OPERATING INSTRUCTIONS Portable High Tonnage Jack
Contents
1. Portable High Tonnage Jack Models SPLE series a N ig mn IVMAYTAN nT A I Tf Aj ga g ag ea Xi ff p 4 ila TU eve WERATE BENANG I NAHH ENJ NI 4 1 RAM AND CYLINDER MAINTENANCE A Always use clean approved hydraulic fluid and change as needed B Any exposed threads male or female must be cleaned and lubricated regularly and protected from damage C If a cylinder or ram has been exposed to rain snow sand grit laded air or any corrosive environment it must be cleaned lubricated and protected immediately after exposure 4 2 PERIODIC CLEANING A routine should be established to keep the hydraulic system as free from dirt as possible All unused couplers must be sealed with dust covers All hose connections must be free of dirt and grime Any equipment attached to the cylinder must be kept clean WARNING Contamination of the hydraulic fluid could cause the valve to malfunction Loss of the load or personal injury could result Use only SUN RUN hydraulic fluid and change as recommended or sooner if the fluid becomes contaminated never exceed 300 hours 4 3 STORAGE Double acting cylinder These units should be stored in a dry well protected area where they will not be exposed to corrosive vapors dust or other harmful elements If a unit has been stored for a year or more it must be thoroughly inspected before it is used s CHU LUN SING CO LTD Page E9 Instructions for Portable High Ton2. seat fully into recessed diameters before lowering piston extension adaptor onto cribbing 16 Follow lifted load with cribbing or blocks 17 Use only approved accessories 18 Use a jack with sufficient capacity to lift the load 19 The total load lifted or supported by a jack must never exceed the rated capacity of the jack 20 Never support a load hydraulically 21 All loads must be supported mechanically 22 Properly support the jack and jack bases 23 Use a friction material under base and between jack and load 24 Lift only dead weight loads 25 Stay clear of lifted loads 26 Do not work on or near unsecured loads Do not allow personnel or dynamic forces on an unsecured load 2 Do not use jack s if damaged altered or in poor repair Page E3 Instructions Tor Portable High Tonnage Jack Models SPLE series 3 OPERATION 3 1 Instructions required to put portable jack into service 3 1 1 Carefully read and understand the safety precautions and operating instructions which describe general safety precautions and the method required to connect the pump hoses fittings and jack Since this unit has been completely assembled and tested at our factory follow the succeeding steps to put the jack into service 3 1 2 Carefully remove all packing materials from the assembled unit 3 1 3 Fill pump reservoir to proper operating level using approved SUN RUN hydraulic oil 3 1 4 Start pump and cycle jack to full extension
3. broken off inside the pipe end Any loose pieces of tape could travel through the system and obstruct the flow of fluid or cause jamming of precision fit parts D Always use protective covers on disconnected quick couplers E When mounting cylinders or rams using the internal piston rod threads collar threads threaded tie rods or base mounting holes the threads must be fully engaged 3 7 SYSTEM EVALUATION Cylinder hose s couplings and pump all must be rated for the same maximum operating pressure correctly connected and compatible with the hydraulic fluid used An improperly matched system can cause the system to fail and possibly cause serious injury If you are in doubt consult your nearest SUN RUN facility 3 7 1 BLEEDING THE SYSTEM The SUN RUN portable jack has been cycled at the factory but to insure proper operation each unit should be cycled full extension and retraction two or more times 3 7 2 INSPECTION Before each use visually inspect for the following items A Cracked or damaged cylinder B Excessive wear bending damage or insufficient thread engagement C Leaking hydraulic fluid D Scored or damaged piston rod E Improperly functioning or damaged heads and caps F Loose bolts or cap screws G Damaged or improperly assembled accessory equipment H Modified welded or altered equipment Bent or damaged couplers or port threads s CHU LUN SING CO LTD Page E8 Instructions Tor
