Durapac DBJ Series User manual

ABSOLUTE EQUIPMENT PTY LTD –2/186 Granite Street, GEEBUNG QLD 4034 –Australia
[e-mail] –Phone: [phone] –Fax: [phone]
Instruction Manual
Manual Hydraulic Bottle Jacks
Model –DBJ Series

Instruction Manual
DBJ Series Bottle Jacks - V1.1 www.durapac.com Page 2 of 11
This is a safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid injury or death
1.0 Product Information
DURAPAC –Hydraulic Bottle Jacks are engineered to meet Industrial Standards for Performance and
Safety. The DBJ Series of bottle jacks are a premium range ideally suited to most industrial lifting
and pushing applications. Models from 10-20 ton feature an additional screw extension and most
can be used in both the vertical and horizontal positions. All jacks are repairable and seal kits are
available.
All jacks have been designed for ease of use and handling
Operating handle is included with all models
Carbon steel base is automatically welded to ensure increased resistance to high pressure
and provide greater durability
Chrome plated steel piston rod resists corrosion and extends life
Internal stroke limiter prevents piston rod over-extension
Special skill, knowledge and training may be required for a specific task and the product may not be
suitable for all jobs. The user must ultimately make the decision regarding suitability of the product
for any given task and assume the responsibility of safety for all in the work area. Contact a Durapac
representative if you are unsure of your bottle jack’s suitability for a particular application.
2.0 Receiving Instructions
It is recommended prior to use that an inspection be done by qualified personnel and that any
missing or damaged parts, decals, warning/safety labels or signs are replaced with Durapac
authorised replacement parts only. Any bottle jack that appears to be damaged in any way, is worn,
leaking or operates abnormally should be removed from service immediately until such time as
repairs can be made. Any bottle jack that has been or suspected to have been subject to a shock
load should be removed from service immediately until inspected by a Durapac authorised service
centre. Owners and operators of this equipment should be aware that the use and subsequent
repair of this equipment may require specialised training and knowledge.
3.0 Safety
Save these instructions. For your safety, read and understand the information contained within. The
owner and operator should have an understanding of this product and safe operating procedures
before attempting to use this product. Instructions and safety information should be conveyed in the
operator's native language before use of this product is authorised. Make certain that the operator
thoroughly understands the inherent dangers associated with the use and misuse of the product. If
any doubt exists as to the safe and proper use of this product as outlined in this factory authorised
manual, remove from service immediately.
DANGER:
To avoid personal injury keep hands and feet away from work area during operation
Do NOT handle pressurised hoses. Escaping oil under pressure can penetrate the skin

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causing serious injury. If oil is injected under the skin, see a doctor immediately
Stay clear of loads supported 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 supported mechanically
WARNING:
The system operating pressure must not exceed the pressure rating of the lowest
rated component in the system. Install pressure gauges in the system to monitor
operating pressure. It is your window to what is happening in the system
Always wear appropriate personal protective equipment (PPE) when operating
hydraulic equipment. The operator must take precaution against injury due to failure
of the tool or work piece(s)
Do NOT hold or stand directly in line with any hydraulic connections while pressurising
Do NOT attempt to disconnect hydraulic connections under pressure. Release all line
pressure before disconnecting hoses
All personnel must be clear before lowering load or depressurising the system
Do NOT attempt to lift a load weighing more than the capacity of the cylinder
IMPORTANT:
If at any stage, the safety related decals become hard to read, these must be replaced
Minimum age of the operator must be 18 years. The operator must have read and
understood all instructions, safety issues, cautions and warnings before starting to
operate the equipment. The operator is responsible for this activity towards other
persons
Do NOT lift hydraulic equipment by the hoses or couplers. Use the carrying handle or
other means of safe transport
Hydraulic equipment must only be serviced by a qualified hydraulic technician. For
repair service, contact the Durapac authorised service centre in your area. To protect
your warranty, use only high quality hydraulic oil
CAUTION:
KEEP HYDRAULIC EQUIPMENT AWAY FROM FLAMES AND HEAT. Hydraulic fluid can
ignite and burn. Excessive heat will soften packings and seals, resulting in fluid leaks.
Heat also weakens hose materials and packings. For optimum performance do not
expose equipment to temperatures of 65°C (150°F) or higher. Protect all equipment
from weld spatter
No alteration should be made to this device
3.1 Hydraulic Bottle Jacks
Do NOT exceed the rated capacity of the jack or any equipment in the system
Do NOT tamper with the adjustment of the jacks internal relief valve screw. To do so
may cause the jack to fail

