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USER AND MAINTENANCE MANUAL

1. pieces of the lever Figure 6 Disassembled lever EE Pao 13 of 19 a Tut EN C N JF PRO ER EQUIPMENT ACCESSORIES 8 MACHINE OPERATION T Lifting loads There is a risk of crushing and or grazing body parts while lifting heavy loads as a result of mishandling Workers must be equipped with standard safety equipment especially gloves and crush resistant safety shoes Q Lifting loads Workers involved in load lifting must operate the machine carefully without abrupt movements and pay the utmost attention In particular the jack and load must be kept under constant control during movement Q Working under loads Working under a lifted load ALWAYS entails a residual risk of the load falling accidentally In this regard IT IS STRICTLY FORBIDDEN to operate under a load lifted only by the jack Always insert a safety support of suitable capacity under the load before operating below it for example a tripod 8 1 Lifting a load 1 With the narrow part of the lifting lever close the vent valve by turning it clockwise see Figure 7 Figure 7 Closing the vent valve EEE TEE Seng FER S ACCESSORIES e d PRO SMART EQUIPMENT 1 Place the Jack under the load in a suitable position for lifting In the case of a vehicle it is recommended for example to refer to the relative user manual 2 If necessary on models up to 20 tons unscrew rotate anti clockwise the plunger on the piston rod of the l
2. 2 2 0062 5 0062 10 0062 15 0062 20 0062 32 and 0062 50 are machines designed for lifting lowering loads and in particular vehicles for the usual operations of maintenance and or repair The Jacks must be used on supporting surfaces that are flat smooth and adequately strong and hard capable of supporting the weight of the Jack plus the maximum nominal load capacity The operating temperature is within 20 50 C The working environment must also be sufficiently well lit to ensure maximum operational safety at least 50 lux is recommended Other types of use or the extension of use beyond that envisaged does not correspond to the designation attributed by the manufacturer and therefore the latter cannot accept any responsibility for any damage resulting from improper use _ AY PRS NIK ORY ANI ON b A NH AS ANH HI PU IHN S EN Hm N EE I W N K H DTN Em AM IN NER Les HN AR So m Um Wi E EE ks SE 13 Figure 1 Section view of the machine Figure 2 General view of the machine 10 Piston pump ETE Pump body 13 O ring pump ER Safety valve 14 Lever coupling 1 Vent valve EA Base ER O ring cylinder ER Hydraulic cylinder 5 Guide tube 6 Hydraulic oil 15 Plate Oil tank EI Plunger Bi Piston rod K Handle ER Upper cap E Page 7 of 19 a Tut EN C N JF PRO ER EQUIPMENT ACCESSORIES The Hydraulic Bottle Jack comprises see figures 1 and 2 e asu
3. E 5 0 Eh WEEN 16 9 1 ORDINARY MAINTENANG ER ee ene anc GEN wenn eee ERR ER KR ERR eee eee 16 10 TROUBLESHOOT TI ING enen kuk KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR 18 11 WAREHOUSE STORAGE seenen ku KN KN KN KN KN KN KN KN KN KN KN KN KR KN KN KN KN KN KR KR KN KR KR KN KR KR KR KR KR Kn 18 be DR 12 v let 20 7 CR 19 a Tut EN C N JF PRO ER EQUIPMENT ACCESSORIES 1 INTRODUCTION This manual is considered an integral part of the machine it was attached to at the time of purchase The manufacturer holds all ownership to material and intellectual property of this manual any disclosure or copying even partial of this publication without prior written consent is forbidden The purpose of this manual is to provide the knowledge necessary for the use and maintenance of the Hydraulic Bottle Jack models 0062 2 0062 5 0062 10 0062 15 0062 20 0062 32 0062 50 and create a sense of responsibility and knowledge of the capabilities and limitations of the device entrusted to the operator Operators must be properly trained and prepared so make sure that this manual is read and consulted by the staff responsible for the commission operation and maintenance of the machine This is to make all operations as safe and effective as possible for those who carry out these tasks Therefore it is imperative to strictly comply with the requirements in this manual necessary for the s
