Brano 15-00-CON-W User manual

translation of the original instructions for use (also applies to special designs)
BRANO a.s., 747 41 Hradec nad Moravicí
the Czech Republic
tel.: [phone]
http://www.brano-zz.cz; http://www.brano.eu;
[email protected]; [email protected]
OPERATION MANUAL
SECURITY PRINCIPLES, OPERATION AND MAINTENANCE
FOR
RACK JACK
Type 15-00 load capacity 2,5t and 5t
Type 15-01 load capacity 10t
CONTAINER WALL-MOUNTED CONSTRUCTION – CON-W
CONTAINER DESIGN – CON
these versions are further available in variants:
DESIGN WITH RATCHET CRANK – RK
DESIGN WITH RATCHET HANDLE-LEVER – RKP
DESIGNED IN EXPLOSIVE ENVIRONMENTS – NEXP
Peruse the operation manual before using the jack. It comprehends substantial security
instructions and instructions for use, installation and maintenance of the product.
Ensure the Operation Manual is available for all responsible persons.
Keep for next usage!
Edition 4
th
JANUARY 2021
Registration number 1
-
55830
-
0
-
1

2
CONTENTS
1 DEFINITION ........................................................................................................................3
2 DEVICE PURPOSE.............................................................................................................3
3 SECURITY PRINCIPLES ....................................................................................................4
3.1 SECURITY PRINCIPLES OVERVIEW ............................................................. 4
3.2. SECURITY PRINCIPLES................................................................................. 4
3.2.1 Prior to use..................................................................................................... 4
3.2.2 When in use ................................................................................................... 4
3.2.3 Risk analysis .................................................................................................. 5
3.2.4 Maintenance .................................................................................................. 5
4 PACKING, STORAGE AND HANDLING..............................................................................5
4.1 PACKING.......................................................................................................... 5
4.2 STORAGE ........................................................................................................ 5
4.3 HANDLING ....................................................................................................... 5
5 MAIN SPECIFICATIONS .....................................................................................................6
5.1 MECHANICAL CLASSIFICATION .................................................................... 7
5.2. MATERIAL AND FINISH.................................................................................. 8
5.3 DATA ON THE PRODUCT ............................................................................... 8
6 JACK INSTAL L A TION............................................................................................................9
6.1 ANCHORAGE TO A STRUCTURE................................................................... 9
6.2 TEST PRIOR TO USE .................................................................................... 10
7 OPERATION AND MAINTENANCE...................................................................................10
7.1 JACK APPLICATION ...................................................................................... 10
7.2 SAFETY WORK ENVIRONMENT................................................................... 10
8 JACK CHECK....................................................................................................................11
8.1 INSPECTION .................................................................................................. 11
8.1.1 Inspections types ......................................................................................... 11
8.1.2 Daily inspection............................................................................................ 11
8.1.3 Regular inspection ....................................................................................... 11
8.1.4 Jack occasionally used ................................................................................ 11
8.1.5 Report on inspection .................................................................................... 11
8.2 INSPECTION PROCEDURE .......................................................................... 12
9 TROUBLE-SHOOTING .....................................................................................................13
10 GREASING .....................................................................................................................13
10.1 GENERAL..................................................................................................... 13
10.2 JACK MECHANISM ...................................................................................... 13
11 MAINTENANCE ..............................................................................................................14
11.1 SECURITY PRINCIPLES.............................................................................. 14
11.2 REPLACEMENT OF BRAKE INSERTS AND BRAKE ADJUSTING............. 14
11.2.1 Brake disassembly (fig. 4).......................................................................... 14
11.2.2 Brake assembly and adjusting (figures 4 and 5) ........................................ 15
11.3 BEARINGS ................................................................................................... 15
11.4 GENERAL INSTRUCTIONS ......................................................................... 15
11.5 CHECK UP ................................................................................................... 15
11.6 REPAIR......................................................................................................... 15
11.7 TEST............................................................................................................. 15
12 PUTTING OUT OF OPERATION – DISPOSAL................................................................15
13 RELATED DOCUMENTATION........................................................................................16
14 FINAL REQUIREMENTS OF THE PRODUCER TO THE CUSTOMER............................16