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Do NOT use in an unstable or hazardous position
Always use the jack on solid and level surface that is capable of carrying the load. If
used to lift a vehicle, set the vehicle’s parking brake and chock the tyres
Keep the load stable during lifting. An unstable load may cause the jack or load to slip
Centre the load on the jack. Off centre loads can damage seals and cause hydraulic
failure
Keep non-essential personnel at a safe distance when using the jack
Do NOT carry the jack by the jacking lever
Do NOT lift people or loads with people on them
Ensure that the jack is undamaged and in good working order. Do not use the jack if it
is damaged
Do NOT use the jack for any purpose other than that for which it is intended
Keep the jack clean, particularly the head
Do NOT operate the system with bent or damaged couplers or damaged threads
Do NOT subject the jack and its components to shock loads
Use only Durapac approved accessories and components
FAILURE TO HEED THESE WARNINGS MAY RESULT IN PERSONAL INJURY AS WELL AS PROPERTY DAMAGE.
4.0 Installation
4.1 Familiarise yourself with the specifications and illustrations in this owner’s manual.
Know your bottle jack, its limitations and how it operates before attempting to use.
Refer to the specification chart below or if in doubt, contact a Durapac representative.
4.2 Check oil level in reservoir before operating the jack.
4.3 Remove air from the system –Air can accumulate in the hydraulic system during the
initial setup or after prolonged use, causing the cylinder to respond slowly or in an
unstable manner. Should removal of air from the jack be required, please follow the
steps in 6.2 –Bleeding Air from the System in the Maintenance Section.
4.4 Lubrication - Oil the pivots of the manual pump mechanism.
Model
Number
Capacity
(ton)
Stroke
(mm)
Collapsed
Height (mm)
Extended
Height (mm)
Weight
(kg)
DBJ-10 147 240 387 8.2
DBJ-10S 95 170 265 6.4
DBJ-20 152 265 417 13.3
DBJ-20S 85 187 272 10.0
DBJ-30 155 282 437 19.6
DBJ-30S 80 182 262 13.8
DBJ-50 50 155 305 460 42.3
10
20
30

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5.0 Operation
CAUTION: Always support the load by mechanical means before working on or under the load
5.1 Raising the Jack
5.1.1 Use the narrow end of the jack handle to tighten/close the release valve
(clockwise).
5.1.2 Position the jack under the load point. Do not use handle in the release
valve to move jack-damage will result.
5.1.3 Insert handle into the socket and pump the jacking lever in an up and down
motion.
10 and 20 ton models can be operated horizontally. When operated in
this position, hydraulic stroke will be reduced to approximately 2/3
Figure 1 –Horizontal Operation
5.2 Lowering the Jack
5.2.1 Check beneath the load for any obstructions and remove any mechanical
supports.
5.2.2 Slowly open the release valve (counter clockwise) with handle. Control the
rate of descent by smoothly opening or closing the valve.
Note: The release valve should not be closed abruptly (except in an
emergency) since this shock loads the hydraulic system.
5.2.3 After use, the jack should be stored with the piston fully retracted.
6.0 Maintenance
IMPORTANT:
Check oil level and lubricate regularly
Use only good quality hydraulic fluid. Do NOT use brake fluid, transmission fluid,
turbine oil, motor oil, alcohol, glycerine etc. Use of anything other than good quality
hydraulic oil will void warranty and damage the jack, hose, and application. We
recommend Durapac Hydraulic Oil or equivalent
Equipment must only be serviced by a qualified hydraulic technician. For repair service,
contact your local Durapac authorised service centre

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The greatest single cause of failure in hydraulic systems is dirt; keep the jack clean and well
lubricated to prevent foreign matter from entering the system. If the jack has been exposed
to rain, snow, sand or grit, it must be cleaned before and after each use.
Maintenance is required when wear or leakage is noticed. Periodically inspect all
components to detect any problem that may require service and maintenance.
6.1 Adding Hydraulic Fluid
6.1.1 With Jack sitting on its base, open release valve with handle (not more than
two counter-clockwise turns).
6.1.2 Press down on head to ensure piston is fully down.
6.1.3 Remove the oil filler plug.
6.1.4 Use a small funnel to fill the reservoir until oil level reaches the bottom of
filler hole.
6.1.5 Bleed air from system if necessary.
6.1.6 Close the release valve (turn clockwise).
6.1.7 Wipe up any spilled fluid and reinstall the oil filler plug.
6.2 Bleeding Air from the System
6.2.1 Repeat Steps 6.1.1 to 6.1.2 (above), if required.
6.2.2 Operate manual pump for three strokes to bleed any air from the system.
6.2.3 Recheck oil level after removing air.
6.2.4 Close the relief valve (turn clockwise).
6.3 Changing Hydraulic Fluid
For best results, change fluid once a year or every 300 hours of use
6.3.1 Repeat Steps 6.1.1 to 6.1.3 (above).
6.3.2 Pour used fluid into a sealable container.
6.3.3 Repeat Steps 6.1.4 to 6.1.7 (above).
6.3.4 Dispose of fluid in accordance with local regulations.
6.4 Lubrication
Oil the pivots of the manual pump mechanism.
6.5 Storage
6.5.1 When not in use, the jack should be stored with the piston fully retracted.
6.5.2 Wipe thoroughly clean and store in a clean, dry environment. Avoid
temperature extremes.

