User Manual - Zinko Jacks
Contents
1. 1 Air in hydraulic system Cylinder Advances IA Sputs 2 Cylinder plunger is binding 1 Leaking connection Cylinder Advances Slower Than Normal 2 Coupler is not fully tightened 3 Pump malfunctioning 1 Cylinder seals leaking 2 Pump malfunctioning 3 Leaking connection 4 Incorrect system setup Cylinder Advances But Will Not Hold 1 Worn or damaged seals Cylinder Leaks Oil 2 Internal cylinder damage 3 Loose connection 1 Pump release valve is closed 2 Coupler is not fully tightened Cylinder Will Not Retract or 3 Pump reservoir overfilled Retracts Slower Than Normal 4 Narrow hose restricting flow 5 Broken or weak retraction spring 6 Cylinder damaged internally Zinko Hydraulic Jack REV 100307 Models ZRM amp ZRB Series Parts Breakdown ZRM Model Description 1 Cylinder 6 Spring 8 Screw O 9 Retaining Ring RP Repair Kits All 6_ 8 9 LRP ZINKO HYDRAUUC JACK PO Box 4903 Ontario CA 91761 Toll Free 1 800 579 8088 http www zinko com Phone 909 989 9526 Fax 909 989 17242. MODELS A ZRM Series amp ZRB Series Hydraulic Jack Low Height Hydraulic Cylinders Toll Free 7 800 579 8088 Web www zinko com Operation amp Maintenance Manual Important Receiving Instructions Visually inspect all components for shipping damage Shipping damage is NOT covered by warranty If shipping damage is found notify carrier at once The carrier is responsible for all repairs and replacement costs during product shipping Safety Information Read and follow all instructions warnings cautions and carefully Follow all safety precautions to avoid personal injury or property damage during system operation ZIMKO is not responsible for damage or injury resulting from unsafe product use lack of maintenance or incorrect product and or system operation Contact ZIAKO when in doubt as to the safety precautions and operations Failure to comply with the following cautions and warnings could cause equipment damage and personal injury Caution Remarks Used In This Manual AXDANGER is only used when your action or lack of action can cause serious injury or death AWARNING indicates a potential danger that requires correct procedures or practices to avoid personal injury AXCAUTION is used to indicate correct operating maintenance procedures and practices to prevent damage to or destruction of equipment or other property Operator Responsibility It is the operator s responsibility to read and understand all of the follow
3. acing up Fully extend and retract the cylinder 2 or 3 times NOTE Collar threads are rated for the full capacity of the cylinder when fully engaged in attachments The use of cylinder attachments or extensions reduces the cylinder capacity by at least 50 Operation Operate the hydraulic pump to advance and retract the cylinder Some single acting cylinders are spring return Double acting cylinders are powered in both directions by the pump IMPORTANT When cylinders are used with power set attachments or components the maximum system pressure must be limited to half the rated pressure of 700 bar 5 000 psi Maintenance 1 Use only certified hydraulic lift oil with these cylinders The use of any other oil may invalidate warranty 2 Use dust caps when cylinders are disconnected from the hose Keep the entire cylinder clean to prolong cylinder life 3 Store cylinders upright to prevent seal distortion Troubleshooting These cylinders should be repaired only by Authorized ZIAKO Technical Service Centers Single acting are spring loaded and require special disassembly techniques to prevent personal injury PROBLEM POSSIBLE CAUSE 1 Pump release valve is open 2 Coupler is not fully tightened Cylinder Will Not Advance 3 Oil level in pump is low 4 Pump malfunctioning 5 Load is too heavy for cylinder 1 Oil level in pump is low Cylinder Advances Part Way 2 Coupler is not fully tightened 3 Cylinder plunger is binding