3
1 DEFINITION
! HAZARD Hazard: it adverts to an imminent hazardous situation, which will inflict
death or serious injury, if the operation personnel do not avoid it.
! WARNING Warning: it adverts to a possible hazardous situation, which could
inflict death or serious injury, if the operation personnel do not avoid it.
! NOTICE Notice: it adverts to a possible hazardous situation, which could inflict
any minor or slight injury, if the operation personnel do not avoid it. The
notice can warn against hazardous practices as well.
Load capacity (Q): is the maximum permitted weight (working load limit) of a load, the
jack can be loaded by when handling it on conditions specified in this Operation Manual.
2 DEVICE PURPOSE
2.1 Rack jack type 15-00 with a load capacity of 2.5 t and 5 t, type 15-01 with a load
capacity of 10 t in the container design - CON, wall container - CON-W in any
combination of designs (-RK, -RKP) and in the design for environments with a risk of
explosion -NEXP (hereinafter referred to as the product, or NEXP = structurally identical
product, differing in the surface protection of selected parts, the material of the marking
label and documentation) is destined entirely for anchorage to structures for the purpose
of manual raising and lowering of movable parts of structures (e.g. covers or container
roofs, waste gates of water basins, screens of sewage disposal plant etc.). The weight
of a movable part of a structure when handling does not have to exceed specified
permitted load capacity of the jack.
2.2 The jack by its design meets requirements provided by Directive 2006/42/EC of the
European Parliament and of the Council as amended by the Czech technical regulation
– ministerial order No. 176/2008 of the Collection of Laws as amended as well as
requirements of the ČSN EN ISO 12100 and ČSN EN 1494+A1 harmonized technical
standards.
2.3 The product has been designed in compliance with the requirements stipulated by
Directive 2014/34/EU of the European Parliament and of the Council, as amended by
the Czech technical regulation – Government Directive No. 116/2016 Coll., as amended.
The product has been designed as IM2ExhIMb equipment pursuant to EN ISO
80079-36:2016 and EN ISO 80079-37:2016. It complies with the conditions stipulated
for use in mining environments classed as “hazardous atmospheric conditions 2”
pursuant to ČSN EN 1127-2.
2.4 The product has been designed in compliance with the requirements stipulated by
Directive 2014/34/EU of the European Parliament and of the Council, as amended by
the Czech technical regulation – Government Directive No. 116/2016 Coll., as amended.
The product has been designed as II2GExhIICT6Gb, II2DExhIIICT85°CDb
equipment pursuant to EN ISO 80079-36:2016 and EN ISO 80079-37:2016. It complies
with the conditions stipulated for use in environments classed as „zone 1 and zone 21“,
“zone 2 and zone 22“ pursuant to ČSN EN 1127-1.
Note: Articles 2.3 and 2.4 apply to NEXP product design.

4
3 SECURITY PRINCIPLES
3.1 SECURITY PRINCIPLES OVERVIEW
A hazard exists when handling movable parts of structures especially in the event that
the jack is not use in the right way or is badly maintained. Whereas as a result an
accident or severe injury could happen, it is necessary to observe the special security
measures when handling, assembling, maintaining and checking the jack.
! VAROVÁNÍ
ALWAYS ensure the raised part of the structure against drop (e.g. by brace rod), if
you intend to work under it.
NEVER jack up persons.
NEVER burden the jack more than is the load capacity indicated on the jack.
ALWAYS warn persons in surroundings before starting work.
ALWAYS read the operation manual and security instructions.
Bear in mind that the oper
ation staff is responsible for faultless technique of raising.
Hence verify all national directives, regulations and standards whether they contain
other information on safety work with your jack.
3.2. SECURITY PRINCIPLES
! WARNING
3.2.1 Prior to use
ALWAYS ensure the jack would be operated by physically fit, qualified and
instructed persons older than 18 years, familiarized with the operation
manual and trained in security of work and mode of operation.
ALWAYS check up the jack every day before starting work according to Section 8.2.
(1) „Daily inspection“.
NEVER use the defective or outworn jack.
NEVER use the jack without visible load capacity marking on the jack.
NEVER use the jack marked with the label „OUT OF OPERATION“.
ALWAYS consult the producer or his authorized representative any application of the
jack in nonstandard or extreme environment.
ALWAYS check that the product is grounded through the ground terminal when
working in an explosive atmosphere
ALWAYS wipe off any dust before handling the product in an explosive atmosphere
3.2.2 When in use
ALWAYS make sure the jack is properly mounted in equipment construction.
ALWAYS pay increased attention, if the jack is drawn up to maximum position.
ALWAYS work with the jack only with manpower.
ALWAYS we recommend with respect to actuating forces the jack operation is
ensured by two persons when handling parts of structures the weight of
which approximate to safe working load of the hoister.

