Вы находитесь на странице: 1из 12

e2b calibration | 521 Fifth Avenue | Chardon, OH | 440.352.4700 | www.e2bcal.

com

Image: tronair.com

Introduction .................................................................................................................................... 3
The Basics of Proof Load Testing .................................................................................................... 3
Proof Load Testing Regulations .................................................................................................. 3
Causes of Hydraulic Jack Failure ................................................................................................. 3
Benefits of Proof Load Testing .................................................................................................... 4
Manufacturer Recommended Testing Schedule ........................................................................ 4
90 day preventative maintenance checklist: .......................................................................... 4
12 month load testing procedure ........................................................................................... 5
On-site vs Off-site Testing Considerations...................................................................................... 5
Shipping Costs ............................................................................................................................. 6
Time and Labor Considerations .................................................................................................. 7
Service Costs ............................................................................................................................... 8
Down time .................................................................................................................................. 8
Putting it all together ................................................................................................................ 10
Time and Costs Comparison Charts .............................................................................................. 10
Conclusion ..................................................................................................................................... 11
About e2b calibration ................................................................................................................... 12

e2b calibration | 521 Fifth Avenue | Chardon, OH | 440.352.4700 | www.e2bcal.com

Does your axle or tripod jack withstand the amount of force it was designed to
withstand? Its no question it was engineered that way, but theres no guarantee that it
still does what is was designed to do after it leaves the manufacturer. Despite this
uncertainty and the critical role hydraulic jacks play in an aircraft maintenance facility, a
large majority of aircraft maintenance professionals are unaware that the jack
manufacturers recommend regular maintenance and annual proof load testing to ensure
optimal performance and safety.
In this guide we discuss why proof load testing should be an important part of your
quality assurance program; the causes of decreased jack performance; best practices in
maintenance and testing frequency as recommended by manufacturers; the pros and
cons of on-site versus offsite proof load testing considerations, and more.

Proof load testing is a process by which the fitness of the load-bearing structure (the
jack) is tested to ensure it will maintain structural integrity during normal use. In other
words, proof load testing ensures the jack is able to perform in accordance with the
manufacturers guidelines.
While FAA regulations that pertain to aircraft maintenance and repair facilities do not
specifically mandate that all jacks be tested on a regular basis, it is a little known fact
that testing is highly recommended by hydraulic jack manufacturers. For example,
Tronair, a leading manufacturer of both axle and tripod jacks, recommends proof load
testing on an annual basis. Further, proof load testing can help with compliance with
other quality assurance programs and best practices that may soon become mandated
regulations.
As mentioned previously, there is no way to tell if your jack can withstand the force it
was built to withstand until its too late. This can create a lot of problems when you think
about it. For example, what if you lift a plane up on the jack and as youre working on it,
the jack leaks. Now the jack may not have the power you need to get the plane back on
the ground safely.
There are many factors that can impact the performance of your jack, but the most
common issues have to do with leaks in the hydraulic system. For example, a seal can
go bad, contamination (especially rust) can cause imperfections in the cylinder, a check
ball valve may not be seating correctly, and other issues can cause hydraulic fluid to
leak which in turn can lead to underperformance or complete failure of the jack.

e2b calibration | 521 Fifth Avenue | Chardon, OH | 440.352.4700 | www.e2bcal.com

Outside of issues with hydraulics, structural damage caused by misuse or mishandling


can also cause equipment to lose integrity. For example, a dented leg on a tripod jack
could easily collapse when being used to lift a plane, which could result in physical harm
to maintenance crew members, the jack itself, or the aircraft being worked on.
Proof load testing verifies that the exterior and interior components of the jack comply
with specifications of the manufacturer to reduce the risk of equipment failure like those
examples given above. Further, regular proof load testing supplies you with required
documentation or certifications that may be necessary to meet internal or external
quality compliance mandates.
Additionally, practicing regular jack maintenance and testing increases your value as a
high quality provider of aircraft maintenance services. This can be a major value-add to
your internal quality assurance program and customer peace of mind. Additional
benefits of proof load testing include:
Compliance with internal quality standards
Compliance with any government or industry regulations
Peace of mind for your staff that they are working with equipment that has been
tested and certified for safety.
Peace of mind for customers that youre providing high quality services.
Increased competitive advantage over other facilities that do not to elect to follow
recommended jack maintenance and testing schedules.
Prolonged life of the jack as well as the aircrafts it is being used on.

