Com 5928-Axle Jack (Pn-Rc4509k5a0a10)

Operating Instructions
+
Spare Parts List
Hydraulic Axle Jack

RC4509K5A0A10
9718800
Serial number: .................................
2005
Year of construction:........................
List of Revisions
The basic version of the manual for axle jack RC4509K5A0A10 was issued
in March 2002:
Revision-No. Chapter Revised pages Date Inserted by
May 2002 - 6-0 34 21.05.2002 A. Ullrich

Rev. 01
Jan. 2003 - 4-3 25 22.01.2003 L. Schober
Rev. 02
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page I
Introduction
A safe operation of the equipment is only guaranteed, if the operator has read and
understood the operating instructions. The equipment may only be operated by
authorized personnel.
Safety instructions are included in chapter 0-0 as well as in the chapters where
operating principles and movements are described.
Any person who is entrusted with operation, maintenance or repair of the equipment
must have read and understood these instructions, and in particular chapter 0-0, Safety.
A disregard of these operating instructions and any damage resulting from such a
disregard leads to an exclusion of liability by Hydro-Gerätebau GmbH & Co. KG.
These operating instructions cannot anticipate every potential application. For further
information or in case of problems that are not described or described insufficiently in
these operating instructions, please contact manufacturer.
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page II
Table of Contents
List of Revisions ........................................................................................................... I

Introduction ................................................................................................................. II
Table of Contents ....................................................................................................... III
List of Figures.............................................................................................................. V
List of Tables.............................................................................................................. VI
0-0 Safety ................................................................................................................... 1
0-1 Warnings and Safety Instructions ..................................................................... 1
0-2 Application / Use according to Intended Purpose ............................................. 2
0-3 Operating Personnel......................................................................................... 3
0-4 Operations on the Hydraulic System ................................................................ 3
0-5 Safety Instructions ............................................................................................ 4
0-5-1 Prohibitions................................................................................................... 4
0-5-2 Safety Instructions ........................................................................................ 4
0-5-3 User-Relevant Data ...................................................................................... 5
0-5-4 General Remarks ......................................................................................... 5
0-6 Modification of the Equipment .......................................................................... 6
0-7 Cleaning of Equipment and Disposal of Materials ............................................ 6
0-8 Transportation................................................................................................... 6
0-9 Copyright .......................................................................................................... 6
0-10 Potential Sources of Danger ............................................................................. 7
1-0 Description .......................................................................................................... 8
1-1 Specifications.................................................................................................... 8
1-2 Overview........................................................................................................... 9
1-3 Operating Material .......................................................................................... 10
1-3-1 Oil Quality................................................................................................... 10
1-3-2 Quality of Lubricants................................................................................... 10
1-4 Spare Parts Service........................................................................................ 10
2-0 Putting into Operation and Application .......................................................... 11
2-1 Putting the Jack into Operation without Air-operated Hydraulic Pump............ 11
2-2 Putting the Jack into Operation with Air-operated Hydraulic Pump................. 12
2-3 Application ...................................................................................................... 14
3-0 Inspection .......................................................................................................... 16
3-1 Periodic Inspection ......................................................................................... 17
3-2 Comprehensive Inspection ............................................................................. 21
4-0 Maintenance ...................................................................................................... 22
4-1 Basic Maintenance Instructions ...................................................................... 22
4-2 Table of Maintenance Instructions .................................................................. 23
4-3 Deaeration of Hydraulic System ..................................................................... 24
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page III
5-0 Trouble Shooting .............................................................................................. 26
6-0 Spare Parts List................................................................................................. 28
7-0 Hydraulic System.............................................................................................. 47
7-1 Hydraulic Diagram .......................................................................................... 48
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page IV
List of Figures
Fig. 1 General overview ................................................................................................ 9

Fig. 2 Deaeration of Hydraulic System ........................................................................ 25
Fig. 3 Hydraulic diagram.............................................................................................. 49
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page V
List of Tables
Tab. 1 Table of Application (00490-712-000) ................................................................. 2

Tab. 2 Potential Sources of Danger ............................................................................... 7
Tab. 3 Periodic Inspection ............................................................................................. 20
Tab. 4 Table of Maintenance Instructions .................................................................... 23
Tab. 5 Trouble shooting ............................................................................................... 27
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page VI
0-0 Safety
0-1 Warnings and Safety Instructions
...indicates an extremely big, imminent danger arising during handling of

the equipment. A non-observance of this indication can definitely result
in severe injuries or even death.
Danger
...indicates a danger that might arise from a product and might result in
severe injuries or even death, if no precautions are taken.
Warning
...indicates a potentially dangerous situation, which might result in

medium or slight injuries to a person or damage to objects.
Caution
...stands for a note from the manufacturer regarding safety and

proprietary rights.
Notice
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 1
0-2 Application / Use according to Intended Purpose
The axle jack, model RC4509K5A0A10, allows wheel and brake changes. It
may be used exclusively to lift the aircraft types listed in the below table at
their Landing Gears at the Jacking Adapters predefined by the aircraft
manufacturer.
Any other application is not in accordance with the intended purpose.
HYDRO-GERÄTEBAU GmbH & Co. KG declines the responsibility for any
damage or dangers resulting from other applications.
In addition, any other application would lead to an expiry of the
manufacturer's warranty.
Hydraulic Axle Jack RC4509 for