5
NEVER use the separate jack (not mounted in the structure for which it is destined)
to handling free loads
NEVER allow the lifted part of the structure would give rise to impacts or vibrations.
NEVER leave the loaded jack without supervision or other securing of a raised part
of the structure.
3.2.3 Risk analysis
The possible risks analysis in light of design, operation and environment of the jack
appointment is presented in freestanding document „Risk analysis“. It is possible to
require the document in service centers.
3.2.4 Maintenance
ALWAYS make possible to competent persons to carry out the regular inspection of
the jack.
ALWAYS ensure slipping parts (except the brake) are sufficiently greased.
At maintenance only such interventions can be done that will be in accordance with
producer’s requirements stated in the chapter 11 and 14 of this OM.
IT IS NOT PERMITTED to carry out repairs and maintenance in other manner than
specified by the producer. It concerns namely the forbiddance of using of unoriginal
spare parts or carrying out changes on the product without the approval of the producer.
4 PACKING, STORAGE AND HANDLING
4.1 PACKING
4.1.1 Jacks are supplied in assembled state in bulk 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) Quality and Completeness Certificates and Guarantee Certificate.
c1) Guarantee period is stated in the Guarantee Certificate.
c2) The guarantee does not apply to defects caused by infringement of the
instructions stated in the Operation Manual and defects arisen by improper
using and unskilled action.
c3) The guarantee does not apply as well to changes on the product or using
of unoriginal spare parts without the approval of the producer.
c4) Reclaiming of product defects is carried out according to applicable
provisions of commercial code eventually as amended.
d) List of service centers.
4.2 STORAGE
Store jacks in dry and clean stores void of chemical impacts and noxious fumes.
(1) Wipe away all dust, water and impurities from the jack.
(2) Grease the rack of the jack.
(3) Put the jack in a dry place.
(4) In next using follow instructions in the article 8.1.4 „Jack occasionally used“.
4.3 HANDLING
During transportation and handling, observe technical regulations and standards in force
for work with heavy loads.

6
5 MAIN SPECIFICATIONS
Specifications
Type-design Load capacity
(t)
Lift
(mm)
Actua-
ting
force
on
crank
(
N)
Range of
opera-
ting
tempera-
ture
Weight
rack
L = 660
(kg)
Weight
rack
L = 970
(kg)
Weight
rack
L = 1200
(kg)
15-00-CON-W 2,5 345 - 850
380
-20
0
C
to
+50
0
C
12,8 15,2 17,0
15
-
00
-
CON
11,4
13,8
15,6
15-00-CON-W 5 360 – 850
550 22,1 25,6 28,5
15
-
00
-
CON
19,0
22,5
25,4
15
-
0
1
-
CON
-
W
10 345 – 825 540
35
40
45
15-01-CON 33 38 43
Dimensions
Type-design Load
capacity
A B C E d L
15-00-CON-W 2,5 320 80 250 180 13 660,
970, 1200
15
-
00
-
CON
-
-
150
-
15-00-CON-W 5 350 80 300 190 13 660,
970, 1200
15
-
00
-
CON
-
-
160
-
15
-
0
1
-
CON
-
W
10
490
80
300
22
5
13
660,
970, 1200
15-01-CON - - 195 -
Fig.1 Product design – CON-W

