10.6 TEST .............................................................................................................................. 13
11 REMOVING FROM OPERATION – LIQUIDATION ...................................................... 13
12 RELATED DOCUMENTATION ....................................................................................... 13
13 FINAL REQUIREMENTS OF THE MANUFACTURER TO A CUSTOMER ................. 13
2
1 DEFINITION
! DANGER
! WARNING
! CAUTION
Lifting capacity (Q): indicates maximum mass of load (working load limit) the cylinder
is designed to support in general service under conditions given by this manual.
Danger: indicates the presence of a hazard, which will cause
death or severe injury if the warning is ignored.
Warning: indicates the presence of a hazard, which can cause
death or severe injury if the warning is ignored.
Caution: indicates the presence of a hazard, which can cause
minor injury if the warning is ignored. Caution can also indicate
dangerous practices.
2 INTENDED PURPOSE
2.1 Hydraulic cylinder type Z321, lifting capacity 25t; 50t; 100t and 200t (further only
cylinder) is designed solely for lifting and lowering free loads of big weight in vertical
direction by the help of manual pump at normal atmospheric condition on a workplace.
Weight of load during lifting must not exceed nominal lifting capacity.
2.2 Design of the cylinder meets requirements given by Directive of European
Parliament and Council 2006/42/EC as amended by the Czech technical regulation –
Government regulation no. 176/2008 Collection of law as amended and requirements
of harmonized Czech technical standards ČSN EN ISO 12100 and ČSN EN 1494+A1.
2.3 Výrobek svým provedením vyhovuje požadavkům stanoveným Směrnicí
Evropského parlamentu a Rady 2014/34/EU ve znění českého technického předpisu –
nařízení vlády č. 116/2016 Sb. v platném znění. Výrobek je proveden jako zařízení
IM2c dle ČSN EN 13463-1:2009 a ČSN EN 13463-5:2012. Splňuje podmínky pro
použití v důlním prostředí „nebezpečné atmosférické podmínky 2“
dle ČSN EN 1127-2.
2.4 Výrobek svým provedením vyhovuje požadavkům stanoveným Směrnicí
Evropského parlamentu a Rady 2014/34/EU ve znění českého technického předpisu –
nařízení vlády č. 116/2016 Sb. v platném znění. Výrobek je proveden jako zařízení
II2GDcT85°C dle ČSN EN 13463-1:2009 a ČSN EN 13463-5:2012. Splňuje
podmínky pro použití v prostředí „zóna 1 a zóna 21“, “zóna 2 a zóna 22“
dle ČSN EN 1127-1.
Note: Articles 2.3 and 2.4 are valid for type of construction of hydraulic cylinder for
explosive environment.
3
3 SAFETY PRINCIPLES
Remember proper rigging and lifting techniques are the responsibility of the operator.
eck all applicable national directions, regulations and standards for further
3.1 SAFETY SUMMARY
Danger exists particularly when the cylinder is not used properly or is poorly
maintained. Since an accident or serious injury could result, special safety precautions
apply to the operation with the hydraulic cylinder during its use, maintenance and
inspection.
! WARNING
NEVER work under lifted load or close to it.
NEVER lift more than lifting capacity shown on cylinder.
ALWAYS make sure the ground is firm enough to support safely fully loaded cylinder
ALWAYS keep sufficient spacing from the load.
ALWAYS let people around to know when lift is about to begin.
ALWAYS read the operation manual and safety instructions.
and all lifting operation.
Ch
information about the safe use of your hydraulic cylinder.
3.2. SAFETY PRINCIPLES
! WARNING
3.2.1 Before use
ALWAYS ensure physically strong, qualified and instructed persons elder 18 years of
age, knowing this manual and trained in safety conditions and way of work
ALWAYS check the cylinder every day, prior starting the work according to the article
ALWAYS make sure the lift is sufficient for intended operation.
ALWAYS ensure load against unwanted motion.
ALWAYS make sure the cylinder stands on firm ground.
ALWAYS make sure the cylinder stands vertically.
ALWAYS use recommended pumps and connection houses only.
operate the cylinder.
8.2.(1) „Daily inspection“.
NEVER use damaged or worn cylinder.
NEVER use cylinder without visible marking of the lifting capacity on it.
NEVER use a cylinder marked by the label „OUT OF SERVICE“.
ALWAYS consult use of the cylinder in non-standard or extreme conditions with
manufacturer or the authorised representative.
4
3.2.2 While operation
ALWAYS make sure the load is properly placed on a cylinder.
ALWAYS pay attention not to exceed maximum height of lift marked by the red
groove on a piston.