4. HIC REPRESENTATION OF SAFETY OPERATIONAL AND RISK WARNINGS uneneen Ke KK KKK KN 5 2 GENERAL SAFETY WARNINGS enk nk uk NK NK NK RENE RENE RENE RENE RENE RENE RENE EE EE EE EE EE EE EE EE AE ue D 2 1 TECHNICALASSISTANCOE EE 6 2 2 OTHER PROVISIONS E 6 3 INTENDED USE AND DESCRIPTION OF THE IACKS nnnenenku KKK KR KR KN KN KN KN KR KN uk 7 3 1 22 n d in e EE uses WEE 9 3 2 IDENTIFICATION PLATE AND PICTOGRAMS a KEN KEE EN KE KR EEN KN ENN KEE EN KEE ER EE ER EE KR EEN KEEN KEREN EN KEN KEN KEE ue 9 3 2 1 CE Mal KG BEE gn WE EE 9 3 2 2 Maximum rated load Capacity ua KEREN RN NNN uv uv uv MER EE EEN KEN 10 3 2 3 Information on operation and residual reke 10 4 TECHNICAL SPECIFICATIONS eene KN KN KN KN KN KN KN ER K RENE KR EN KR KEEN EN KR KR KR KR KR KR KN KR KR Kn 11 5 IMPROPER USE AND HAZARDS ee e KR KR KR KR KR ER EN KR KR KR ER ER KR KR KR KR KR KR KR KR KR KR KR KR Kn 12 6 TRANSPORTING LIFTING AND MOVING senken NENNEN KKK ENK KR KE KN KN KR KKK 13 7 eieiei deit Ca dE ER re 13 7 1 UNPACKING INSTRUCTIONS enn Ka Ka KEN KE KE KE KE KE KR ERR ERR ERR ENK ENK ENKEN eee KEN een KEN KEN KEN KEN KEN KEN KEN KEN KEN Ku 13 7 2 ASSEMBLING THE LIFTING LEVER dh nennen vu unn REE nun RE RR ER KK ERR KK ER EEN ERR ER KK ERR KK ERR KK e 13 8 MACHINE OPERATION wc enc ccc off uv nun bt uv u Kn ne KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR KR 14 8 1 LIFTING A LOAD NEEN ei ee ee 14 SZ LOWERING A LOAD KEEN En WE 15 9 MAINTENANC
5. USER AND MAINTENANCE MANUAL Hydraulic Bottle Jack Art 0062 2 0062 5 0062 10 0062 15 0062 20 0062 32 0062 50 WG SMART EQUIPMENT TRANSLATION OF THE ORIGINAL INSTRUCTIONS a Tut EN C N JF PRO ER EQUIPMENT ACCESSORIES PREFACE Q Please ensure you have read this manual before operation TRANSLATION OF THE ORIGINAL INSTRUCTIONS It is compulsory to read this instruction manual before starting operation The assurance of smooth operation and full compliance of machine performance is strictly dependent on the rigorous application of all the instructions contained in this manual Oo Operator Qualification The workers responsible for the use of this machine must have all the necessary information and instruction and should be given adequate training in relation to safety regarding a Conditions of use for the equipment b Foreseeable abnormal situations C pursuant to art 73 of Legislative Decree no 81 08 We guarantee that the machine complies with the specifications and technical instructions described in the Manual on the date of issuance and listed herein On the other hand the machine may also be subject to important technical changes in the future without the manual being updated Consult FERVI for information on any changes that may have been implemented VERSION 3 May 2013 E Page 2 of 19 MACHINES AND ACCESSORIES o FEN bh A PRO SMART EQUIPMENT INDEX 1 INTRODUCTION MEET 1 1 GRAP
6. afe and satisfactory operation of the Jack Before starting operation installation and use of the machine authorized staff must therefore e read this technical document carefully e know which protections and safety devices are available on the Jack their location and how they work The buyer is responsible for ensuring that users are properly trained that they are aware of all the information and instructions in this document and that they are aware of the potential risks of operating the Jack The manufacturer will not be held responsible for any damage to people and or property caused by non compliance with any instructions tn this manual Operators will be held fully responsible for any changes they have made to the machine the manufacturer will not be held responsible for any damage to persons and or property resulting from maintenance performed by unqualified personnel and in a manner that differs from the operating procedures shown below The Jack has been designed and built with mechanical guards and safety devices designed to protect the operator user from possible injury It is strictly forbidden to modify or remove guards safety devices and caution labels If this must be done for example for cleaning or repair ensure that no one uses the machine MM Page 4 of 19 MACHINES AND ACCESSORIES o FERVI PRO SMART EQUIPMENT 1 1 Graphic representation of safety operational and risk warnings The following
7. boxes are designed to attract the attention of the reader user for the purposes of proper and safe use of the machine d Attention This highlights behavioural rules to prevent damage to the machine and or the occurrence of dangerous situations A Residual Risks This highlights the presence of dangers that cause residual risks to which the operator must pay attention in order to avoid injury or damage to property a Tut EN C N JF PRO ER EQUIPMENT ACCESSORIES 2 GENERAL SAFETY WARNINGS Even if you are already familiar with the Hydraulic Bottle Jack you must read this manual carefully to acquire full knowledge of the machine and the general precautions to be observed during operation T Risks associated with using the machine Despite the implementation of all the safety devices for safe use of the machine it is necessary to take note of all the requirements for the prevention of accidents reported in various parts of this manual Q Risks associated with using the machine The machine must only be used by qualified personnel trained to use the machine by authorized personnel Q Risks associated with using the machine Every person responsible for machine operation and maintenance is required to have read the instruction manual first and specifically the chapter on safety instructions Use the Hydraulic Bottle Jack exclusively for lifting Before lifting make sure the Jack is in good condition Do not adjust the saf