7
Fig.2 Product design – CON
5.1 MECHANICAL CLASSIFICATION
Safety and working life of the jack is guaranteed providing that it works in accordance
with specified classification.
The jack is designed for class 1Bm according to the FEM 9.511 regulation – see table
5.1. (it corresponds to mechanism classification M3 according to the ISO 4301/1).
Average daily operating time is specified in the load diagram.
Tab. 5.1 MECHANICAL CLASSIFICATION
Load diagram
(load distribution) Definition Load coefficient Average daily
operating time
(h)
1
(light)
Jacks usually being subject to
the low load and only in
special cases to the
maximum load.
k ≤0,50 1 - 2
2
(mean)
Jacks usually being subject to
the low load, but quite often
to the maximum load.
0,50 < k ≤0,63 0,5 - 1
3
(heavy)
Jacks usually being subject to
the mean load, but frequently
to the maximum load.
0,63 < k ≤0,80 0,25 – 0,5
4
(very heavy)
Jacks usually being subject to
the maximum load or load
approximating to the
maximum.
0,80 < k ≤1,00 0,12 – 0,25

8
Load diagram Load diagram Load diagram Load diagram
1 2 3 4
Percentage of operating time
5.2. MATERIAL AND FINISH
5.2.1 All parts of the jack are manufactured from steel and cast iron.
5.2.2. Materials inclinable to creation of an incendiary spark in terms of the annex
No. 2 article 1.3.1 to the ministerial order No. 116/2016 of the Coll. of Laws and
the ČSN EN 1127-2 article 6.4.4 ČSN EN 1127-1 article 6.4.4 and EN ISO 80079-
36 article 6.4.2.1 harmonized technical standards are not used.
5.2.3. Materials with dangerous effects of static electricity within the meaning of the ČSN
EN 1127-2 article 6.4.7, ČSN EN 1127-1 article 6.4.7, EN ISO 80079-36 article
6.7 and ČSN ČSN CLC/TR 60079-32-1 are not used in the chain block.
5.2.4 The jack does not exceed the noise values specified in the Annex No.1 article
1.7.4.2 letter u of the ministerial order No. 176/2008 of the Collection of Law (EP
and RE directive No. 2006/42/EC).
Note: Articles 5.2.2 and 5.2.3 3 apply to NEXP product design.
5.3 DATA ON THE PRODUCT
Each product is equipped with the label with specified data as follows:
Standard finish:
NEXP produc
t de
sign
:
Mark of the producer
Mark of the producer
Address of the producer
Address of the producer
Product type
Product type
Load capacity
Load capacity
Serial number
Serial number
Production year
Production year
CE marking
CE marking
Protection type symbol (IM2ExhIMb for group I, II2GExhIICT6Gb
and
II2
D
Ex
h
I
II
C
T
85
°C
D
b
for group II)

9
6 JACK INSTALLATION
! WARNING
ALWAYS before installation check up thoroughly whether the jack is not damaged.
NEWER the weight of the jacked up structure or resulting pushing (pulling) force on
the rack bar have to exceed the safe working load of the jack.
The NEXP product must be installed in such a way as to prevent creeping charges.
Charging mechanisms stronger than manual friction must be avoided at the installation site .
A NEXP product when used in a mine or other environment where the product could
collide with falling, flying… objects (rock, stones…) must be protected to minimize the
likelihood of a collision (sufficiently dimensioned cover, …).
6.1 ANCHORAGE TO A STRUCTURE
6.1.1 Product design – CON-W:
Two grips on the coating with holes for screws M12 (2,5t load capacity) or M16
(5t ,10t load capacity) and holes at the ridge bar ends with ∅25 mm (2,5t load
capacity) or ∅30 mm (5t,10t load capacity) serve for mounting to a structure.
6.1.2 Product design – CON:
The manufacturer of the equipment, in which the jack will be used, specifies the
assembly method for the structure. The jack anchorage to the equipment as a
rule represents an intervention to the jack design (e.g. welding very grip,
mounting of other parts on the jack).
! NOTICE
Any guarantee does not apply to the jack modified according to Article 6.1.2,
unless the modification type is negotiated and approved by the manufacturer.
ALWAYS we recommend consulting a technical department of the jack manufacturer
the type of intended modification.
6.1.3 Installation of jack with respect to rack load.
When installing the – CON and – CON-W rack jacks it is essential to assure that
the load on the jack is in the right direction. The pressure (tension) load on the
rack must always act in the direction from the handle hub to the catches (see
diagram), and never the other way round.
Q
T
– tensile load
Q
D
– pressure load