As mentioned above, manufacturers recommend 90 day maintenance and testing be


done on your jack(s) once every 12 months. Testing may also be advised outside of the
regular schedule if an event takes places that could potentially damage the jack. For
example, being dropped or having something dropped on the jack that may cause
damage to the structure or the hydraulic system.
Below is an example of maintenance and testing guidelines recommend by most
manufacturers. Keep in mind these procedures might vary slightly depending on the
specific jack you are working with.

90 day preventative maintenance checklist:


Check the hydraulic system for leaks.
o Hydraulic lines; hoses and fittings.
o Hand pump; cylinder, fittings and seals.
o Reservoir; welds and fittings.
o Air operated pump (optional equipment); fitting, air side and oil side seals.

e2b calibration | 521 Fifth Avenue | Chardon, OH | 440.352.4700 | www.e2bcal.com

Check the jack structure for corrosion, bending, cracking, excessive wear, etc.
o Ball lock pins.
o Mechanical extension.
o Welded joints; tripod legs, cylinder and foot pads.
o Ram lock nuts; gouge marks and cracks in thread.
o Jack pads.
Check fluid levels with rams fully retracted.
Extend rams to visually inspect for corrosion, foreign mater, excessive wear, or
leaks around the seal.
Check paint condition and touch up any exposed areas.
Actuate the hand pump and raise the ram to full extension at least once.
Apply DoAll, RPM, LPS, or equivalent water repellant that is Buna N compatible
to the rams (for tripod jacks).
Open the release valve and verify that rams fully retract.
Lubricate casters (if applicable)
It is possible for all of the above maintenance to be done without the assistance of the
manufacturer or a third party service provider. The only difference is that if you do it
yourself the maintenance will not be certified, which may or may not meet your internal
or external compliance mandates.

12 month load testing procedure


Annual load test includes everything in the 90 day maintenance checklist as well as:
Checking the hydraulic fluid for contamination (dirt or water) then draining and
flushing the fluid if necessary.
Capacity test to 105-110% of the jacks rated capacity. This means that the tester
will apply a load above that expected in actual use to ensure complete safety and
confidence in everyday applications.

When it comes to getting a jack tested most facilities will ship the jack back to the
original manufacturer or send the jack to a third party testing and repair shop. The down
side to both of these options though is the overall investment of both time and money,
especially for those facilities with multiple jacks that require attention. To avoid the
inconvenience and cost of shipping the jacks out for testing, some facilities will call a
company who can provide on-site proof load testing which can be a hassle-free and
more affordable option.
It is important to note that on site proof-load testing requires the calibration service
provider to purchase and maintain expensive mobile fixtures. As such very few ISO
17025 accredited calibration service laboratories provide on-site calibration and proofload testing services.

e2b calibration | 521 Fifth Avenue | Chardon, OH | 440.352.4700 | www.e2bcal.com

Deciding whether to use on-site testing service or to ship your equipment out for service
is one that should be made strategically after considering all of the following:
-

Shipping costs: Hydraulic jacks are expensive to ship due to their size, weight,
and the cost of freight. For companies who have multiple jacks that require
testing, this can really add up. Most tripod jacks must ship via freight carrier (not
common carrier) and require significant effort to crate or otherwise prepare the
jack for shipment.

Time and labor: The time and labor involved in scheduling shipment, prepping
for shipment, and putting the jack back into rotation upon testing completion is
arduous. From beginning to end the process can take hours to days when you
likely have more important work to be done.

Service costs: Many manufacturers charge a testing fee that is likely 25-30%
higher than independent calibration service providers who can provide on-site
testing. While the fees are not astronomical either way, this again adds up when
you consider how many jacks your facility has.

Down time: You must consider the length of the entire process as you will be
without your jack during shipping, testing, any necessary repairs, and return
shipping. Can your facility be without your jack for a month at the very minimum?