NLG MLG
A300/A310 A319 A300/A310 A319
A320 A321 A320 A321
A330 A340
B707 B727 B707 B717
B737 B777 B727 B737
DC-10/MD-11 L-1011 DC-9/MD-80
Tab. 1 Table of Application (00490-712-000)
For any other application an approval in writing is required from Hydro-

Gerätebau GmbH & Co. KG.
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 2
0-3 Operating Personnel
The operator must ensure that the equipment is only operated by trained and
instructed personnel. The personnel's responsibilities (for start-up, operation,
maintenance and repair) must be clearly defined.
Every person who is instructed to start-up, operate, maintain or repair the
equipment must have read and understood these instructions.
Operating personnel as well as supervisors must check the unit for visible
damage or defects before every use. In case of a changed operating
behavior of the equipment, the operation of the equipment must be stopped
immediately.
The equipment may not be operated by persons being under the influence of
alcohol, illegal or legal drugs.
Any person working on or with the equipment must wear safety boots and
safety gloves.
0-4 Operations on the Hydraulic System
Repairs or maintenance work on the hydraulic system may only be carried

out by persons with special knowledge and experience in hydraulics.
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 3
0-5 Safety Instructions
0-5-1 Prohibitions
- Lifting and transportation of persons is prohibited.

- No person may stand on the unit or reach into moving parts.
- The jack may not be operated in case of defects or damage. Any defects
or damage must be repaired immediately.
- After overload or in case of damage to the hydraulic lift cylinder the jack
may no longer be operated. The hydraulic lift cylinder must be replaced
immediately. After a replacement of the hydraulic lift cylinder, the jack
must be subjected to a comprehensive inspection (see chapter 3-2).
- It is not allowed to change or modify the setting of the pressure relief
valves (chap. 6-0, Abb. 4.1, Pos. 3).
- An outdoor storage of the equipment is not admissible.
0-5-2 Safety Instructions
- Safety instructions and indications of danger as well as warning signs

may not be removed or covered at any time. They must always be clearly
visible and legible.
- In addition to the operating instructions, the general as well as the local
regulations regarding accident prevention and environment protection
must be provided by the operator and respected.
- Special rules and regulations provided by aircraft manufacturers/aircraft
operators must be respected.
- Lighting at the workplace must be such that any work on the equipment or
operation of the equipment is possible without risk.
- All safety instructions and indications of danger on the equipment must be
observed.
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 4
0-5-3 User-Relevant Data
- The max. total load of 450 kN (50 short tons) may not be exceeded.
- The max. side load of 15% of the nominal load may not be exceeded.
- The admissible operating temperature of -20°C to +60°C (-4°F to +140°F)
for operation with hand-pump and -10°C to +60°C (+14°F to +140°F) for
operation with air-hydraulic pump must be respected at all times.
- Max. admissible towing speed: 3km/h.
0-5-4 General Remarks
- These operating instructions are part of the equipment. They must always
be accessible to the operator and allow the operator to inform himself.
- If the jack is sold, the operating instructions must be supplied with the
equipment.
- The axle jack may only be used for the purpose defined in chapter 0-2.
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 5
0-6 Modification of the Equipment
No conversions or modifications may be made to the jack without prior

permission in writing from Hydro-Gerätebau GmbH & Co. KG.
Hydro-Gerätebau GmbH & Co. KG will not take responsibility for any non-
approved modifications to the equipment.
Only original manufacturer's spare parts may be used.
0-7 Cleaning of Equipment and Disposal of Materials
Used substances and materials must be handled properly and in accordance

with the local regulations, in particular
- when working on lubrications systems and equipment
- when cleaning with solvents.
0-8 Transportation
The equipment may only be transported in an upright position. The tank

cover must show to the top. For shipping of the equipment, a pallet of a
suitable size is to be used (see specifications, chapter 1-1). The pallet must
at least have the size of the basic dimensions of the equipment.
Furthermore the equipment must be fastened properly on the pallet, so that a
slipping of the equipment is avoided during transportation.
0-9 Copyright
These operating instructions are only intended for the operator and his
personnel.
HYDRO-GERÄTEBAU GmbH & Co. KG, D-77781 Biberach/Baden has the
copyright on these operating instructions.
No part of these operating instructions may be reproduced in any form or by
any means without permission in writing from HYDRO-GERÄTEBAU GmbH
& Co. KG.
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 6
0-10 Potential Sources of Danger
Where What How to avoid
Mechanical Ground plate During lowering risk of ►Keep feet away from
system contusion for feet. ground plate!
Hydraulic lift cylinder During lowering of ►Keep fingers/hands

pistons risk of contusion away from area
for fingers/hands. between cover and
cylinder tube.
When jack is applied to ►Keep fingers/hands

the aircraft, risk of away from area
contusion for between adapter of
fingers/hands. jack and jacking
adapter of aircraft.
Hydraulic Hydraulic In case of damage ►Check parts at periodic

system components, e.g. hydraulic oil may squirt intervals and replace
hoses out with high pressure. them if necessary.
See chapter 3-1.
Hydraulic lift cylinder Do not extend pistons to ►Stop extension of

end positions by means pistons before end
of high-pressure pump positions are reached.
or air-operated hydraulic
pump, when jack is not
loaded or only slightly
loaded.
Hydraulic lift cylinder
might be damaged!
Tab. 2 Potential Sources of Danger
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 7
1-0 Description
1-1 Specifications
Nominal load....................................................... 450 kN (50 short tons)