10
6.1.4 Documentation:
Method of the container jack anchorage and eventual jack modifications are
necessary to be documented by drawing documentation and stress analysis.
The equipment manufacturer has to elaborate the operation manual to the
equipment, in which the jack is used.
! WARNING
The jack anchorage to a structure must be solved so that the ridge bar is not
stressed by bend. Loading only by simple pulling or pushing forces is permitted.
Maximum force on the jack must not exceed maximum load capacity of the jack.
6.2 TEST PRIOR TO USE
! NOTICE
(1) At first go over again the previous Articles of this Operation Manual and make sure
that all steps were well done and all parts are safely mounted.
(2) Inspect visually the jack and anchoring in the structure whether they are without any
defect.
(3) Test the function of the jack by crank motion.
(4) Jack up and consequently lower the movable part of the structure. At the same time
verify whether the jack holds the load without slipping when lowering and stopping.
7 OPERATION AND MAINTENANCE
7.1 JACK APPLICATION
7.1.1 The jack is a single purpose device destined entirely for anchorage to structures
with the purpose of manual jacking up and lowering of movable parts of structures.
It can be used not only in current environment, but also in environments with
explosion risk in the event that there is the symbol of the protection type marked
on the label – see articles 2.3, 2.4 and 5.3 of this OM.
7.1.2 The jack is operated by a crank. Jacking up and lowering of a structure can be
interrupted in any lift height. A lowering brake and pawls system with forced mesh
in the crank ensure position stability.
7.1.3 By reason that the work with heavy loads can constitute unexpected hazard it is
necessary to follow all „Security principles“ according to Chapter 3 of this OM.
7.2 SAFETY WORK ENVIRONMENT
! WARNING
(1) The operating personnel must be demonstrably acquainted with this Operation
Manual; they must adhere to valid security and hygienic regulations and must be
qualified for operation of this equipment.
(2) When working with the jack the operation staff must be equipped with gloves and
appropriate footwear.
(3) When operating by more persons always one worker must be determined who is
trained in safety at work and is responsible for jack handling.
(4) Before starting the work, the operation staff must check up whether all work area is
safety and whether there is a possibility of eventual escape from the environment of
jeopardy.
(5) With a product load capacity of 2,5t and 5t, the cover with the product casing is not
sufficiently dimensioned in terms of "breakthrough", therefore any cover that could
cause a collision with gears must be repaired or replaced. If the product collides with
a falling, flying (object (rock slide…) that could sufficiently damage the covers, work
must be stopped immediately and the product inspected.

11
8 JACK CHECK
8.1 INSPECTION
8.1.1 Inspections types
(1) Introductory inspection: it precedes first use. The responsible competent person
must check up all new or repaired jacks to ensure the qualified fulfilment of
requirements of this OM.
(2) The jack inspections carried out regularly are generally divided to two groups
according to inspections intervals. Intervals depend on the state of critical parts of
the jack and rate of wear, damage or malfunction. Two main groups are here
marked as daily and regular ones. The appropriate intervals are defined as follows:
(a) Daily inspection: visual inspection carried out by the operation staff determined by
the user that is made at the beginning of each use.
(b) Regular inspection: visual inspection carried out by the competent person
determined by the user.
Current operation – once a year,
1) Heavy operation – every six month,
2) Special or occasional operation – according to recommendations of the competent
person at first use and according to the order of qualified employees (maintenance
workers).
8.1.2 Daily inspection
Check up at parts recommended in Section 8.2(1) „Daily inspection“, whether the jacks
are not damaged nor have no defect. Carry out 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 the detailed inspection is
necessary.
8.1.3 Regular inspection
Carry out overall inspections of the jack in the form of recommended regular
inspections. The recommended regular inspection stated in Section 8.2(2) must be
performed under the supervision of competent persons who will determine, whether the
jack is necessary to be taken to parts. These inspections comprise also requirements of
the daily inspection.
8.1.4 Jack occasionally used
(1) Submit the jack not being in operation for a period of one month or longer but less
than a year to inspection complying with requirements in Section 8.1.2 before follow-
up putting it into operation.
(2) Submit he jack not being in operation for a period of one year to inspection
complying with requirements in Section 8.1.3 before follow-up putting it into
operation.
8.1.5 Report on inspection
Keep the record of performed tests, repairs, inspections and maintenances of jacks
every time. Carry out dating reports on inspections in intervals specified in Section 8.1.1
(2) (b) and keep them in the place specified by the user.
The person responsible for safety and determined by the user must be advised of
defects detected by the inspection or recorded during the operation.