4. pressure will build and the cylinder hose or coupler can burst possibly causing serious injury or death 3 6 2 When extending double acting cylinders or rams the retract port must not be restricted A restricted retract port will prevent pressure from being released and the cylinder can burst possibly causing serious injury or death 3 6 3 Do not attempt to adjust or service the rod end relief valve on a double acting cylinder or ram If oil leakage is detected from this relief valve discontinue use of the cylinder or ram immediately and contact your nearest Authorized Hydraulic Service Center If improperly adjusted the cylinder or ram could develop excessive pressure and cause the cylinder hose or couplers to burst which could cause serious injury or death Naa relief valve location er 3 CHU LUN SING CO LTD Page E5 Instructions Tor Portable High Tonnage Jack Models SPLE series 3 0PERATION 3 6 SAFETY PRECAUTIONS 3 6 4 When extending a cylinder or ram under load always insure that the couplers or port threads have not been damaged or do not come in contact with any rigid obstruction If this condition does occur the coupler s attaching threads may become stripped or pulled from the cylinder or ram resulting in the instantaneous release of high pressure hydraulic fluid flying objects and loss of the load All of these possible results could cause serious inj
5. prevent personal injury do not allow personnel to go under or work on a load before it is properly cribbed or blocked All personnel must be clear of the load before lowering T Never use extreme heat to disassemble a hydraulic cylinder or ram Metal fatigue and or seal damage will result and can lead to unsafe operating conditions U Do not created an uneven fulcrum and lever condition or overload condition where force exerted by one cylinder on a lever will intensify v downward force on a pressure checked cylinder at the other end of N the lever For example If straightening an axle as illustrated when cylinder A extends and uneven fulcrum and lever condition will Cyl A Cyl B intensify force downward on pressure checked cylinder B The L N pressure created in cylinder B will be increased to dangerously high N gt levels s CHU LUN SING CO LTD Page E7 Instructions Tor Portable High Tonnage Jack Models SPLE series 3 OPERATION _ 3 6 SAFETY PRECAUTIONS 3 6 9 IMPORTANT A Keep the cylinder clean at all time B While at a job site when the cylinder is not in use keep the piston rod fully retracted C Use an approved high grade pipe thread sealant to sealant to seal all hydraulic connections Teflon tape can be used if only one layer of tape is used and it is applied carefully two threads back to prevent the tape from being pinched by the coupler and
6. series 1 Side load damage the jack or cause failure of the joint connecting the base or extensions resulting in loss of the load and possible personal injury 2 Center load on jack 3 Align load and jack so that stack force is straight and in line with the load and so that the movement of the load does not cause instability 4 Do not drive or push the load off the jack Lower jack and remove before moving the load 5 Completely cover the top of the load cap with a secure and properly supported load lifting point Do not lift off center on a rounded or uneven surface 6 Lift by pushing against a flat surface parallel to the cylinder base within 4 degrees as shown 7 Always place the tallest extension on the bottom and the shortest on the top when stacking extensions 8 Always pin the first extension the tallest one used to the piston rod to prevent accidental disengagement of the connection 9 Use only one of the shortest extensions black in color and also referred to as load caps at a time Never stack them 10 Cribbing blocks must be fully seated and evenly loaded 11 Do not use more cribbing blocks than those provided with one complete set Use only one set Do not add components 12 Do not lower the load directly onto the cribbing blocks 13 Use each set only with the cylinder for which it was designed 14 Read and understand all operating instructions and warnings 15 If cribbing is used it must be installed properly Align handles
7. Ei ARR o Sir LEAL CHU LUN SING CO LTD No 199 Gangshan N Rd Gangshan Township Kaohsiung County 820 Taiwan http www sunrun com tw E mail sun run msa hinet net TEL 886 7 6210505 FAX 886 7 62175 75 R SUN RUN OPERATING INSTRUCTIONS Portable High Tonnage Jack SPLE series English E1 E12 Instructions for Portable High Tonnage Jack 1 SAFETY PRECAUTIONS 4 and warnings could cause equipment Fail to comply with the following cautions damage and personal injury operator must be 18 years The operator must have read and understood all instructions safety issues cautions and warnings before starting to operate the SUN RUN equipment The operator is responsible for this activity towards other persons WARNING To avoid personal injury and possible equipment damage make sure all hydraulic components withstand the maximum pressure of 700 bar 10 000psi a IMPORTANT Minimum age of the WARNING Always wear safety glasses The operator must take precaution against injury due to failure the tool or workpiece mm WARNING Stay clear of loads supported 2 by hydraulics A cylinder when used as a load lifting device should never be used as a load holding device After the load has been raised or lowered it must always be blocked mechanically 3 WARNING USE ONLY RIGID PIECES TO HOLD LOAD Carefully select steel or wood blocks that are capable of supporting the load Never use a hyd