ALWAYS after lifting a load ensure the piston of the cylinder by the nut.
ALWAYS underlay load, if you intend to work on it.
ALWAYS pay a special attention to a cylinder, if piston is released to maximum
position
(marked by the red groove on a piston).
NEVER use cylinder for permanent underlying of loads.
NEVER allow the load, causes impacts or vibrations.
3.2.3 After use
NEVER leave lifted load without attendance and without ensuring the piston against
self downturn by the nut.
3.2.4 Risk analysis
The analysis of possible risk in turn of design, operation and environment of the
hydraulic cylinder application is mentioned in freestanding document “Risk analysis”.
This document can be required in service centres.
3.2.5 Maintenance
ALWAYS let qualified personnel inspect the cylinder regularly.
Only such interventions can be done when maintaining that are in compliance with
requirements of the manufacturer specified in the chapter 13 of this manual.
It is not allowed to provide repairs and maintenance in a different way then specified
by the manufacturer. It is especially prohibition of use of no original parts or providing
changes of product without the agreement of manufacturer.
4 PACKING, STORAGE AND MANIPULATION
4.1 PACKING
4.1.1 Cylinders are supplied assembled with hydraulic liquid, free loaded in transport
cases.
4.1.2 The following accompanying documentation is a part of the delivery:
a) Operation manual
b) EC Declaration of conformity
c) Certificates of Quality and Completeness and Guarantee Card
c1) Guarantee period is stated in the Guarantee Card.
c2) The guarantee does not apply to defects caused by infringement of the
instructions stated in this Operation Manual and defects occurred owing to
improper use and unskilled intervention.
c3) The guarantee does not apply also to any modifications on the product
without a written approval of the manufacturer.
c4) Claim of product defects is carried out according to applicable provisions
of commercial code eventually as amended.
5
STORAGE
4.2
Store jacks in dry and clean stocks free of chemical influences and vapors.
(1) Remove from jack all dust, water and impurities.
(2) Push piston into the initial (lowered) position.
(3) Store the cylinder so as the piston was in vertical position.
(4) During further use follow instructions of the article 8.1.4 „Occasionally used jack“.
4.3 MANIPULATION
Follow the valid technical regulation and standards and standards for work with heavy
loads.
The hydraulic jack is not portable by women and persons under 18 years of age.
5 MAIN TECHNICAL PARAMETERS
Range of
working
temperatu
re
-10°C
to
+50°C
Connecting
screw
(mm)
M18 x 1,5
Weight
(kg)
20
Type
Z321
Lifting
capacity
(t)
Lift
(mm)
25 145
50 145 1,4 40
100 145 2,23 87
Operating
pressure
(MPa)
65
Swept
volume
( l )
0,56
200 145 4,55 190
5.1 DATA ON PRODUCT
Every product is fitted with a label with specified data as follows:
Standard design: Design for explosive environment:
Manufacture’s identification Manufacture’s identification
Address of the manufacturer Address of the manufacturer
Type of product Type of product
Pressure Pressure
Serial number Serial number
Year of production Year of production
CE marking CE marking
Symbol of protection type (IM2c for group I , II2GDcT85°C for
group II)
5.2. MATERIAL AND DESIGN
5.1.1 All parts are made of steel.
5.1.2. There are no materials inclinable to spark ignition used in construction of the
cylinder by course of amendment no. 2 article 1.3.1 of Government regulation
no. 116/2016 Collection of law and harmonized technical standards ČSN EN
1127-2 article 6.4.4, ČSN EN 1127-1 article 6.4.4 and ČSN EN 13 463-1 article
8.1.
5.1.3. Materials with dangerous effects of static electricity in terms of ČSN EN 1127-2
article 6.4.7, ČSN EN 1127-1 article 6.4.7, ČSN EN 13463-1 article 7.4.3 and
ČSN 33 2030 are not used in cylinder.
5.1.4 Plastics (high pressure hoses, pressure liquids) used in operation of cylinder in
explosive environment according to the article 2.3 and 2.4 of this manual must
meet ČSN EN 1127-2 article 6.4.7, ČSN EN 1127 – 1article 6.4.7, ČSN EN
13463-1 article 7.4.3,
ČSN 33 20 30 and for use in mining environment § 185
paragraph (1) Czech mining office no. 22/89 Collection of law as amended.
6
6 OPERATION OF CYLINDER
Before installation carefully check the cylinder, whether is not damaged.
Cylinder is supplied without the oil charge.