8. cribed which obviously can not cover the entire range of potential possibilities of misuse of the machine are to be considered strictly prohibited A IT IS STRICTLY FORBIDDEN To lift persons and or animals that could fall To lift loads while there are people near the machine To work under loads only lifted by the jack without using additional safety supports such as a tripod To lift loads heavier than the maximum rating indicated on the plate To lift vehicles without applying the brakes to the wheels correctly To lift unbalanced loads or change their static configuration and or their centre of gravity To lift dangerous loads molten metals acids radioactive materials fragile and or brittle loads To load the jack on uneven polished surfaces and or surfaces that are not strong enough to support the load jack maximum rated load capacity To use the jack when there is a possibility of the load moving accidentally To leave the loaded jack unattended To allow untrained staff to use the jack TO Operate the jack if you are not psycho physically fit To operate the jack without due attention TO Operate the jack for purposes other than those for which it was designed To use the jack in unforeseen environmental conditions adverse weather conditions refrigerators high magnetic fields etc To use the jack in potentially explosive environments Use the jack in the event of insufficient light To use the
9. d the Jack refer to Chapter 8 of this manual MACHINE OPERATION The maximum rated load capacity must never be exceeded 3 2 3 Information on operation and residual risks The following pictogram can be found on the back of the Jack that summarizes the main operating instructions and provides some information on the residual risks associated with the use of the Jack see Figure 5 ran FOR LIFTING BEFORE PUMPING ROTATE THE RELEASE VALVE AT THE BASE OF THE JACK CLOCKWISE FOR LOWERING SLOWLY ROTATE THE VALVE ANTI CLOCKWISE MAXIMUM 1 2 TO 1 TURN TO ADD OR REPLACE THE OIL PUSH THE PISTON ALL THE WAY DOWN REMOVE THE PLASTIC CAP ON THE SIDE OF THE TANK AND INSERT THE OIL UP TO THE LEVEL CRICCO DN EVARE Rug valvola dif pr ji AS WITH THE JACK IN A VERTICAL POSITION ATTENTION DO NOT USE OIL FOR BRAKES ONLY USE THE JACK TO LIFT YOUR VEHICLE IN THE EVENT YOU NEED TO WORK UNDER THE VEHICLE INSERT SPECIAL TRIPODS FOR INCREASED SAFETY ONLY USE HYDRAULIC MINERAL OIL Figure 5 Close up of the pictogram on the back of the jack E Pac i019 EE mee E TED a ACCESSORIES d JF PRO ER EQUIPMENT 4 TECHNICAL SPECIFICATIONS Description unit of 0062 2 0062 5 0062 10 0062 15 0062 20 0062 32 0062 50 measurement 2 000 5 000 10 000 15 000 20 000 32000 50000 mm EE Pee 11 of 19 a TE mm CP N JF PRO ER EQUIPMENT ACCESSORIES 5 IMPROPER USE AND HAZARDS The following actions des
10. e the cap by exerting a pressure on it Figure 13 Filling cap Q Type of hydraulic oil When you top up the hydraulic oil only use the oil type recommended by the manufacturer Do not use brake fluid or engine oil 7 Bleed air from the hydraulic circuit To remove any air bubbles in the hydraulic system of the Jack which could reduce its efficiency follow these instructions Open the vent valve by turning it anti clockwise and remove the oil tank cap see Figure 13 Pump repeatedly to release the air Close the vent valve by turning it clockwise and replace the cap applying pressure to it Check that the Jack functions properly If you still have problems repeat the procedure or if necessary contact the Customer Service Department EE Pao 17 of 19 a Tut EN C bh ed PRO SMART EQUIPMENT DN EASAN 10 TROUBLESHOOTING The following table shows the type of defect problem possible causes and possible remedies for the malfunction The table is a useful aid for the maintenance technician when looking for problems with the machine The jack does not lift the The vent valve is not Close the vent valve load properly closed The jack lowers when The vent valve is not Close the vent valve pressure is applied properly closed Clean the valves To do this lower the piston rod of the jack close the vent valve raise the jack s piston rod with your hands and then open the vent valve and lower the pist