8. HP 220V 10 7A Power Unit ili 2 BS 7 SPE 554TQJ 1 1 8HP Power Unit Al EN SS FT SPE 554TQJ Single Phase 220V 10 7A 50 60Hz Single Phase Stroke 333mm 50 60Hz Single Phase 50 60Hz Single Phase HAIR Dimensions mm Tire Dia mm E E eine 1538 850 1592 659 660 458 52 4360 DBa 700bar IESE Dimensions mm NERY B Cribbing Blocks Model No E AEIR XKSPLE5013 A01 XKSPLE5013 A02 XKSPLE10013 A01 38 5 XKSPLE10013 A02 765 5 XKSPLE15013 A01 38 5 XKSPLE15013 A02 765 5 XKSPLE20013 A01 38 5 44 5 254 2 XKSPLE20013 A02 765 825 2542 HAIR Dimensions mm Jack Module Ext Total stack H Ht Wt kg WARR KREA Sie S A C Total stack Ht Jack Module Ext Model No AI he XKSPLE5013 A03 XKSPLE10013 A03 228 6 XKSPLE15013 A03 219 2 C D E 1 8UN 1 3 4 12UN 3 3 8 16UN F CHU LUN SING CO LTD Page E2 Instructions for Portable High Tonnage Jack 3 OPE RATION Load Load cap Load from this direction only Extension and Cribbing A KG blocks NNYSNNS NAN AN NE NANA This guide cannot cover every situation so always do the job with SAFETY FIRST s CHU LUN SING CO LTD Models SPLE
9. ad sealant and tighten connection 3 Make sure all couplers are fully coupled If relief valve is still leaking do not attempt to service this component Contact SUN RUN office nearest to you for advice technical assistance s CHU LUN SING CO LTD Page E11 Instructions for l Portable High Tonnage Jack Models SPLE series Problem Cause Solution Cylinder will not retract or retracts 1 Pump release valve closed 1 Open pump release valve slower than normal 2 Loose couplers 2 Tighten couplers 3 Blocked hydraulic lines 3 Clean and flush 4 Cylinder damaged internally 4 Send to service center for repair 5 Pump reservoir too full 5 Drain hydraulic fluid to correct level 6 Pump or valve malfunctioning 6 Check pump or valve operating instructions s CHU LUN SING CO LTD a
10. h shift or usage to prevent unsafe conditions from developing F Do not use cylinder with bent or damaged couplers or damaged port threads G Under certain conditions the use of an extension with a hydraulic cylinder may not be advisable and could present a dangerous condition H Avoid pinch points or crush points that can be created by the load or parts of the cylinder To help prevent material fatigue if the cylinder is not be used in a continuous application the load should not exceed 85 of the rated capacity J Cylinder must be on a stable base which is able to support the load while pushing or lifting K To help prevent personal injury use shims friction material or constraints to prevent slippage of the base or load L Surfaces contacting the cap must be parallel to the base supporting surface within 4 M At least 75 of the load cap and base must be supported securely when pushing or lifting a load N Block or secure the load to prevent movement during lifting O Do not set poorly balanced or off center loads on a cylinder The load can tip or the cylinder can kick out and cause personal injury P Do not exceed 4 misalignment of the load on the cap Q If this component is used to lift or lower loads be certain that the load is under operator control at all times and that others are clear of the load Do not drop the load R As the load is lifted use blocking and cribbing to guard against a falling load S To help
11. ink twist curl cut or bend so tightly that the fluid flow within the hose is blocked or reduced Periodically inspect the hose for wear because any of these conditions can damage the hose and possibly result in personal injury F Do not use the hose to move attached equipment Stress can damage the hose and possibly cause personal injury G Hose material and coupler seals must be compatible with the hydraulic fluid used Hoses also must not come in contact with corrosive materials such as creosote impregnated objects and some paints Hose deterioration due to corrosive materials can result in personal injury Consult the manufacture before painting a hose Never paint a coupler s CHU LUN SING CO LTD Page E6 Instructions Tor Portable High Tonnage Jack Models SPLE series 3 OPERATION 3 6 SAFETY PRECAUTIONS 3 6 8 WARNING 3 6 8 2 Cylinder A The user must be a qualified operator familiar with the correct operation maintenance and use of the cylinders Lack of knowledge in any of these areas can lead to personal injury B Read and understand all safety and warning decals and instructions C Use only approved accessories and approved hydraulic fluid Hoses seals and all components used in a system must be compatible with the hydraulic fluid used D Do not exceed the rated capacities of the cylinders Excess pressure can result in personal injury E Inspect each cylinder fitting tube line hose valve and coupler before eac