6.1 CHECKING BEFORE THE INSTALLATION
6.1.1 Support face
! WARNING
ALWAYS make sure the support face is firm enough to support assumed load for the
whole time of manipulation. Installation must not be carried out on the surface
ALWAYS the user is responsible for positioning the cylinder!
NEVER allow the weight of the load or total piston thrust exceeds nominal lifting
capacity.
6.2 CONNECTION OF CYLINDER WITH PUMP
Cylinders are determined for use in connection with manual hydraulic pump type
HP03L, HP05L or HP07L. Pump association depends on swept volume of cylinder.
Recommended association of pump to cylinder describes the following tablet:
we cannot check the loading capacity or is unstable
Capacity
of
cylinder
(t)
25
50
100
200 1 HP 05L, HP 07L 4,55
Cylinders are connected with pump by the help of high pressure hoses of type 4SP
DKOS/DKOS about inner diameter 6mm. Hoses are supplied as the separate product
in basic length 2m or in other length to 6m according to wish of the customer. Hoses is
fitted on both ends with screw M18 x 1,5mm.
Number of connecting
cylinders (pcs)
1 HP 03L
2 HP 05L
1 HP 03L
2 HP 05L, HP 07L
1 HP 03L
2 HP 05L, HP 07L
Association of pump -
type
Swept
volume (l)
0,56
1,4
2,23
! CAUTION
During use of long hoses connection between pump and hydraulic cylinder is
necessary ALWAYS judge individually, whether amount of oil in houses do not limit
use of hydraulic cylinder lift.
Note: 10m of hose of inner diameter 6mm represent cca 0,3l oil.
7
6.3 POSITION OF CYLINDER DURING LIFTING OR LOWERING
During lifting or lowering of load the bottom of cylinder shall sit on firm a large enough
so as to avoid sinking of the cylinder. Pay attention the cylinder stand vertically. Axes
of piston can be diverted at max. about 3°.
! WARNING
ALWAYS make sure the jack stands vertically during lifting.
6.4 LIFTING A LOAD
Before lifting a load make sure the piston
nut is not screwed up to prevent its full
insertion into the cylinder. Piston shall be in
its initial (lower) position.
Lifting is provided by the oscillatory motion
of the hand lever of the pump. Instructions
for operating the pump are stated in
separate manual that is delivered to each
pump. After finishing the lifting ensure
piston against self-dropping by the nut - see
fig. 6.5.
Fig. 6.5
! WARNING
ALWAYS before lifting make sure, the piston matrix does not prevent its full insertion
into the cylinder.
ALWAYS pay attention during lifting so as not exceed maximum height of lift.
NEVER lift piston of cylinder over red marked groove, which is under screw
of piston!!
ALWAYS ensure the piston by the matrix after termination of lifting.
6.5 LOWERING A LOAD
Before lowering a piston, at first slightly lift up the piston by several pendulum motions
of the hand lever and then unscrew the piston matrix to its top position.
Lowering the piston and speed of lowering control by releasing the screw of the drain
valve thanks to slide on hand lever. Before lowering the piston in dusty environment
we recommend to clean up the surface of the piston.
6.6 TEST BEFORE THE USE
! CAUTION
(1) Visually check the cylinder and support area, whether they are without defects.
(2) At first, look again at the previous articles of this manual and make sure that all
steps were done correctly and cylinder is correctly connected with appropriate
pump.
(3) By the move of pump lever check the function of the cylinder without a load.
(4) Provide several lifting and lowering with a suitable load (10% up to 50% capacity).
(5) At the same time check the cylinder and pump, whether at interruption keep load
without a drop of piston.
(6) Check, whether there is no outflow of oil due to the leakage.
8
7 OPERATION
7.1 USE OF THE CYLINDER
Cylinder is intended for vertical lifting and lowering of heavy loads under normal
condition on workplace. It is operated by the help of separately delivered pump and
connecting hoses. Can be used by organisations as well as the private persons.
As work with heavy loads can pose unexpected danger, it is necessary to follow all
“Safety principles” according to the chapter 3.
7.2 SAFETY WORKING ENVIRONMENT
! WARNING
(1) The operating staff of the hydraulic cylinder must be demonstrably familiarized with
this operation manual, must observe applicable safety and hygienic regulations
and must be qualified for operation of this equipment.
(2) The operating staff should be equipped with protective footwear and gloves for
work with the jack.
(3) When operating by more persons ALWAYS there must be determined one worker
trained with safety of work responsible for manipulation with the cylinder.
(4) The operating staff must have a clear and unobstructed view of the whole working
area before starting the work. When it is not possible, one or more persons must
help to supervise in the nearby area of the hydraulic cylinder.