11. essure safety valve be carried out by the operator Other safety devices include e the plunger 16 on the piston rod of the hydraulic lifting cylinder designed so that the friction and the grip with the load are maximised see Figure 3 The hydraulic bottle jacks 0062 32 and 0062 50 are provided with a non slip plunger with a different design e the gripping handle on the body of the oil tank for movement and fixed or oscillating transport starting from the 10 ton version ref 17 in Figure 1 Figure 3 Close up of plunger 3 2 Identification Plate and Pictograms 3 2 1 CE Marking The identification plate of the machine is attached to the body of the oil tank see component No 15 in Figure 1 Figure 4 Plate for model 0062 20 The plates of the remaining models 0062 2 0062 5 0062 10 0062 15 0062 32 0062 50 are identical to the one above except for the plate data which is as follows D FER ee eee lee e ale Article Capacity t 0062 15 15 0062 15 0062 15 EC 0062 20 0062 20 0062 50 3 2 2 Maximum rated load capacity The maximum rated load capacity that the Jack can lift under standard conditions is indicated on the plate i e when e it is in good conditions of efficiency and conservation e it operates within the permitted temperature range and ambient conditions e is applied to a flat hard and durable surface For a more detailed explanation on how to use and loa
12. ety valve Place the Jack on a flat solid and durable work surface Do not try to operate the machine at higher performance levels than those for which it was designed in particular regarding the magnitude of the load to be lifted In other words do not load the Jack beyond its capacity e If you use the Jack to lift a vehicle lock the wheels of the vehicle with the emergency brake e Always use a safety support such as a tripod to support the vehicle load in case you need to work under the vehicle load e Itis recommended that users of this publication for maintenance and repair have a basic knowledge of mechanical principles and procedures inherent in repair technique e Replace worn or damaged parts and check that the repairs and protection devices work correctly before operating e Make sure that the work environment is forbidden to children and non employees 2 1 Technical assistance For any problems or concerns please contact without hesitation the Customer Service Department which has competent and specialised staff specific equipment and spare parts 2 2 Other provisions The first thing to do when starting work is to check the presence and integrity of the protections and the operation of the safety devices If any defect is detected do not use the Hydraulic Bottle Jack MM Page 6 of 19 Sen CR PERV ACCESSORIES d JF PRO ER EQUIPMENT 3 INTENDED USE AND DESCRIPTION OF THE JACKS The Jacks models 006
13. ifting cylinder until it touches the bottom of the load see Figure 8 Figure 8 Plunger adjustment 3 Insert the lifting lever into the coupling on the pump 4 Pump until the desired height is reached see Figure 9 8 2 Lowering a load 1 With the narrow part of the lifting lever open the vent valve by turning it anti clockwise see Figure 10 Figure 10 Opening the vent valve Q Vent valve adjustment Rotate the vent valve 1 2 turn and never more than one full turn 2 When the piston rod is fully lowered remove the Jack If the plunger is raised on the piston rod not allowing the jack to be pulled out from the bottom of the load turn it clockwise to lower it only for models up to 20 tons Page 15 of 19 a Tu mm Cep Eeleren DN ACCESSORIES 9 MAINTENANCE The purpose of this chapter is to provide all the information on maintenance procedures and frequency required for the Hydraulic Bottle Jack Maintenance and repairs must be performed b ualified personnel 9 1 Ordinary maintenance Weekly 1 General visual inspection 2 Check the legibility of the plates circuit 3 Verify the absence of leaks in the hydraulic S i N 4 General cleaning X 5 Lubrication and greasing Vv 6 Check the oil level and top up o E 7 Bleed air from the hydraulic circuit 1 General visual inspection Check the general condition of the machine if there are any damaged or missing par
14. jack on ships at sea To put the jack in contact with foodstuffs E Pac i2019 Sen CR SERV ACCESSORIES d JF PRO ER EQUIPMENT 6 TRANSPORTING LIFTING AND MOVING The lifting of the Jack for transport purposes can be done manually by one or two people depending on the model to be transported The relatively low weight of the machine up to 32 kg for the 50 ton version allows it to be moved manually and safely without the danger of injury to the operator When lifting and moving the jack the operator will have to hold it with both hands possibly using the gripping handle found in versions 0062 15 and 0062 20 0062 32 and 0062 50 see component No 17 in figure 1 7 COMMISSIONING 7 1 Unpacking instructions The Jack is supplied in a cardboard box with the lifting lever disassembled Before disposing of the cardboard packaging check that no parts of the machine the user manual or any other documentation are thrown away Q Standard packaging Packaging materials plastic bags polystyrene foam etc must not be left within reach of children as these are potentially dangerous 7 2 Assembling the lifting lever To assemble the lifting lever for the Jack proceed as follows 1 Remove the two plastic caps that hold the lifting lever pieces together see Figure 5 2 Insert the narrower piece of the lever inside the wider piece until it locks see Figure 6 This is possible due to the slightly conical shape of the two