Closed height ..................................................... 173 mm (6.8")
Extended height ................................................. 561 mm (22.1")
Hydraulic lift ....................................................... 325 mm (12.8")
Screw extension ................................................. 63 mm (2.5")
Max. width ......................................................... 175 mm (6.9")
Max. length ........................................................ 1355 mm (53,3“)
Operating fluid ................................................... siehe Kap. 1-3
Capacity of oil reservoir ..................................... 4,2 l (0.92 gal US)
Admissible operating temperature:
with hand pump ........................................... - 20° C to + 60° C
(- 4° F to + 140° F)
with air-operated hydraulic pump ................- 10° C to + 60° C
(14° F to + 140° F)
Max. towing speed ............................................. 3 km/h (2 mph)
Supply pressure for
air-operated hydraulic pump............................... 5 bar to max. 10 bar
(72 psi to max. 145 psi)
Max. ground pressure ........................................ 3,4 N/mm² (493 psi)
Weight ............................................................... 145 kg (320 lbs)
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 8
1-2 Overview
Fig. 1 General overview
1 Hydraulic lift cylinder 8 Stop-cock

2 Hand release valve 9 Low-pressure pump
3 Air-operated hydraulic pump 10 High-pressure pump
4 Manometer / Compressed air 11 Tank ventilation
5 Tow bar 12 Tank cap
6 Compressed air supply for 13 Threaded spindle
air-operated hydraulic pump 14 Pump lever
7 Pressure regulator 15 Oil level gauge
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 9
1-3 Operating Material
1-3-1 Oil Quality
On delivery the jack is filled with the hydraulic oil ESSO UNIVIS J-13.
If oil has to be refilled, we recommend to use the above brand.
If another oil type is used, ensure that the specifications of the oil types are
identical and that the oils can be mixed.
Regarding the oil quantity, see chapter 1-1.
1-3-2 Quality of Lubricants
For greasing standard lubricating greases that are suitable for the
aeronautical and the automotive industries can be used.
For a greasing of the hydraulic lift cylinder we recommend to use
FIN LUBE supplied by Interflon (www.interflon.com).
1-4 Spare Parts Service
For all parts of the jack manufactured by HYDRO-GERÄTEBAU GmbH &

Co.KG a spare parts service of ten (10) years is guaranteed.
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 10
2-0 Putting into Operation and Application
Before the jack is put into operation, the operator must ensure that his
personnel has been trained and instructed sufficiently.
In addition, he must ensure that the operating instructions have been read
and understood.
2-1 Putting the Jack into Operation without Air-operated

Hydraulic Pump
1. Check oil level gauge (Fig. 1, Pos. 15). Oil level must reach at least
middle of oil level gauge while hydraulic lift cylinder is completely
retracted.
2. Open hand release valve (Fig. 1, Pos. 2) by turning counter-clockwise.
Attach pump lever to low-pressure and high-pressure pump (Fig. 1,
Pos. 9+10) and operate each pump approximately 20 times.
3. Close hand release valve (Fig. 1, Pos. 2) by turning pump lever (Fig. 1,
Pos 14) clockwise and extend hydraulic lift cylinder almost completely
(stop shortly before end position).
Explosion hazard of hydraulic lift cylinder
Hydraulic oil squirting out under high pressure and parts flying around
can lead to death or severe injuries.
Danger
► Do not extend hydraulic lift cylinder completely if jack is unloaded or
only slightly loaded.
4. Open hand release valve (Fig. 1, Pos. 2) and retract hydraulic lift
cylinder.
5. Close hand release valve (Fig. 1, Pos. 2) by turning clockwise.
6. Check oil level and refill oil if oil level does not reach at least middle of
oil level gauge (Fig. 1, Pos. 15).
THE JACK IS READY FOR OPERATION
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 11
2-2 Putting the Jack into Operation with Air-operated
Hydraulic Pump
1. Check oil level gauge (Fig. 1, Pos. 15). Oil level must reach at least
middle of oil level gauge while hydraulic lift cylinder is completely
retracted.
2. Open hand release valve (Fig. 1, Pos. 2) by turning counter-clockwise.
Attach pump lever to low-pressure and high-pressure pump (Fig. 1,
Pos. 9+10) and operate each pump approximately 20 times.
3. Connect compressed air supply to air-operated hydraulic pump (Fig. 1,
Pos 6).
4. Set air pressure by means of pressure regulator (Fig 1, Pos 7) to
5 - 10 bar (72 - 145 psi). Check air pressure at manometer (Fig 1, Pos
14).
5. Activate air-operated hydraulic pump (Fig. 1, Pos. 3) in unloaded
condition for approx. 30 seconds by means of opening of stop-cock
(Fig. 1, Pos 8). While doing so hand release valve (Fig. 1, Pos. 2) must
be open.
Danger
► Do not extend hydraulic lift cylinder completely if jack is unloaded or
only slightly loaded.
6. Close hand release valve (Fig. 1, Pos. 2) by turning clockwise and