(5) The operating staff must check, whether the entire work place is safe and whether
there is as possibility of escaping from this area in case of endanger, before
starting to operate the cylinder.
(6) During the work with the cylinder the suitable distance of the operating staff from
the load must be kept. It is prohibited to lift or lower bulky loads preventing to keep
sufficient safety distance.
8 INSPECTION OF CYLINDER
8.1 INSPECTION
8.1.1 Inspection classifications
(1) Initial inspection: precedes first use. All new or repaired hydraulic cylinders shall be
inspected by a responsible qualified person to ensure the qualified fulfillment of
requirements of this operation manual.
(2) Inspection procedures of hydraulic cylinders operated regularly are generally
divided into two classifications based on the intervals at which should be performed.
The intervals depend on the condition of the critical components of the hydraulic
cylinders and the degree of the wear and tear, deterioration or malfunction. The two
general classifications are herein classed as daily and regular ones. The respective
intervals are defined as follows:
(a) Daily inspection: visual inspection, carried by the operator, designated by the
user on the beginning of each use.
(b) Regular inspection: visual inspection carried out by the qualified person
designated by the user.
1) normal operation – once per year,
2) heavy operation – twice per year
3) special or infrequent operation – according to the recommendation of the qualified
person at first usage and according to the directions of the qualified person (workers of
maintenance).
9
8.1.2 Daily inspection
Regarding parts such as those recommended in the section 8.2(1) „Daily inspection“
verify, whether the girder clamp is without any defect. Provide this inspection also
during operation in the interval between regular inspections. Qualified employees will
determine whether any defect or damage can constitute a hazard and whether more
detailed inspection is necessary.
8.1.3 Regular inspection
Complete inspections of the hydraulic jack perform as recommended regular
inspections. These inspections may be performed with the hydraulic jack in its normal
location. Recommended regular inspection specified in the section 8.2(2) shall be
performed under the supervision of qualified persons that will determine, whether it is
necessary to repair the girder clamp. These inspections shall include the requirements
of the daily inspection as well.
8.1.4 Occasionally used hydraulic cylinder
(1) Hydraulic cylinder, which has been idle for a period of one month or longer but less
than one year, remit to the inspection conforming to the requirements of the section
8.1.2 before follow-up putting it into operation.
(2) The hydraulic cylinder, which has been idle for a period of one year, remit to the
inspection conforming to the requirements of the section 8.1.3 before follow-up putting
it into operation.
8.1.5 Inspection record
Always keep the record of the performed tests, repairs, inspections and maintenance
of the girder clamp. Dated inspection records perform in time intervals specified in the
section 8.1.1 (2) (b) and such records store in an accessible place designated by the
user.
Defects discovered by the inspection or reported during work must be announced to
person responsible for safety designated by the user.
8.2 INSPECTION PROCEDURE
(1) Daily inspection (carried out by the operation start or a qualified person)
PART
1. Function of the
cylinder
2. Check of piston
matrix.
3. Connection with a
pump.
INSPECTION
METHOD
By testing.
By screwing.
Visually.
LIMIT/CRITERIA
FOR DISCARDING
Slow or no movement
of piston during
lifting.
Matrix cannot be
screwed up.
Oil leakage in the
place of thread.
REMEDY
Exchange of piston
cup.
----------
Note: This defect can be
caused by the failure of
the pump – see manual
for pump.
Clean the tread of
matrix and piston and
lubricate.
Tighten nut of hose or
repair.
10
(2) Regular inspection (carried out by the qualified person)
PART
1. Piston
2. Screwing Visual check Oil leakage Tighten screwing or
3. Label – marking of
capacity on cylinder
4. All parts
INSPECTION
METHOD
Visual check Oil leakage around
Visual check Illegible lifting
Visual check Worn or damaged
LIMIT/CRITERIA
FOR DISCARDING
the piston
capacity
parts
Polluted parts
REMEDY
Exchange of piston
cup (see art. 10.3)
repair
Repair or exchange
by the new one
Replace by new part.
Dismantle, clean up
and assemble again
9 TROUBLSHOOTING
Possible malfunctions can be caused by the pump. Since pump is integral part of the
lifting complete we state the possible malfunctions caused by the pump.
SITUATION TROUBLE CAUSE REMEDY
1. During lifting the piston
moves very slowly or it does
not move at all. Drop of
piston cased by the load does
not occur.
2. After finishing of lifting
self-acting drop of piston
occur.
Leakage of pump inlet valve
or forcing valve of pump or
piston cup of pump.
Struck piston.
Leakage of drain valve.