12. le s CHU LUN SING CO LTD Page E10 Instructions Tor Portable High Tonnage Jack 5 TROUBLESHOOTING Models SPLE series Problem Cylinder extends only partially Cause 1 Pump reservoir is low on hydraulic fluid 2 Load is above the capacity of the system 3 Cylinder piston rod binding Solution 1 Fill and bleed the system 2 Use the correct equipment 3 Check for dirt or leaks Check for bent misaligned worn parts or defective packings Cylinder moves slower than normal 1 Loose connection or coupler 2 Restricted hydraulic line or fitting 3 Pump not working correctly 4 Cylinder seals leaking 1 Tighten 2 Clean and replace if damaged 3 Check pump operating instructions 4 Replace worn seals Check for excessive contamination or wear Cylinder moves but does not maintain pressure 1 Leaky connection 2 Cylinder seals leaking 3 Pump or valve malfunctioning 1 Clean reseal with thread sealant and tighten connection 2 Replace worn seals Check for excessive contamination or wear Replace contaminated fluid as necessary 3 Check pump or valve operating instructions Cylinder leaks hydraulic fluid 1 Worn or damaged seals 2 Loose connections 3 Rod end relief valve has activated 1 Replace worn seals Check for excessive contamination or wear Replace contaminated fluid as necessary 2 Clean reseal with thre
13. luid leaks Heat also weakens hose materials and packings For optimum performance do not expose equipment to temperatures of 65 C 150 F or higher Protect hoses and cylinders from weld spatter ep DANGER 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 Page E1 Instructions Tor Portable High Tonnage Jack Models SPLE series SETA f 5 position adjustable handle D F pa 1 SOT E Na po AT Cribbing blocks with handles and i storage racks 1 f G 50 200 MES 70 fa sy Heavy duty 50 200 ton ae lifting capacity 6 A SEAL SR TSS AR 16 Sie B All steel cylinder is 16 tires thread into base H BAER Nema See DONE HES l Steel base not prone j h 20 ft remote control to cracking like cast re eS eee oeModel No SPLE 15013 5 Cylinder EH iL AD oe RSR 15013 Cap 1386kKN Stroke 333mm SPLE 20013 5 Cylinder TH il AY oe RSR 20013 Cap 1995kN Stroke 330mm SPLE 10013 Cylinder TH il AY oe RSR 10013 Cap 933kN SPLE 5013 Cylinder TH il BY oe RSR 5013 Cap 498kN Stroke 334mm Power Unit Al EN SS FT SPE 554TQJ 1 1 8HP 220V 10 7A Power Unit EI Eber SPE 554TQJ 1 1 8
14. nage Jack 5 TROUBLESHOOTING Models SPLE series Problem Erratic action Cause 1 Air in system or pump cavitation 2 Internal leakage in cylinder 3 Cylinder or valve sticking or binding 4 Malfunctioning valve Solution 1 Add fluid bleed air and check for leaks 2 Replace worn packings Check for excessive contamination or wear Replace contaminated fluid as necessary 3 Check for dirt or leaks Check for bent misaligned worn parts or defective packings Replace contaminated hydraulic oil with clean compatible hydraulic oil 4 Replace This valve is NOT serviceable Cylinder does not move 1 Loose couplers 2 Faulty coupler 3 Improper valve position 4 Low or no hydraulic fluid in pump reservoir 9 Air locked pump 6 Pump not operating 7 Load is above the capacity of the system 8 Fluid leaks out of rod end relief valve 9 No pilot pressure 10 Malfunctioning valve 1 Tighten couplers 2 Verify coupler is not locked up Replace as needed 3 Close release valve or shift to new position 4 Fill and bleed the system 5 Prime pump per pump operating instructions 6 Check pump s operating instructions 7 Use the correct equipment 8 Make sure all couplers are fully coupled Contact SUN RUN office nearest to you for advice technical assistance 9 Check connections pump valve position and pressure 10 Replace This valve is NOT serviceab
15. raulic cylinder as a shim or spacer in any lifting or pressing application DANGER To avoid personal injury keep hands and feet away from cylinder and workpiece during operation WARNING Do not overload equipment Overloading cause equipment failure and possible personal injury The cylinders are designed for a max Pressure of 700 bar 10 000psi J CHU LUN SING CO LTD A Models SPLE series DANGER NEVER set the relief valve to a higher pressure than the maximum rated pressure of the pump Higher settings may result in equipment damage and or personal injury Do not remove relief valve WARNING The system operating pressure a must not exceed the pressure rating of the lowest rated component in the system Install pressure gauges in the system to monitor operating pressure It is your window to what is happening in the system lt that will cause severe back up pressure in hoses Bends and kinks lead to premature hose failure CA CAUTION Avoid sharp bends and kinks p 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 IMPORTANT Do not lift hydraulic equipment by the hoses or couplers Use the carrying handle or other means of safe transport CA CAUTION KEEP HYDRAULIC EQUIPMENT AWAY FROM FLAMES AND HEAT Excessive heat will soften packings and seals resulting in f
