3/8 - 24 x 1" LGSPLIT LOCKWASHER, 3/8ELBOW, 3/8 T x 3/8 SAEELBOW, 3/8 T x 1/2 MPTTUBE, 3/8 O.D. x .065 WALLTUBE, 1/2 O.D. x .049 WALLNIPPLE, 1/2 MPTSWIVEL ADAPTEROIL SCREENELBOW, STREET, 1/2 NPTSPLIT LOCKWASHER, 5/16FLAT WASHER, 3/8O-RING (PART OF ITEM 17)

5

22

21

* 21

* 24

* 23

1425

32

* PARTS ARE LOCATED INSIDERESERVOIR TANK

20

9

1


94

67

8

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876014 LOAD GAUGE KIT

NO. QTY PART NO. DESCRIPTION8 1 714-0019 1 711-003

10 1 424-00111 1 722-02112 1 721-01113 A/R 732-00314 1 MS28778-4

- 17 -

FIGURE 6

LOAD GAUGESHCS, 10-32 x 3 1/2 LGSPLIT LOCKWASHER, # 10HEX NUT, 10-32SPACERTEE, 1/4 FPTPLUG, 1/4 MPT

13

NO. QTY PART NO. DESCRIPTION1 1 8760152 3 323-0723 3 363-0094 3 351-0085 3 8760256 1 713-0027 1 717-006

10

11

REDUCER, 1/2 FPT x 1/4 MPTNIPPLE, 1/4 MPTSHUTOFF VALVEELBOW, 1/4 T x 1/4 MPTCONNECTOR, 1/4 T x 1/4 SAETUBE, 1/4 O.D. x .035 WALLO-RING (PART OF ITEM 12)

1214

8

9

7

6

1

2345


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11

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876068 ADJUSTABLE FOOT KIT WITH HYDRAULIC CASTER

FIGURE 7

TRIPOD LEG WELDMENTTRIPOD LEG w/ HANDLE BRKTTRIPOD LEG w/ HANDLE HLDRFOOT WELDMENTFOOT SCREWSPRINGSHORT PINLONG PINRETAINING RING


1 1 8760752 1 8760763 1 8760804 3 8760215 3 793396 3 793447 3 793488 3 793459 12 55923-75

4


LOCKNUTRETAINING RINGFSHCS, 1/2-13 x 1 1/2 LGGUIDE SCREW, 5/8-11SPLIT LOCKWASHER, 5/8STICKER, FOOTPADHYDRAULIC CASTERHHCS, 1/2-13 x 2" LGSPLIT LOCKWASHER, 1/2

10 3 7934311 3 7934612 18 325-00113 3 7934714 3 363-00515 3 7594116 3 88180017 12 321-00518 12 363-004

12

1718

DRAIN

16

89

123

5

79

10

1314

15

6

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FIGURE 8

881800 HYDRAULIC CASTER ASSEMBLY


12 1 372-00913 1 373-00514 1 483-00615 1 712-06016 2 717-00517 1 717-00618 2 722-01819 A/R 732-02420 2 MS28778-621 1 881817

- 19 -

PLUNGERCYLINDERCAPRETAINING SCREWRESERVOIR & BASEVALVE BLOCK & HAND PUMPCASTER MOUNTING PLATEO-RINGO-RINGO-RINGBACK-UP RING


1 1 8818032 1 8818043 1 8818054 1 8818065 1 8818076 1 8818087 1 8818098 2 55925-0409 1 55925-045

10 1 55925-33011 1 55929-330

16

7

DRAIN

COTTER PIN, 3/32 x 1/2 LGFLAT HEAD PIN, 3/8 DIABREATHER, 1/8 MPTELBOW, 1/8 MPT x 1/8 FPTPLUG, 1/8 MPTPLUG, 1/4 MPTELBOW, 3/8 TUBE x 3/8 SAETUBE, 3/8 OD x .035 WALLO-RING (PART OF ITEM 18)SETSCREW ORIFICE

2

4

1213

8

1820

6

16

18 20

1721

19

3

1

10

8

11

9

APPLY LOCTITE NO. 242 ONTHREADS

PART OF HYDRAULIC CASTERREPAIR PARTS KIT

14

15

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8

- 20 -

FIGURE 9


881808 VALVE BLOCK & HAND PUMP ASSEMBLY

18 1 88184719 1 88184620 1 55926-11221 1 55911-1522 1 55925-21023 2 55922-1524 3 5500225 3 372-02826 1 5501127 1 352-00428 1 5501229 REF 88180730 1 MS28778-431 1 88181632 1 717-00333 1 MS28778-634 1 412-007

VALVE BLOCKGASKETSPRINGSTEEL BALL, 7/32 DIASTEEL BALL, 1/4 DIARELEASE VALVE KNOBRELEASE VALVE STEMBACK-UP RINGO-RINGSTEEL BALL, 5/16 DIASHSS, 5/16-24 x 5/16 LGPLUG, 1/4 SAESAFETY BY-PASS SCREWSPRING GUIDERELEASE VALVE LOCKSCREWSPRINGFULCRUM

1 1 550102 2 550243 1 552954 1 412-0035 1 412-0046 1 793667 1 793658 1 55929-0119 1 55925-011

10 1 412-00211 1 331-00412 1 717-00113 1 5514814 1 5515315 1 6522816 1 495-04817 1 881815


31

11

6 12 30

13

14

34

16

PLUNGER, 3/4 DIABODY, 3/4 DIARETAINING RINGSCRAPER RINGO-RINGBACK-UP RINGFLAT HEAD PIN, 5/16 DIABOW TIE COTTERANCHORHEX JAM NUT, 5/8-18LINKBASEO-RING (PART OF ITEM 12)SAFETY POP-OFF VALVE ASSYPLUG, 3/8 SAEO-RING (PART OF ITEM 32)STEEL BALL, 9/32 DIA

29

2

5

7

1

3

9

10

32 33

15

4

23

19

17

18 25

2 21

27

2622

PART OF HYDRAULIC CASTERREPAIR PARTS KIT

24

24

28

20

24

25

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FIGURE 10

1

23

37° FLARE END OF ITEM 2 TO BEINSERTED INTO ITEM 1

881818 SHOCK ABSORBER KIT

DIAPHRAGM ACCUMULATORCONN, 3/8 37° x 3/8 SAEO-RING (PART OF ITEM 2)


1 3 490-0292 3 721-0403 6 MS28778-6

DRAIN

HYDRAULIC CASTER ASSEMBLY

- 21 -

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FIGURE 11

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876060 LADDER ASSEMBLY KIT


LADDERPLATFORMSTRAPSAFETY CHAIN ASSEMBLYHHCS, 3/8-16 x 1" LGHHCS, 1/2-13 x 1 1/2 LG

1 1 8760502 1 8760513 2 8760314 1 763785 4 321-0116 4 321-014


HHCS, 1/2-13 x 2 3/4 LGFLAT WASHER, 3/8 SAEFLAT WASHER, 1/2 SAESPLIT LOCKWASHER, 3/8SPLIT LOCKWASHER, 1/2HEX NUT, 1/2-13

7 2 321-1398 4 362-0039 12 362-005

10 4 363-00311 6 363-00412 6 351-003

4

158

10

61112

2

61112

3

79

1112

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aircraft maintenance & support equipment property of … · 2018-12-03 · malabar...

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