The cost of technician travel: If you opt for on-site testing you will not have to
deal with excessive shipping costs, but you will need to pay for certain aspects of
the calibration technicians travel. In most cases, the travel costs for the
technician will be considerably lower than the cost to ship your jack to an external
calibration facility.

We discuss each of these points in more detail below.

As mentioned above, shipping a hydraulic jack can be very expensive. The cost of
shipping will vary depending on factors such as distance, jack type, and shipping
service provider. In our experience, many companies wind up expediting shipping to
reduce down time which can further add to the price. Keeping the variables in mind,
lets consider the cost of shipping an axle jack from your facility to the manufacturer or
third party testing facility.
The average axle jack weighs about 75 pounds and can be shipped via FedEx or UPS.
To overnight this jack via UPS from your facility, lets say you are in Ohio, back to the
manufacturer facility in California youre looking at about $350 each way; a total of
$700.00 in shipping alone.
A tripod jack on the other hand can only be strapped to a pallet or crated and shipped
via freight carrier due to the weight of the equipment (a typical tripod jack used for

e2b calibration | 521 Fifth Avenue | Chardon, OH | 440.352.4700 | www.e2bcal.com

aircraft maintenance weighs about 238 pounds) including the weight of the pallet or
crate which is typically a 48x48x48 dimension with a cost of around $1,000 one-way or
$2,000 round-trip. Even if your facility was closer to the service provider, cutting
shipping to $500 each way- youre still looking at freight costs of $1,000 and thats
before any testing or repair has been done.
Consider that most aircraft maintenance facilities have at least three tripod jacks per
type of aircraft and the shipping costs can increase dramatically. For example, if you
service two types of aircraft you would be shipping 6 axle jacks out annually for service.
Thats a cost of $6,000 to $12,000 annually compared to the costs of bringing a
qualified technician directly to your facility.
Something that many maintenance facilities find to be even more concerning than the
cost of shipping is the time and labor involved in preparing to ship the jack and then
putting it back into use upon its return. The time and labor investment just for shipping a
jack out for service will typically look similar to this:
For an axle jack:
Step #1: Arrange a UPS pickup, you will need to plan this at least a day in advance. (10
minutes)
Step #2: Drain all the hydraulic liquid UPS does not allow them to be shipped unless
this step is completed. (30 minutes)
Step #3: Pack your jack into a crate or box for shipping; being sure to use plenty of
protective precautions to avoid damager during shipping. (10 minutes)
Step #4: You will need to weigh and measure the crate and go online or use your
shipping system to print out a shipping label and attach it to the crate. (20 minutes)
Step #5: UPS will come to pick up your package on the designated day or time.
Upon receiving the package back at your facility you will need to unpack the crate (5
minutes) and refill the jack with hydraulic liquid (30 minutes)
That is a total of 1 hour and 45 minutes spent on shipping/receiving the jack; and thats
assuming everything goes smoothly. Also consider that this time investment is for a
single axle jack. Most aircraft maintenance facilities will have about a dozen (or more)
axle jacks meaning that youre losing almost three days of labor managing the process.
For a tripod jack:
Step #1: Drain all the hydraulic liquid. Freight carriers will not ship your jack until this is
complete. (30 minutes)
Step #2: Get the overall weight and size dimensions of your jack; you will need this
when you call to schedule the freight pickup (20 minutes)

e2b calibration | 521 Fifth Avenue | Chardon, OH | 440.352.4700 | www.e2bcal.com

Step #3: Go online or call to get a freight quote and schedule pick up; you will need to
plan ahead and schedule this a day or two in advance. (25 minutes)
Step #4: Secure the jack to the pallet for shipping and ensure any additional carrier
packing requirements are met (40 minutes)
Step# 5: Ensure proper labeling is completed per your carriers request and that a bill of
lading has been completed. (20)
Step#6: The freight carrier will pick up your package on the designated day or time.
Upon receiving the shipment back you will need to unpack it from the pallet (20) and
replace the hydraulic fluid (30 minutes)
This is a total time of about 185 minutes (a little over three hours) spent on shipping and
receiving for one jack. Again, most facilities will have a minimum of a dozen tripod jacks
meaning that youre losing nearly a week of labor every year managing the process.
Considering all of the above, on-site testing can save you a significant amount of time
and hassle that is simply wasted on shipping and receiving activities that you could be
spending on other more important activities. All you need to do is call the on-site
calibration service provider, answer a few questions, and schedule a day for on-site
service. The whole conversation may take 30 minutes at the very most (and this could
be for service on every jack you own).
When they get to your location, the calibration technicians will take care of any fluid
handling involved and eliminate any of the additional work for you in terms of
scheduling, shipping, and packing/unpacking.
On top of the cost of shipping you must also consider the cost of the actual calibration
testing services being provided.
-