12
8.2 INSPECTION PROCEDURE
(1) Daily inspection (carried out by operating staff or competent person)
Part Inspection method
Limi
t / criterion for
putting-out of
o
peration
Remedy
1. Jack function Visually,
aurally
The jack goes
hardly, stammers,
emits noise etc.
To clean up and
grease the jack. If
the defect will not
be removed, get the
jack repaired.
2. Pawls function Visual inspection
when jacking up
Pawls do not snap
behind dents of the
ratchet.
To clean up,
grease, eventually
change the spring.
3. Fixative parts Visual inspection of
all screws, nuts,
rivets etc.
Faulty or missing
parts;
Released parts
Replace by new
ones;
To retighten
released parts
(2) Regular inspection (carried out by competent person)
Part
Inspection
method
Limit / criterion for
putting-out of
operation
Remedy
1. Fixative parts Visual inspection
of all screws, nuts,
rivets etc.
Faulty or missing
parts;
Released parts
Replace by new
ones;
To retighten
released parts
2. All parts Visual inspection Outworn or
damaged parts;
Fouled and
ungreased parts
Replace by new
ones;
To take to parts,
clean up, grease
and again assemble
3. Label – marking of
load capacity on the
jack
Visual inspection Load capacity is not
readable
To repair or replace
by new one
4. Brake Jack up and lower
the part of the
equipment
When interrupting
jacking up the brake
must hold firmly the
load in each
position during
raising and lowering
If it will not be so,
ask for repair and
adjusting of the
brake

13
9 TROUBLE-SHOOTING
Situation Cause of trouble Remedy
1. Jack does not hold firmly
the load.
Brake slipping. Brake adjusting or repair
according to Chapter
„Maintenance“.
2. Jack jacks up heavily or
does not raise the load.
(1) Jack is overloaded.
(2) Damaged geared
transmission.
(1) Remove the cause-
sticking, seizing of
equipment mechanism
(2) Repair of the jack
3. Jack emits the special
noise.
Insufficiently greased
geared transmission.
Carry out the lubrication of
the geared transmissions
by grease.
4. Characteristic sound is
not heard when snapping
the pawls to dents of
ratchet.
Malfunction of pawls.
Rust, impurities, broken
spring.
Clean up, replace the
spring.
10 GREASING
10.1 GENERAL
Before application of the grease remove old grease, clean up components with grease
solvent and apply new grease. Use grease specified by the producer.
Lifters of load capacity 2,5, 5 a 10t are equipped with a lubrication plug on the cover of
the gear transfer. We recommend regular lubrication of the gear mechanism at least
once every 6 months.
Use grease: Universal lithium plastic lubricant, water resistant, usable in a minimum
range of working temperatures from -20°C to +50°C. For example A2, LV2EP.
! WARNING
All lubricants (grease, oil) used in the NEXP version must have an ignition temperature
higher than 135°C. E.g. LV2EP, ….
10.2 JACK MECHANISM
Lubricate products with a load capacity of 2,5t, 5t and 10t with a lubrication press via a
lubrication plug on the cover.
Grease all slipping or moveable surfaces on the crank of the jack.
! NOTICE
Imperfect maintenance and insufficient greasing can cause serious accidents.
ALWAYS grease it more often in corrosive environment (salt water, oceanic climate,
acids etc.) than in ordinary circumstances.