Leakage caused by impurities
you can try to remove by
flushing of pump e.g. quick
pendulum movement of hand
lever.
If the leakage appears
henceforth, dismantle valves
and clean up carefully.
Exchange the rubber piston
cup (see art. 10.3)
Complete repair necessary.
Tighten drain valve.
If the fault lasts, dismantle
valve and clean up.
10 MAINTENANCE
10.1 SAFETY PRINCIPLES
! WARNING
Maintenance can be carried out only by qualified persons trained in safety and
maintenance of these cylinders.
ALWAYS use only original parts supplied by the manufacturer.
It is not permitted to perform repairs and maintenance the other way then prescribed
by the manufacturer. It concerns especially the forbiddance of using unoriginal parts or
carrying out modifications on the product without any approval of the manufacturer.
11
ALWAYS check the function of the cylinder after maintenance.
ALWAYS mark the defective or repaired jack by the suitable label (for example: „OUT
OF OPERATION“).
NEVER start maintenance, when a load is on the cylinder.
NEVER work with a jack, which is under repair!
NEVER use cleaning liquids on acid base.
10.2 GENERAL INSTRUCTION
The following instructions give general important information about dismantling,
inspection, repair and assembly. If the hydraulic jack was dismantled from any reason,
proceed according to the following instructions:
1. Provide maintenance in a clean environment.
2. NEVER dismantle jack more than it is necessary for providing a repair.
3. NEVER use excessive force during dismantling parts.
4. NEVER use heat as a means during dismantling parts, if these parts are
determined for further use.
5. Keep the workplace clean and without foreign substances that could get onto
piston bearing surface or into the inner mechanism of the jack.
6. If the part is gripped in a vice, ALWAYS use suitable material (leather, copper,
piece of wood, etc.) to protect surface of parts.
10.3 EXCHANGE OF PISTON CUP (DISMANTLING OF PISTON) - fig. 10.3
1. Drain all oil of the cylinder and disconnect cylinder from the pump.
2. Take out the piston ( 1 ) from cylinder ( 2 ) together with the piston nut.
3. Remove safety ring ( 3 ), and pull out the piston cup ( 4 ).
4. After exchange of the cup ( 4 ) provide assembly in an opposite sequence.
Pay attention, the piston cup was not damaged during putting the piston into the
cylinder.
Pay attention the piston was utterly clean.
10.4 CHECK
Check all dismantled parts, whether they are suitable for further use.
1. Check all parts, if they are not worn out or do not have scratches or cracks.
2. Check, whether the thread parts does not have damaged thread.
3. Check especially piston cup.
2
1
4
3
Fig. 10.3
12
10.5 REPAIR
Worn out or damaged parts shall be replaced. Small surface burns and scratches or
other small surface defects remove and smooth by the fine abrasive stone or the
abrasive cloth.
10.6 TEST
The load test shall be carried out at all repaired cylinders:
A load not exceeding nominal lifting capacity is applied to a cylinder. Piston moved up
about 10 mm and in this rest position is remained at minimum 3 minutes (without
locking of the piston by the nut). Then the load is lowered into origin position.
At this test the correct function of the pump, hydraulic cylinder, high pressure hose and
discharge valve is checked. Lifting and lowering must be fluent, jamming and seizure
must not occur. During 3 minutes of steady load must not occur an apparent drop of
piston and to oil leakage around piston cup or other sealing.
11 REMOVING FROM OPERATION – LIQUIDATION
Before removing the jack from the operation remove all oil and rinse cylinder by the
degreasing agent (benzine, etc.).
Thus treated jack give you can give to a firm dealing with liquidation of metal scrap.
Piston cup give over to the liquidation of plastic.
Drained oil pass over to an authorised and professional firm dealing with petroleum
waste category SR (special risk) or give it directly to garbage disposal plant having
authorisation to combustion of such a waste.
12 RELATED DOCUMENTATION
EC declaration of conformity
Instruction manual was elaborated in accordance with the following technical regulations,
technical standards and national regulations:
•Government regulation no.176/2008
European Parliament and Council 2006/42/EC)
• ČSN EN ISO 12100
• ČSN EN 1494+A1
Collection of law as amended
(Directive of
13 FINAL REQUIREMENTS OF THE MANUFACTURER TO A
CUSTOMER
Any changes of the product, eventually use of unoriginal spare parts can be
realised only based on approval of the manufacturer.
When not observing this condition the manufacturer does not guarantee safety
of this product. In such a case the manufacturer warranty does not apply to the
product.
13
Loading...
+ hidden pages
You need points to download manuals.
1 point = 1 manual.
You can buy points or you can get point for every manual you upload.