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7.0 Troubleshooting
Problem
Cause
Solution
Jack will not lift load
Release valve not fully closed
Close valve firmly
No oil or low oil level
Top-up to correct level
Air-locked system
Refer to 6.2 - Bleeding Air
from the System
Load is above capacity of system
Use correct equipment
Erratic Action
Air in system
Refer to 6.2 - Bleeding Air
from the System
Viscosity of oil too high
Change to lower viscosity oil
Internal leakage in cylinder
Replace worn seals
Check for excessive
contamination or wear
Cylinder sticking or binding
Check for dirt, gummy
deposits or leaks
Check for misalignment, worn
parts or defective seals
Jack will not lift smoothly
or to full height
Oil level low
Top-up to correct level
Air in system
Refer to 6.2 - Bleeding Air
from the System
Cylinder sticking or binding
Check for dirt, gummy
deposits or leaks
Check for misalignment, worn
parts or defective seals
Jack advances slowly
Pump not working correctly
Rework pump
Leaking seals
Replace seals
Jack advances but does
not hold load
Pump check valve not working
correctly
Clean/replace check valve
Cylinder seals are leaking
Replace seals
Overload valve leaking or not
adjusted correctly
Replace / adjust overload
valve
Jack leaks oil
Worn or damaged seals
Replace seals
Jack will not retract or
retracts slowly
Release valve is closed
Open release valve
Cylinder damaged internally
Send to a Durapac authorised
service centre for repair
Reservoir too full
Drain oil to correct level

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8.0 Parts Breakdown and List
8.1 Models: DBJ-10 & DBJ-10S
Item Description Qty Item Description Qty
1 Barrel 1 14 Piston rod thread 1
2 Up-stop ring 1 15 Piston rod nut 1
3 Up-tube ring 2 16 Piston rod 1
4 O-ring 1 17 Up-piston ring 1
5 Inlet bolt 2 18 Seal 1
6 Spring 2 19 C-type ring 1
7 Steel ball 5 20 Cardan joint 1
8 Release valve bolt 1 21 Joint pin - long 1
9 O-Ring 1 22 Joint pin - short 1
10 Oil cap 1 23 Pin 1
11 Filter 1 24 Spacer 1
12 Filter-spring 1 25 O-ring 1
13 PT plug 1 26 Handle bar 1

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8.2 Models: DBJ-20 & DBJ-20S
Item Description Qty Item Description Qty
1 Barrel 1 19 Joint pin 1
2 Piston rod thread 1 20 Pin 10 1
3 Piston rod nut 1 21 C-type ring 3
4 Up-stop ring 1 22 Joint piston rod 1
5 Up-tube ring 2 23 Back-up ring 1
6 O-ring 1 24 O-ring 1
7 Piston rod 1 25 U-cup 1
8 Safety valve pin 1 26 Inlet bolt 1
9 Low tube ring 1 27 Spring 2
10 Back-up ring 1 28 Release valve bolt 1
11 Seal 1 29 O-Ring 1
12 Piston ring 1 30 Outlet bolt 1
13 C-type ring 1 31 Outlet plug 1
14 Oil return-pin 1 32 PT plug 1
15 Steel ball 4 33 Filter spring 1
16 Safety valve spring 1 34 Filter 1
17 Bolt 1 35 Oil cap 1
18 Cardan joint 1 36 Handle bar 1

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8.3 Models: DBJ-30 and DBJ-30S
Item Description Qty Item Description Qty
1 Barrel 1 20 E-type ring 2
2 Saddle 1 21 Joint piston rod 1
3 Saddle ring 1 22 Back-up ring 1
4 Up-stop ring 1 23 O-ring 1
5 Up-tube ring 2 24 Inlet bolt 1
6 O-ring 1 25 Spring 2
7 Piston rod 1 26 Steel ball 1
8 Safety valve pin 1 27 Release valve bolt 1
9 Up piston ring 1 28 O-ring 1
10 Seal 1 29 Steel ball 1
11 Low piston ring 1 30 Outlet bolt 1
12 C-type ring 1 31 Steel ball space 1
13 Oil return-pin 1 32 Steel ball 1
14 Steel ball 1 33 Bolt 1
15
Safety valve spring
134 Filter-spring 1
16 Bolt 1 35 Filter 1
17 Cardan joint 1 36 Oil cap 1
18 Joint pin-long 1 37 Handle bar 1
19 Joint pin-short 1

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8.4 Model: DBJ-50
Item Description Qty Item Description Qty
1 Body combination 1 17 Omnibearing ring 1
2 Plug 1 18 C-type ring 1
3 Back-up ring 1 19 Rod 1
4 O-ring 1 20 Back-up ring 1
5 Piston seal 1 21 O-ring 1
6 Back-up ring 1 22 Fixed bolt 2
7 Seal 1 23 C-type ring 4
8 Piston seal 1 24 Bolt 1
9 C-type ring 1 25 Spring 2
10 Saddle 1 26 Steel ball 3
11 Stop-ring 1 27 Bolt 1
12 Stop-ring 1 28 O-ring 1
13 Up-lining ring 2 29 Bolt 1
14 O-ring 1 30 Ball pedestal 1
15 Rocker joint 1 31 Oil bung 1
16 Stop-ring 1 32 Rocker bar 1
Serial number and model need to be quoted when ordering parts.
Repair kits are available on request.