4. els ZRM amp ZRB Series To avoid personal injury KEEP HANDS AND FEET AWAY FROM CYLINDER AND WORK PIECE during operation Only use hydraulic cylinders in a coupled system Never use a cylinder with unconnected couplers If the cylinders become extremely overloaded components can fail catastrophically causing severe personal injury IMPORTANT Hydraulic equipment MUST ONLY be serviced by a qualified hydraulic technician For repair service contact the authorized ZINKO service center in your area To protect your warranty use only certified hydraulic lift oil Immediately replace worn or damaged parts with genuine ZIMKO parts Standard grade parts may break causing personal injury or property damage ZIMKO parts are designed to fit properly and with stand high loads Installation 1 Make hydraulic connections Use a pump with a release valve or a 3 way valve and one hose for single acting cylinders a Use a pump with a 4 way valve and two hoses for double acting cylinders b IMPORTANT Double acting cylinders must have both couplers connected Fully hand tighten all couplers Loose couplers connected will block the flow of oil between the pump and the cylinder s 2 Remove air from cylinder a Single acting cylinders Position the cylinders so that the plunger is pointed down and the cylinder is lower than the pump Fully extend and retract the cylinder 2 or 3 times b Double acting cylinders Lay the cylinder in its side and have the couplers f
5. ing safety statements AWARNING STAY CLEAR OF LOADS SUPPORTED BY HYDRAULICS A cylinder when used as a lifting load device should never be used as a load holding device After the load has been raised or lowered it must always be blocked mechanically Use only rigid pieces to hold loads CAREFULLY select steel or wood blocks that are capable of supporting the load NEVER USE A HYDRAULIC CYLINDER AS A SHIM OR SPACER IN ANY LIFTING OR PRESSING APPLICATION DO NOT EXCEED EQUIPMENT RATINGS Never attempt to lift a load weighing more than the capacity of the cylinder Overloading causes equipment failure and possible personal injury The cylinders are designed for a maximum pressure of 700 bar 10 000 psi DO NOT CONNECT A JACK OR CYLINDER S TO A PUMP WITH A HIGHER PRESSURE RATING NEVER SET THE RELEASE VALVE TO A HIGHER PRESSURE THAN THE MAXIMUM RATED PRESSURE OF THE PUMP Higher settings may result in equipment damage and or personal injury The system operating pressure MUST NOT exceed the pressure rating of the lowest rated component in the system Install pressure gauges in the system to monitor operating pressure t is a window to what is happening within the system BE SURE SETUP IS STABLE BEFORE LIFTING LOAD Cylinders should be placed on a flat surface that can support the load Where applicable use a cylinder base for added stability DO NOT WELD OR OTHERWISE MODIFY THE CYLINDER TO ATTACH A BASE OR OTHER SUPPORT Avoid situa
6. tions where loads are not directly centered on the cylinder plunger Off center loads produce considerable strain on cylinders and plungers In addition the load may slip or fall causing potentially dangerous results Distribute the load evenly across the entire saddle surface ALWAYS USE A SADDLE TO PROTECT THE PLUNGER Wear the proper personal protective gear when operating hydraulic equipment Hydraulic Hoses Avoid damaging hydraulic hoses including sharp bends and kinks when routing hydraulic hoses Using a bent or kinked hose will cause severe back pressure Sharp bends and kinks will internally damage the hose leading to premature hose failure 1 DO NOT DROP HEAVY OBJECTS ON HOSE A sharp impact may cause internal damage to hose wire strands Applying pressure to a damaged hose may cause it to rupture 2 DO NOT LIFT HYDRAULIC EQUIPMENT BY THE HOSE OR SWIVEL COUPLERS Use the carrying handle or other means of safe transport 3 KEEP HYDRAULIC EQUIPMENT AWAY FROM FLAMES AND HEAT Excessive heat will soften packings and seals resulting in fluid leaks Heat also weakens hose materials and packings For optimum performance DO NOT expose equipment to a temperature of 65 150 F or higher Protect hoses and cylinders from weld spatter 4 DO NOT HANDLE PRESSURIZED HOSES Escaping oil under pressure can penetrate the skin causing serious injury If oil is injected under the skin SEE A DOCTOR IMMEDIATELY Q Zinko Hydraulic Jack Mod
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