16. then to full retraction three or more times until the jack advance and retracts smoothly throughout the cycle 3 1 5 Allow the pump to build to full pressure with the jack first fully extended and then fully retracted Stop pump and check each hose fitting and other system components for any oil leakage If any leakage is found correct the problem and retest 3 2 Bleeding air from the system The portable jack has been bled at the factory however air can accumulate in the hydraulic system if the reservoir oil level is too low or if the unit has not been used for a prolonged period This air cause the jack to respond in an unstable or slow manner Before attempting to lift a load for the first time remove the air 1 With no load on the jack cycle the hydraulic system three or more times fully extend and retract the jack 2 Check the pump reservoir level Refer to the pump operating instructions for the proper fill level and direction on how to add oil if necessary 3 3 Only qualified individuals should operate this equipment Position the unit under the load to be lifted and select the extension or extensions required 3 4 The cylinder must not exceed 4 from centerline alignment at any time with or without extensions To lower to load Start the unit and raise the load just enough to remove the cribbing blocks Switch the valve to retract and lower the load NOTE This uit is equipped with a load lowering valve that req
17. uires pump pressure throughout the lowering operation NOTE Unit weight 237kg without extensions or cribbing blocks Transport with care s CHU LUN SING CO LTD Page Ed Instructions Tor Portable High Tonnage Jack Models SPLE series 3 OPERATION 3 5 Double acting Hydraulic System A basic double acting hydraulic system consists of a pump which moves the hydraulic fluid a double acting cylinder or ram to do the work a hydraulic hose which routes the fluid to the advance cylinder or ram port a second hydraulic hose which routes the fluid to the retract cylinder or ram port and a control valve which can change the direction of the hydraulic fluid TYPICAL INSTALLATION Ih WU imme pS Fe A double acting cylinder or ram can be either extended or retracted hydraulically Most double acting cylinders or rams are classed as differential cylinders because of the different sized areas that the hydraulic fluid pushes against during the extend and retract strokes Because of this difference the extend stroke can exert more force than the retract stroke NOTE The capacity of a hydraulic system is determined by the effective area of the cylinder and the system pressure 3 6 SAFETY PRECAUTIONS 3 6 1 A double acting cylinder or ram must have both hoses and all couplers securely connected to both ports If one of the two ports is restricted or becomes disconnected
18. ury or death 3 6 5 Avoid off center loads which could damage the cylinder or ram and or cause loss of the load possibly Causing serious injury or death 3 6 6 Control the load at all times Do nit drop the load 3 6 7 Properly rated adapters be installed and used correctly for each application 3 6 8 WARNING 3 6 8 1 Hydraulic Hose and Fluid Transmission Lines A Avoid straight line tubing connections in short runs Straight line runs do not provide for expansion and contraction due to pressure and or temperature changes B Eliminate stress in the tube lines Long tubing runs should be supported by brackets or clips Tubes hrough bulkheads must have bulkhead fittings This makes easy removal possible and helps support the tubing C Before operating the pump all hose connections must be tightened with the proper tools Do not overtighten Connections should only be tightened securely and leak off Overtightening can cause premature thread failure or high pressure fittings to split at pressure lower than their rated capacities D Should a hydraulic hose ever rupture burst or need to be disconnected immediately shut off the pump and release all pressure Never attempt to grasp a leaking pressurized hose with your hands The force of escaping hydraulic fluid could cause serious injury E Do not subject the hose to potential hazard such as fire sharp surfaces extreme heat or cold or heavy impact Do not allow the hose to k
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