extend hydraulic lift cylinder almost completely (stop shortly before end
position).
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 12
7. Open hand release valve (Fig. 1, Pos. 2) and retract hydraulic lift
cylinder completely.
8. Close hand release valve (Fig. 1, Pos. 2).
9. Check oil level and refill oil if oil level does not reach at least middle of
oil level gauge (Fig. 1, Pos. 15).
THE JACK IS READY FOR OPERATION
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 13
2-3 Application
Hydraulic oil squirting out under high pressure and parts flying
around can lead to death or severe injuries.
Danger
► Before putting the jack into operation, make sure once more that
the jack is suitable for the respective application (see table in
chapter 0-2).
Danger ► When the jack is applied to the aircraft, no auxiliary means may be
used (e.g. hammer or similar devices).
1. Move jack underneath jacking adapter provided at the aircraft.
2. Screw out threaded spindle (Fig. 1, Pos. 13) if necessary.
Danger ► Do not extend hydraulic lift cylinder completely by means of high-
pressure pump or air-operated hydraulic pump, if jack is unloaded
or only slightly loaded.
3. Attach pump lever to low-pressure pump (Fig. 1, Pos. 9) and extend

hydraulic lift cylinder until there is a space of approx. 20 mm between
adapter of jack and jacking adapter of aircraft
4. Adjust position of jack underneath aircraft by means of tow bar (Fig. 1,
Pos. 5).
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 14
An incorrect application to the aircraft can also result in invisible
Danger
damage to the hydraulic lift cylinder.
► When applying the jack to the aircraft (jacking adapter at landing
gear), make sure that the jacking adapter sits perfectly in the pan of
the jack.
5. Continue to extend hydraulic lift cylinder with the help of low-pressure

pump, until adapter of jack and jacking adapter at landing gear of the
aircraft fit precisely.
6. Connect compressed air to compressed air supply connector (Fig. 1,
Pos 6).
7. Set air pressure by means of pressure regulator to
5 - 10 bar (72 - 145 psi). Check air pressure at manometer.
8. For load lifting, open stop-cock (Fig. 1, Pos 8). Air-operated hydraulic
pump (Fig. 1, Pos. 3) will start working.
In case no compressed air is available:
For load lifting, attach pump lever (Fig. 1, Pos 14) to high-pressure
pump (Fig. 1, Pos 10) and pump manually.
9. When the load has reached the desired height, close stop-cock (Fig. 1,
Pos 8).
Air-operated hydraulic pump will stop working.
10. To lower the load, open hand release valve (Fig. 1, Pos. 2) by turning it
slowly counter-clockwise by means of pump lever (Fig. 1, Pos 14).
11. Retract hydraulic lift cylinder completely.
12. Remove jack from aircraft.
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 15
3-0 Inspection
The operator must ensure that all tests and inspections which have to be
carried out are recorded. The records must include information on the test or
inspection, in particular date and scope of inspection, result of inspection and
detected faults, expertise on whether there are any objections against putting
the equipment into operation or against a further operation of the equipment,
indication of necessary additional inspections, name and signature of the
inspector.
In case faults are detected, the operator must acknowledge in the inspection
records that he has taken note of the faults and will rectify them.
The inspection records must be kept on file during the service life of the
equipment. If the equipment is free of faults, a test badge will be attached,
which also indicates the latest possible date of the next inspection.
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 16
3-1 Periodic Inspection
Hydraulic systems are pressurized
In case of improper maintenance, hydraulic fluid may squirt out under

high pressure and cause serious accidents.
Danger
► Before carrying out maintenance work, depressurize system by
turning hand release valve (Fig. 1, Pos. 2) counter-clockwise by
means of pump lever (Fig. 1, Pos 14).
Periodic inspections have to be carried by an expert at least once a year and

in accordance with the following list.
An expert is any person who has sufficient knowledge (gained in technical
studies and by experience) in the field of aircraft axle jacks and is familiar
with the local worker's protection rules, accident prevention regulations,
directives and generally recognized technical regulations (such as VDE, DIN,
etc.) so that he can assess whether aircraft axle jacks are in a condition
which is safe enough for operation.
For the inspection a suitable test rig must be available.
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 17
The following checks are required before every use of the jack:
Check Procedure Remark

- General ► Completeness Correct faults and
visual inspection. replace defective parts
► Leakage immediately.
► Hydraulic system, in particular

hydraulic lift cylinder
(cylinder: dirt, visible damage
to hydraulic lift cylinder)
► Defective or rusty parts
- Check oil level ► Oil level must reach middle of For oil level check
oil level gauge. pistons must be
completely retracted.
See chapter 1-3-2.
- Check hose lines. ► Check hose lines for damage In case of damage,
to outer casing, e.g.: replace hose lines.
- cracks
- kinks
- cuts
- peelings
- chafe marks
► Embrittlements
- Check hydraulic lift ► Extend hydraulic lift cylinder In case of damage,

cylinder for damage. completely by means of low- replace hydraulic lift
pressure pump. cylinder immediately
and carry out a
► Visual inspection. comprehensive
inspection in
accordance with
chapter 3-2.
- Check trapezoidal ► Turn out extension screw. In case of dirt, clean

thread of extension trapezoidal thread
screw for significant ► Visual inspection. immediately.
dirt.
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 18
The following checks are required at least once a year:

- General Check unit for: Correct faults and
visual inspection replace defective parts
► completeness immediately.
► defects in paint Correct defects in paint
immediately.
► leakage
► hydraulic system and hydraulic

lift cylinder
(cylinder: dirt / visible damage
to hydraulic lift cylinder)
► defective or rusty parts
- Check functioning of ► Extend pistons by means of - Response value of

pressure relief low-pressure pump until piston pressure relief valve /
valves underneath touches test rig and pressure low-pressure pump:
test rig. relief valve reacts. 5% of the nominal
load.
► Extend pistons by means of - Response value of

high-pressure pump or air- pressure relief valve /
operated hydraulic pump until high-pressure pump
piston touches test rig and and air-operated
pressure relief valve reacts. hydraulic pump: max.
110 % of the nominal
load.
- In case the setting is

not correct, the
pressure relief valves
must be reset by an
expert before the jack
is used again.
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 19
- Check hydraulic lift ► Extend hydraulic lift cylinder In case of damage,
cylinder for damage. completely by means of low- replace hydraulic lift
pressure pump. cylinder immediately
and carry out a com-
► Visual inspection. prehensive inspection
(see chap. 3-2).
- Check welds for ► Visual inspection of welds.

cracks.
Tab. 3 Periodic Inspection
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 20
3-2 Comprehensive Inspection
After a replacement of load carrying parts, such as the hydraulic lift cylinder
and after inadmissible operating conditions, such as overload, the jack must
be subjected to a comprehensive inspection.
This inspection may only be carried out by the manufacturer or by a company
which has been authorized by Hydro-Gerätebau GmbH & Co. KG.
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 21
4-0 Maintenance
The prescribed maintenance work may only be carried out by trained and
authorized personnel.
Hydro-Gerätebau GmbH & Co. KG disclaims all responsibility for damage
or consequential damage caused by improper maintenance or repair.
4-1 Basic Maintenance Instructions
Hydraulic systems are pressurized
In case of improper maintenance, hydraulic fluid may squirt out under

high pressure and cause serious accidents.
Danger ► Maintenance operations on the jack may only be carried out when
the jack is unloaded.
► During maintenance operations the jack must be switched off and

disconnected from the compressed-air supply system.
► Before commencing the maintenance work, depressurize the

system by turning the hand release valve (Fig. 1, Pos. 2) counter-
clockwise.
Damage caused by cleansing agents and solvents
Damage might be caused to composite, rubber or plastic materials.

► Use cleansing agents and solvents for the cleaning of metallic surfaces
Caution only.
► Wear safety gloves.
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 22
4-2 Table of Maintenance Instructions
WHEN WHAT REMARKS

Weekly or after ► Clean trapezoidal thread of For grease types
every 20 extension screw (Fig. 1, Pos. see chapter 1-3-2
13) and grease it slightly.
operating hours
Every 6 months ► Grease all mobile parts and For grease types
or after every 100 lubrication nipples. see chapter 1-3-2
operating hours ► Clean pistons and extension See chapter 1-3-2
screw (Fig. 1, Pos. 13) (in
particular trapezoidal thread).
Then regrease parts to avoid
corrosion.
Caution: Danger of incrustation
if not cleaned before greasing!
If necessary and ► Replace seals of hydraulic lift After a replacement of the

at the latest after cylinder seals, carry out leakage
test with the help of
3 years testing equipment (Hydro
ref. no. PV10005-003) or
underneath test stand.
► Carry out oil change.
► Clean sieve screw (chap. 6-0,

Fig. 4.1, Pos. 5) (at least once
a year).
► Replace hose lines.
Tab. 4 Table of Maintenance Instructions
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 23
4-3 Deaeration of Hydraulic System
Danger
► Do not use high-pressure pump or air-operated hydraulic pump.
Use low-pressure pump only.
Hydraulic oil issuing under pressure
Eye injuries might be caused by hydraulic oil issuing under pressure.

Caution
► Wear safety goggles.
1. Turn out extension screw (Fig. 1, Pos. 13) manually as far as possible
2. Attach pump lever (Fig. 1, Pos. 14) to low-pressure pump (Fig. 1, Pos. 9).
3. Extend hydraulic lift cylinder (Fig. 1, Pos. 1) completely (end position) by

means of low-pressure pump (Fig. 1, Pos. 9) and pump three times.
4. Apply flex head socket wrench to extension screw (Fig. 1, Pos. 13) and
further turn out extension screw by jerky movements until locking bolt
(Chap. 6-0, Fig. 3.0, Pos. 9) shears off.
5. Open hand release valve (Fig. 1, Pos. 2).
6. Unscrew screw (chap. 6-0, Fig. 3.0, Pos. 12).
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 24
Fig. 2 Deaeration of Hydraulic System
7. Open non-return valve (chap. 6-0, Fig. 3.0, Pos. 10). For this purpose,
press down ball with the help of thin object (e.g. welding wire, etc.) and
hold ball in this position (see also Fig. 2).
8. Operate low-pressure pump (Fig. 3, Pos. 9) until oil issues bubble-free.