The typical jack manufacturer charge for proof load testing an axle jack is around
$250 per jack.
The typical cost for the manufacturer to test a tripod jack is about $375 per jack.

While those numbers are not going to break the bank; it adds up if you have multiple
jacks that need to be tested or if testing shows there are repairs that need to be done.
A third party testing facility can provide the same level of quality testing and typically
charges 25-30% less than the manufacturer whether the jack is being shipped to the
third party or tested on site.
Shipping your jacks and having them tested and repaired can leave your facility without
one of your most vital maintenance tools for months. Consider this:

e2b calibration | 521 Fifth Avenue | Chardon, OH | 440.352.4700 | www.e2bcal.com

The average time for freight shipment on a tripod jack is one week in each direction and
the average turnaround time for testing, regardless of whether youre using the
manufacturer or a third party provider, is one week. This leaves you without your tripod
jack for a minimum or three weeks! If youre shipping an axle jack out for testing, the
shipping time may be a day or two shorter since you will not be required to ship via
freight carrier or you may choose to overnight the shipment, but either way youd still be
looking at a few weeks without your equipment. If youre using a manufacturer or
provider who is slower than average, or if your jack requires repair after testing, it can
take even longer.
If you choose to utilize and on-site testing provider, testing can be done in about 30
minutes per jack and it is possible that small adjustments or repairs can be made on
site. The only way you would be without your equipment is if the jack is tested and fails
and requires larger repairs off-site or if the jack cannot be repaired and must be
replaced altogether.

While there are some very attractive savings for on-site testing services, you must
carefully consider the cost of technician travel before you make your decision. These
costs can be highly variable.
For example: If your facility is in New Jersey and your on-site testing provider is
traveling from Ohio the technicians would typically be driving to your location, so the
only travel costs you would need to consider would include fuel, hotel, and per diem
costs for the technician. If this is the case you stand to benefit significantly with on-site
services even if you have only a couple jacks that need to be tested.
If your facility is located in California and you were still using an Ohio based service
provider you would need to cover travel costs including the cost of the flight, rental car,
hotel, per diem, and shipping of the proof load testing fixture if applicable (the tool the
technicians would use for testing).
If this is your situation, consider the number of jacks you have that need attention. If you
only have one or two jacks, this may not be the best option for you. But if you have a
larger number, you may still find on-site testing to be the most cost effective way to go
with the added benefit that your jacks wouldnt be out of service for weeks to months.
For example: If you have 10 tripod jacks even if we are being highly conservative in
shipping and service costs, it will cost (at $500 each way for shipping) $10,000 for
shipping. Again this is being very conservative. Services would be $3,750.00 for all ten
jacks. Then consider the down time, the hassle of shipping and liquid handling, and the
potential that repairs will be needed.
When you look at it like that and then consider that a calibration service technician can
take care of all ten jacks in about a day and all you need to pay for is those travel costs,
the latter may be the best choice for you.
e2b calibration | 521 Fifth Avenue | Chardon, OH | 440.352.4700 | www.e2bcal.com

We find that our average customer has 15 jacks on hand that must be tested and
maintained every year in accordance with manufacturer specifications. If you consider
all of the facts above, that equates to a huge investment of time and money to ensure
they are functioning properly. Even if your facility has only 5 jacks on hand, you could
still be looking at thousands of dollars in shipping and services each year; not to
mention the hassle involved, weeks of down time, etc. In comparison, on site testing
services can cut the cost significantly and a technician can complete the testing of 1520 jacks in about a day and all you had to do was make a simple phone call to set it up.