14
11 MAINTENANCE
11.1 SECURITY PRINCIPLES
! WARNING
Only qualified persons (service organizations), trained in safety and maintenance
of the jacks, can carry out maintenance and professional inspections.
ALWAYS use entirely components supplied by the producer.
It is not permitted to carry out repairs and maintenance in other way than
specified by the producer. It means namely the forbiddance of using
unoriginal spare parts or carrying out changes on the product without an
approval of the producer.
ALWAYS test jack function after carrying out the maintenance.
ALWAYS mark disabled or repaired jack with appropriate inscription (i.e. „OUT OF
OPERATION“).
NEVER carry out maintenance if there is a load on the jack.
NEVER work with the jack that is under repair!
ALWAYS when repairing the paint, it is necessary to observe the total thickness of the
paint layer maximum 0,2 mm (original + new paint, or after cleaning the
surface new paint, applies to NEXP product design).
11.2 REPLACEMENT OF BRAKE INSERTS AND BRAKE ADJUSTING
11.2.1 Brake disassembly (fig. 4)
Demount the crank from the jack. Unbolt safety screws (6) and consequently the nut (5).
Take out the spring (4) and crank arm (7). Take out from the hub (1) the ratchet (3) with
brake insert (2A), take off the brake insert (2B), and replace both brake inserts (2A)
(2B).
Fig. 4 Fig. 5
7
6
5
4
2A
3
2B
1
4 to 6 m m

15
11.2.2 Brake assembly and adjusting (figures 4 and 5)
Proceed in the opposite way when assembling. Slip over the hub (1) the friction insert
(2B); ratchet (3) and second friction insert (2A). Set it in the crank arm (7), slide on the
spring (4) and screw on the nut (5). Tighten the nut so that the clearance in the dent is
from 4 to 6 mm (see fig. 5) and screw down the screws (6).
11.3 BEARINGS
Cast iron plain bearings are used in the product. The theoretical service life of bearings
is several times higher than the theoretical service life of the product. Therefore, they do
not need any special maintenance except for cleaning and lubrication during the regular
inspection interval, see 8.1. In the event that the bearing is damaged during
disassembly, assembly or due to dirt (sand, rock, dust ...) entering the working space of
the bearing, the bearing must be replaced immediately.
11.4 GENERAL INSTRUCTIONS
Following instructions give general important information on disassembly, check up,
repair and assembly. If the jack was dismounted from any reason act upon the
instructions as follows.
1. Perform maintenance in clean environment.
2. NEVER disassemble the jack more than it is necessary to carrying out the needful
repair.
3. NEVER use excessive power when dismantling parts.
4. NEVER use heat (fire) as the mean when dismantling parts, if the parts are destined
for next use.
5. Keep the workplace clean and without foreign materials that could get into bearings
and other movable parts.
6. If you squeeze the part in vice, use always the appropriate pads for protection of
parts surfaces.
11.5 CHECK UP
Check up, whether all disassembled parts are suitable for next use.
1. Check up, whether no parts are worn out and have no chutes or fissures.
2. Check up, whether threaded parts have no damaged thread.
11.6 REPAIR
Outworn or damaged parts must be replaced.
Remove little burrs and scratches or other minor surface defects and flatten out with fine
grinder or abrasive cloth.
11.7 TEST
The load test must be performed at all repaired jacks by qualified person with the load
exceeding the load capacity by 10% for verification of function and brake of the jack.
12 PUTTING OUT OF OPERATION – DISPOSAL
The jack do not contain any noxious agents, its parts are from steel and cast iron. Hand
over the jack after putting it out of operation to the firm dealing with disposal of waste
metal.

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13 RELATED DOCUMENTATION
EC declaration of conformity
The Operation Manual was elaborated in accordance with following technical regulations,
technical standards and national regulations:
•Ministerial order No.176/2008 of the Collection of Law as amended (EP and Council
directive 2006/42/EC)
•Ministerial order No.116/2016 of the Collection of Law as amended (EP and Council
directive 2014/34/EU )
•ČSN EN ISO 12100
•ČSN EN 1494+A1
•ČSN EN 1127 - 2
•ČSN EN 1127 - 1
•ČSN EN ISO 80079-36
•ČSN EN ISO 80079-37
•Regulation of CBM (Czech Bureau of Mine) No.22/89 of the Collection of Law
•ČSN CLC/TR 60079-32-1 .
14 FINAL REQUIREMENTS OF THE PRODUCER TO THE
CUSTOMER
Any changes of the product, eventually usage of unoriginal spare parts can be
realized only based on the approval of the producer.
When not observing this condition the producer does not guarantee safety of his
product. In this case, any producer’s guarantees do not apply to the product.