Then release ball and stop pumping.
9. Turn in screw (chap. 6-0, Fig. 3.0, Pos. 12) along with new seal (chap.
6-0, Fig. 3.0, Pos. 11).
10. Remove oil residues.
11. Turn in extension screw (Fig. 1, Pos. 13) along with new locking bolt
(Chap. 6-0, Fig. 3.0, Pos. 9) and new compression spring (Chap. 6-0, Fig.
3.0, Pos. 8).
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 25
5-0 Trouble Shooting
After any trouble shooting the hydraulic system must be
deaerated before the jack is returned to service (see chapter 4-3).
Trouble Probable cause Remedy

Hydraulic lift cylinder does Nominal load is exceeded ► Check whether application
not extend. and pressure relief valve is in accordance with Table
reacts (chap. 6-0, Fig. 4.1, 1, Chapter 0-2.
Pos. 3).
Pressure relief valve (Fig. ► Replace pressure relief
4.1, Pos. 3) is out of order valve.
and reacts before the Have pressure relief valve
nominal load is reached. set by an expert to 110 %
of the nominal load. Make
sure a suitable test rig is
available for this purpose.
Air-operated hydraulic ► Replace air-operated
pump does not work hydraulic pump.
properly.
Hydraulic lift cylinder Air in the hydraulic system. ► Deaerate hydraulic system
extends jerkily. (see chapter 4-3).
Hydraulic lift cylinder Hand release valve (Chap. ► Open hand release valve
retracts slowly. 1-2, Fig. 1, Pos. 2) is not briefly, then close it
closed properly. properly.
Seals (Chap. 6-0, Fig. 3.0, ► Replace damaged seals.
Pos. 13, 14, 15, 16) of
hydraulic lift cylinder are
damaged and oil leaks out.
Hydraulic lift cylinder does Pistons are dirty and friction ► Dismount hydraulic lift
not retract although hand in guide bushings is cylinder and clean it
release valve is open. excessive. thoroughly.
Hand pump is not sucking. Air in the hydraulic system. ► Deaerate hydraulic system
(see chapter 4-3).
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 26
Trouble Probable cause Remedy
Sucking valve is jammed. ► Dismount pump cylinder
and check seat of ball
(Chap. 6-0, Fig. 4.1, Pos.
8).
Sieve screw (Chap. 6-0, ► Remove sieve screw and
Fig. 4.1, Pos. 5) is dirty. clean sieve thoroughly.
Hand pump is leaking. Damaged seal – oil issues ► Replace grooved rings
from pump piston. (Chap. 6-0, Fig. 4.1.1, Pos.
8 and/or Fig. 4.1.2, Pos.
11).
Damaged seal – oil issues ► Replace copper gasket
from pump cylinder. (Chap. 6-0, Fig. 4.1, Pos.
9).
Tab. 5 Trouble shooting
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 27
6-0 Spare Parts List
When ordering spare parts for this jack, please indicate

- part number
- designation of part
- model
- serial number
- year of construction
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 28
Nummer Bestellnummer Benennung Stück
Number Reference Number Designation Quantity
No. No. de référence Désignation Quantité
No. No. de referencia Disignación Cantídad
RC4509K5A0A10 Hydraulic axle jack

---------------------------------------------------------------
1 17161-005-000 Frame 1 Fig. 2.0

2 17161-006-000 Hydraulic lift cylinder 1 Fig. 3.0
3 17159-003-000 Drive 1 Fig. 4.0
4 00166-084-000 Undercarriage 1 Fig. 5.0
5 00490-712-000 Indicating lable 1
RC4509K5A0A10 Hydraulic axle jack Jan.2003-Rev.02

Fig. 1.0 Page 29
17161-005-000 Frame
-----------------------------------------------
1 17161-005-001 Frame 1
2 00102-049-015 Accessories, oil reservoir 1 Fig. 2.1
RC4509K5A0A10 Frame Jan.2003-Rev.02

Fig. 2.0 Page 30
00102-049-015 Accessories, oil reservoir

-----------------------------------------------------------------------
1 00474-019-000 Grooved ring 1

2 00410-092-000 Cover, oil reservoir 1
3 DIN 912-M6x25 Cylindric head screw 6
4 00411-009-000 Copper gasket 6
5 00480-044-000 Oil level indicator 1
6 00515-054-000 Nut 1
7 00154-016-000 Air valve 1
RC4509K5A0A10 Accessories, oil reservoir Jan.2003-Rev.02

Fig. 2.1 Page 31
17161-006-000 Hydraulic lift cylinder

------------------------------------------------------------------
1 17161-006-001 Cylinder tube 1

2 17161-006-002 Piston III 1
3 17161-006-003 Piston II 1
4 17161-006-004 Piston I 1
5 17161-006-005 Extension screw 1
6 00414-031-000 Retaining ring 1
8 N-730 Compression spring 1
9 S-2552 Locking bolt 1
10 00489-053-000 Non-return valve 1
11 00411-009-000 Copper gasket 1
12 DIN 912-M6x8 Cylindric head screw 1
13 00301-323-000 O-ring 1
14 00316-023-000 Turcon-Glyd ring Ø 90 1
15 00316-035-000 Turcon-Glyd ring 1
16 00317-006-000 Turcon-Glyd ring 1
RC4509K5A0A10 Jan.2003-Rev.02
Page 32
RC4509K5A0A10 Hydraulic lift cylinder Jan.2003-Rev.02
Fig. 3.0 Page 33
17159-003-000 Drive
---------------------------------------------
1 15139-000-000 Hand pump 1 Fig. 4.1

2 17027-020-000 Air-hydraulic installation 1
3 DIN 6912-M10X25 Cylindric head screw 6
4 54568 Spring washer 6
5 00420-007-000 Pump lever 1
6 00418-046-000 Pivot 1
7 DIN 915-M10X40 Threaded pin 1
RC4509K5A0A10 Drive Jan.2003-Rev.02

