5.
Remove unit from the vice, take off the Cap Tool and re-locate the unit horizontally in the vice again using the Body
Clamps (Tool 1).
(See Fig 3.)
6.
Screw the ‘T’ Bar (Tool 4) onto the Air Jack Inlet Adaptor thread. Pull on the ‘T’ Bar to expose approximately 8 coils of the
internal Tension Spring and slide the Spring Trap Plate (Tool 5) over 1 spring coil and against the open end of the Body.
(See Fig 3.)
7.
Remove the ‘T’ Bar and unhook the Cap from the Tension Spring. Locate Spring Hook Tool (Tool 6) onto the Tension Spring
hook, pull gently to take the spring load and remove the Spring Trap Plate. Carefully release the load to allow the spring fully
back inside the Air Jack and remove the Hook Tool.
(See Fig 4.)
8.
Remove the unit from the vice and pull on the Foot to expose the Air Jack Ram. Fit the pair of Ram Clamps (Tool 7) to the
Ram and tighten securely in the vice but do not over tighten. Then clean the Ram first if it is dirty. Fit Pin Tool (Tool 3) onto
the Foot and unscrew the Foot anti-clockwise out of the Ram using either a Torque spanner and a 21mm Socket or using a
15mm diameter Tommy Bar (Not supplied) through the hole in the Pin Tool. Pull the Foot and spring out of the Ram.
(See Fig 5.)
9.
Remove the Inlet Adaptor from the Cap and discard the copper washers.
10.
The Bearing Housing is still located in the Body, but no tool is supplied, as it is not necessary to remove it. The small
Bearing in the Bearing housing can be replaced in situ.
11
. The Air Jack is now sufficiently dis-assembled to clean, lubricate and fit replacement parts.
Airjack Servicing Instructions and Re-Assembly
These notes assume that all metal components are in a re-usable condition. If any component is damaged beyond use, then
the Air Jack should either be returned to AP Racing for full re-conditioning, including replacement of the damaged components,
or additonal replacement parts will need to be ordered.
1. Remove all 3 O-rings from the Cap, the Piston and the Foot and both plastic Bearings and discard them. Thoroughly
clean all other metal components. Use an alcohol based cleaning fluid. i.e. Methylated Spirit or warm soapy water.
DO NOT
USE ANY PETROLEUM BASED CLEANERS AS THESE WILL DAMAGE THE RUBBER SEALS.
2.
Use the 3 O-rings, the 2 Bearings and the 2 Copper washers contained in Repair Kit CP2985-1RK to replace those parts
discarded. In order to install both Bearings, they will need to be split as shown in the illustration included in the repair kit.
3
. Apply Silicon Spray lubricant to the main Bore of the Body and pack the Main O-Ring groove of the Piston with Silicon
Grease as shown in the illustration below. Take care not to allow lubricant onto any of the threads that are to be bonded with
Loctite.
(See fig 6.)
4.
Re-Assembly is the exact reverse of the operations
listed above. Assembly Bullet (Tool 8) is to be engaged
in the end of the Ram to aid its re-insertion through the
Body and Bearing Housing assembly.
5.
The Foot is to be bonded to the Ram and the Cap is
to be bonded into the Body using Loctite 270. Ensure
threads are clean, apply Loctite Activator 7649 and then apply 1 complete circumferential ring of Loctite to the first turn only
of the Male thread. Do not apply excess Loctite. With the Activator applied, the Loctite will set quickly, so follow the procedure
above, only just prior to threading any pair of parts together. Quickly screw parts together until fully seated, ensuring that any
O-rings are correctly positioned and are not cut. Using the same tools used for dis-assembly, tighten all parts securely. Use
a compressed air supply of 5 Bar maximum to check for leaks.
(Fig 3.)
(Fig 4.)
(Fig 5.)
Position O-Ring in this groove, against the face shown.
Pack the remainder of the seal groove with silicon grease.
(fig 6.)