The charts below are designed to provide a general comparison of the typical costs
associated with both off-site and on-site proof load testing.
Please keep in mind the information in these charts is based on average costs
discussed throughout this document and may be different for your unique situation
based on variables such as geographical location, shipping rates, service rates, etc.
Axle Jack: Average cost comparison for off-site vs. on-site testing. Multiply shipping
costs by the number of axle jacks to get your total. Costs such as technician travel costs
will be amortized across the total number of jacks being serviced.
Item
Shipping
Service
Technician Travel
Total cost
Lost Labor Time
Out of Service Time

Off-site (manufacturer)
$700.00
$250.00
N/A
$950.00
1 Hr 45 Minutes
2-3 Weeks +

On-site (e2b calibration)


N/A
$200.00
Variable
$200.00 + travel + fixture shipping
(if applicable)
30 Minutes
30 Minutes

Tripod jack: Average cost comparison for off-site vs. on-site testing. Multiply shipping
costs by the number of tripod jacks to get your total. Costs such as technician travel
costs and shipping cost for the proof-load testing fixture will be amortized across the
total number of tripod jacks being serviced.
Item
Shipping
Service
Technician Travel
Total cost
Lost Labor
Out of Service Time

Off-site (manufacturer)
$1,500.00
$375.00
N/A
$1,875.00
3 Hours 5 Minutes
3-4 Weeks +

On-site (e2b calibration)


N/A
$300.00
Variable
$300 + travel + fixture shipping (if
applicable)
30 Minutes

30 Minutes

e2b calibration | 521 Fifth Avenue | Chardon, OH | 440.352.4700 | www.e2bcal.com

If ensuring equipment safety and longevity is something critical to your facility and
youre not currently following the recommended 90 day maintenance and 12 month
proof load testing schedule recommended by jack stand manufacturers then you are
failing to ensure the safety of your aircraft maintenance technicians and you may not be
in compliance with internal or external quality control mandates.
Shipping jack stands back to the manufacturer will almost always cost you more in
shipping and in services than having a qualified calibration technician perform the same
services on-site at your facility especially if you own multiple jack stands that need to
be serviced and tested annually. In addition to the considerable cost savings, your
critical assets will be more readily available to you with absolute minimal downtime
since you are not shipping them to the manufacturer and waiting weeks for them to
return to your facility.
e2b calibration is one of the few ISO 17025 Accredited calibration and repair
laboratories in North America providing on-site jack stand proof-load testing services.
We have made a considerable investment in the design and production of a proprietary
proof load testing fixture that allows us to conduct on-site services at a fraction of the
cost of other providers.
In most cases, having a service technician on-site is much more cost effective and
enables you to do what you do best maintain your aircraft with confidence to ensure
the safety of the passengers and crew.

e2b calibration | 521 Fifth Avenue | Chardon, OH | 440.352.4700 | www.e2bcal.com

Located in Northeast Ohio, e2b calibration


(www.e2bcal.com) provides on-site proof load
testing for aircraft tripod jacks (both single-stage
and multi-stage) and axle jacks with a capacity
up to 75,000 pounds servicing a broad range of
manufacturers including Tronair, Malabar,
Langa, Columbus, Dedienne, Meyer, GB
Barberi, Hyro Systems, JSM AG, Wag-Aero, and
more.
Our customers include leading aircraft maintenance facilities including Delta, Cape Air,
Constant Aviation, Flight Options and other FAA-regulated maintenance facilities for
commercial airlines, charter services, private and fractional jet businesses, and cargo
air service providers.
As an ISO 17025 accredited test equipment calibration and repair laboratory traceable
to NIST and ANAB accredited, e2b calibration provides turnkey calibration and repair
services for most IFR (instrument flight rules) aviation and avionics equipment including
air data test sets, pitot static systems, traffic control avoidance systems (TCAS), aircraft
scales, and other maintenance equipment such as crimpers, multi meters, flow meters,
and test equipment for pressure, torque, and electronics.
Contact us today for a free on-site jack stand proof load testing quote or for additional
information about our aviation, avionics, or general calibration and repair services.

e2b calibration | 521 Fifth Avenue | Chardon, OH | 440.352.4700 | www.e2bcal.com

Вам также может понравиться