15. on rod quickly The pump is weak Low oil level Add hydraulic oil The oil leaks from the tank Tank overflow Remove the excess oil The jack does not lift to the Air bubbles in the hydraulic Purge air in the hydraulic maximum height circuit circuit 11 WAREHOUSE STORAGE In the event that the machine should be stored and unused for some time proceed as follows e Keep the piston rod the pump and the plunger lowered e Keep the vent valve slightly unscrewed e Lubricate all parts of the jack e Store the jack indoors in a dry location The valves are not closed properly or there is a foreign body in the valves The lifting lever fails to raise under the weight of the load E Pac i8019 Sen CR SERV ACCESSORIES d JF PRO EI RUE 12 DECOMMISSIONING Disassembly and disposal of materials and components If the machine is to be scrapped its parts must be differentiated for disposal Q Respect the environment Contact a specialist centre for the collection of metallic materials The structure of the jack is made from steel while some seals are made from polymeric material The pump and the tank contain hydraulic oil In this regard differentiate the materials according to their nature with the assistance of specialist companies authorized for waste disposal in compliance with the requirements of the law EE Pao 19 of 19
16. pport base 2 made of steel in a quadrangular shape e a lifting unit composed of the hydraulic lifting cylinder 4 and the oil tank body 7 e a Dumping unit consisting of the piston pump 10 manually operated e avent valve 1 for adjusting the lowering speed of the piston rod 8 of the cylinder 4 e amaximum pressure valve 13 which constitutes a safety device against overloads e a handle 17 for the grip for the purpose of moving and transport on the 15 ton and 20 ton versions The control system of the Jack therefore consists of e the piston pump 10 that once operated allows the extension of the piston rod 8 of the hydraulic cylinder 4 i e the lifting of the load e the vent valve 1 that once opened allows the return of the piston rod 8 of the hydraulic cylinder 4 i e the lowering of the load In this regard for a more detailed explanation see Chapter 8 of this manual MACHINE OPERATION MM Page 8 of 19 Sen CR ERV ACCESSORIES d JF PRO ER EQUIPMENT 3 1 Safety devices The main safety device present on the machines is the load limiter consisting of a maximum pressure valve see component No 13 in Figure 1 and in Figure 2 which protects the jack against overloads This valve ensures that the pressure inside the hydraulic circuit can not exceed the fixed set value determined by the maximum rated load capacity Q Load limiter Under no circumstances should the adjustment of the maximum pr
17. ts 2 Check the legibility of the plates the plates and pictograms on the machine must be perfectly legible it is therefore necessary to keep them clean and request a replacement if they are illegible 3 Verify the absence of leaks in the hydraulic circuit there can be no measurable accidental loss in the hydraulic circuit except for slight moisture insufficient to form a drop 4 General cleaning cleaning is necessary to free the structure and moving parts from the accumulation of dust dirt and stains caused by excess lubricants Cleaning should be done with the use of means equipment and detergents or solvents commonly used in the cleaning of industrial equipment 5 Lubrication and greasing it is necessary to lubricate the moving parts of the Jack namely the adjustment screw of the lift of the plunger up to the 20 ton model see Figure 11 the pins hinges and levers on the pumping system see Figure 12 Figure 11 Plunger screw Figure 12 Pins and hinges of the pump Pace 16 fo eee emeng F es TER ACCESSORIES d d PRO SMART EQUIPMENT 6 Check the oil level and top up Check the oil level and if necessary top up with hydraulic mineral oil Place the Jack in a vertical position Fully lower the pump and the lifting cylinder Remove the oil cap see Figure 13 Add hydraulic mineral oil Fill up to the bottom edge of the opening Bleed the air in accordance with the instructions given in paragraph 7 Replac

USER AND MAINTENANCE MANUAL

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