Fig. 4.0 Page 34
15139-000-000 Hand pump

------------------------------------------------------
1 15048-000-000 Low-pressure pump assy. 1 Fig. 4.1.1

2 15049-000-000 High-pressure pump 1 Fig. 4.1.2
3 00150-014-000 Pressure relief valve 2
4 00153-001-000 Stop valve 2 Fig. 4.1.3
5 00434-014-000 Sieve screw 1
6 00151-030-000 Release valve 1 Fig. 4.1.4
7 00153-006-000 Stop valve 1 Fig. 4.1.5
8 DIN 5401-9 Ball 2
9 00411-002-000 Copper gasket 2
10 DIN 906-M8X1 Screw plug 5
11 DIN 906-M10X1 Screw plug 2
12 00411-005-000 Copper gasket 2
13 00411-052-000 Copper gasket 1
RC4509K5A0A10 Jan.2003-Rev.02
Page 35
RC4509K5A0A10 Hand pump Jan.2003-Rev.02
Fig. 4.1 Page 36
15048-000-000 Low-pressure pump assy.

------------------------------------------------------------------------
1 00405-005-000 Bolt 3
2 DIN 6799-9 Retaining ring 6
3 15024-001-017 Connecting link 1
4 DIN 471-50x2 Retaining ring 1
5 00423-001-000 Pump lever 1
6 15008-000-002 Pump piston 1
7 00302-020-000 Wiper 30x38x7 1
8 00304-037-000 Grooved ring 1
9 15038-000-003 Pump cylinder 1
10 15008-000-009 Bearing ring 1
11 DIN 71412-AM8X1 Lubrication nipple 1
12 00480-016-000 Washer 1
RC4509K5A0A10 Low-pressure pump assy. Jan.2003-Rev.02

Fig. 4.1.1 Page 37
15049-000-000 High-pressure pump

-----------------------------------------------------------------
1 DIN 6799-9 Retaining ring 6

2 00405-005-000 Bolt 3
3 15024-001-017 Connecting link 1
4 DIN 471-50x2 Retaining ring 1
6 00423-001-000 Pump lever 1
7 15035-000-001 Pump piston 1
8 00302-021-000 Wiper 12X20X7 1
9 15035-000-007 Pump guide 1
10 15035-000-004 Pump cylinder 1
11 00304-031-000 Grooved ring 1
12 DIN 71412-AM8X1 Lubrication nipple 1
13 00480-016-000 Washer 1
14 15008-000-009 Bearing ring 1
RC4509K5A0A10 High-pressure pump Jan.2003-Rev.02

Fig. 4.1.2 Page 38
00153-001-000 Stop valve

----------------------------------------------------
1 00431-001-000 Shank screw 1

2 00411-008-000 Copper gasket 1
3 00404-022-000 Compression spring 1
4 DIN 5401-7 Ball 1
RC4509K5A0A10 Stop valve Jan.2003-Rev.02

Fig. 4.1.3 Page 39
00151-030-000 Release valve

---------------------------------------------------------
1 00441-069-000 Sleeve 1
2 DIN 1481-4x32 Spacer bushing 1
3 00301-024-000 O-ring 12X3 1
4 00452-001-000 Sleeve 1
5 00451-033-000 Release spindle 1
6 00453-001-000 Cone sealing 1
7 00411-007-000 Copper gasket 1
RC4509K5A0A10 Release valve Jan.2003-Rev.02

Fig. 4.1.4 Page 40
00153-006-000 Stop valve

----------------------------------------------------
1 00430-024-000 Screw plug 1

2 00411-022-000 Copper gasket 1
3 00404-059-000 Compression spring 1
4 DIN 5401-9 Ball 1
5 00506-001-000 Valve seat 1
RC4509K5A0A10 Stop valve Jan.2003-Rev.02

Fig. 4.1.5 Page 41
17027-020-000 Air-hydraulic installation

----------------------------------------------------------------------
1 00433-053-000 Male stud coupling 3

2 00433-013-000 Adjustable male stud Tee 2
3 00417-006-00150 Pipe line 1
4 00131-022-000 Air-hydraulic pump 1
5 00470-037-000 Manometer 1
6 00463-175-000 Equal elbow coupling 2
7 00469-007-000 Ball valve 1
8 00417-004-00095 Pipe line 1
9 00463-148-000 Hose connection 1
10 00463-154-000 Locking nipple 1
11 DIN 933-M6X30 Hexagonal head screw 4
12 DIN 125-B6,4 Washer 4
13 00445-098-000 Spacer 2
15 00417-006-00102 Pipe line 1
16 00417-006-00300 Pipe line 1
18 00417-006-00034 Pipe line 2
22 00463-144-000 Screw plug 1
23 00495-044-000 Pressure regulator 1
24 00463-120-000 Reducing nipple 1
25 00463-088-000 Double-threaded nipple 1
26 00463-177-000 Bulkhead coupling 1
28 17027-020-001 Pump support assy. 1
29 00433-124-000 Stud standpipe adapter 1
30 00417-006-00040 Pipe line 1
RC4509K5A0A10 Jan.2003-Rev.02
Page 42
31 00463-194-000 Test connector 1

32 00480-294-000 Cover 1
33 00480-295-000 Felt washer 1
34 00305-004-000 NOBÜ washer 4
35 00305-005-000 NOBÜ washer 1
36 00305-003-000 NOBÜ-washer 2
RC4509K5A0A10 Jan.2003-Rev.02
Page 43
RC4509K5A0A10 Air-hydraulic installation Jan.2003-Rev.02
Fig. 4.2 Page 44
00166-084-000 Undercarriage
---------------------------------------------------------
1 00166-084-001 Wheel support 1

2 00418-127-000 Bolt 1
3 00465-010-000 Wheel 4
4 00441-046-000 Sleeve 1
5 DIN 916-M5X8 Threaded pin 2
6 DIN 316-M12X25 Wing nut 2
7 17027-014-016 Tow bar 1
8 17027-014-028 Support 1
9 DIN 933-M12X30 Hexagonal head screw 2
10 54555 Spring washer 2
RC4509K5A0A10 Undercarriage Jan.2003-Rev.02

Fig. 5.0 Page 45
7-0 Hydraulic System
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 47
7-1 Hydraulic Diagram
1.0 See chapter 6-0 Hydraulic lift cylinder

2.0 00151-030-000 Hand release valve
3.0 00153-006-000 Non-return valve
5.0 00150-014-000 Pressure relief valve
(low pressure)
6.0 00150-014-000 Pressure relief valve
(high pressure)
8.0 15048-000-000 Low-pressure pump
9.0 15049-000-000 High-pressure pump
10.0 DIN 5401-9 Non-return valve (ball)
11.0 DIN 5401-9 Non-return valve (ball)
12.0 See chapter 6-0 Oil reservoir
13.0 See chapter 6-0 Air-operated hydraulic pump (option)
14.0 00434-014-000 Sieve screw
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 48
Fig. 3 Hydraulic diagram
RC4509K5A0A10 Jan. 2003 – Rev. 02

Page 49

Com 5928-Axle Jack (Pn-Rc4509k5a0a10)

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Operating Instructions

Hydraulic Axle Jack

Revision-No. Chapter Revised pages Date Inserted by

May 2002 - 6-0 34 21.05.2002 A. Ullrich

RC4509K5A0A10 Jan. 2003 – Rev. 02

RC4509K5A0A10 Jan. 2003 – Rev. 02

List of Revisions ........................................................................................................... I

RC4509K5A0A10 Jan. 2003 – Rev. 02

RC4509K5A0A10 Jan. 2003 – Rev. 02

Fig. 1 General overview ................................................................................................ 9

RC4509K5A0A10 Jan. 2003 – Rev. 02

Tab. 1 Table of Application (00490-712-000) ................................................................. 2

RC4509K5A0A10 Jan. 2003 – Rev. 02

...indicates an extremely big, imminent danger arising during handling of

...indicates a potentially dangerous situation, which might result in

...stands for a note from the manufacturer regarding safety and

RC4509K5A0A10 Jan. 2003 – Rev. 02

Hydraulic Axle Jack RC4509 for

Tab. 1 Table of Application (00490-712-000)

For any other application an approval in writing is required from Hydro-

RC4509K5A0A10 Jan. 2003 – Rev. 02

0-4 Operations on the Hydraulic System

Repairs or maintenance work on the hydraulic system may only be carried

RC4509K5A0A10 Jan. 2003 – Rev. 02

- Lifting and transportation of persons is prohibited.

0-5-2 Safety Instructions

- Safety instructions and indications of danger as well as warning signs

RC4509K5A0A10 Jan. 2003 – Rev. 02

0-5-4 General Remarks

RC4509K5A0A10 Jan. 2003 – Rev. 02

No conversions or modifications may be made to the jack without prior

0-7 Cleaning of Equipment and Disposal of Materials

Used substances and materials must be handled properly and in accordance

The equipment may only be transported in an upright position. The tank

RC4509K5A0A10 Jan. 2003 – Rev. 02

Where What How to avoid

Hydraulic lift cylinder During lowering of ►Keep fingers/hands

When jack is applied to ►Keep fingers/hands

Hydraulic Hydraulic In case of damage ►Check parts at periodic

Hydraulic lift cylinder Do not extend pistons to ►Stop extension of

Tab. 2 Potential Sources of Danger

RC4509K5A0A10 Jan. 2003 – Rev. 02

Nominal load....................................................... 450 kN (50 short tons)

RC4509K5A0A10 Jan. 2003 – Rev. 02

Fig. 1 General overview

1 Hydraulic lift cylinder 8 Stop-cock

RC4509K5A0A10 Jan. 2003 – Rev. 02

1-3-1 Oil Quality

1-3-2 Quality of Lubricants

1-4 Spare Parts Service

For all parts of the jack manufactured by HYDRO-GERÄTEBAU GmbH &

RC4509K5A0A10 Jan. 2003 – Rev. 02

2-1 Putting the Jack into Operation without Air-operated

Explosion hazard of hydraulic lift cylinder

THE JACK IS READY FOR OPERATION

RC4509K5A0A10 Jan. 2003 – Rev. 02

Explosion hazard of hydraulic lift cylinder

6. Close hand release valve (Fig. 1, Pos. 2) by turning clockwise and

RC4509K5A0A10 Jan. 2003 – Rev. 02

THE JACK IS READY FOR OPERATION

RC4509K5A0A10 Jan. 2003 – Rev. 02

Explosion hazard of hydraulic lift cylinder

Explosion hazard of hydraulic lift cylinder