Durapac DRJ-10 User manual

ABSOLUTE EQUIPMENT PTY LTD –2/186 Granite Street, GEEBUNG QLD 4034 –Australia
[e-mail] –Phone: [phone] –Fax: [phone]
Instruction Manual
Hydraulic Rail Jack
Model –DRJ-10

Instruction Manual
DRJ-10 Rail Jack - V1.2 www.durapac.com Page 2 of 10
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 Rail Jacks are engineered to meet Industrial Standards for Performance and
Safety. The DRJ-10 rail jack is ideally suited to aligning, gauging and lifting of rail or sleepers. Utilising
a forged aluminium upright base, this 10 ton1capacity jack has been designed to be robust, light
weight and reduce the risk of operator injury. It has a spring return mechanism that will allow a jack
with no load to be returned to the retracted position. The jack is fitted with an internal safety
pressure relief valve to protect against overloading. The bladder system inside the aluminium
protected reservoir allows the jack to be used in both the horizontal and vertical position making it
exceptionally versatile.
80cm removable extension handle
36kg maximum handle effort with extension handle
Release valve allows for controlled lowering and is recessed for protection against accidental
knocks
Internal oil reservoir bladder allows operation in horizontal or vertical position
Oil reservoir cover manufactured from aluminium (6061)
One piece of forged aluminium (7075T) base provides great support in soft ballast
Minimum base height of 50mm allows easy positioning under the base of the rail
10 ton1of lifting force
Indexed toe minimises swivel and allows for a safe, stable platform
Internal spring return allows an unloaded jack to return to the retracted position
Chrome plated steel piston rod resists corrosion and extends life
Fixed in-line padded carrying handle
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 rail 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 rail 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 rail 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.
1Nominal Jack Capacity in ton –see kN values shown in specification table (page 5) for actual capacity

Instruction Manual
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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
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

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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 Rail 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
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 block 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
Do NOT lift a load on the end of the toe. Fully engage the load with the toe and where
practical ensure that the top of the vertical face “head-toe” attachment is also
engaged with the load
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-toe attachment
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.

Instruction Manual
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4.0 Installation
4.1 Familiarise yourself with the specifications and illustrations in this owner’s manual.
Know your rail 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.
5.0 Operation
IMPORTANT: Do NOT lift a load on the end of the toe. Fully engage the load with the toe
5.1 Raising the Jack
5.1.1 Close the release valve in a clockwise direction with the jacking handle.
5.1.2 Position the jack so that the toe is under the load point.
5.1.3 Pump the jacking lever in an up and down motion.
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 in a counter clockwise direction. Control the
rate of descent by smoothly opening or closing the valve.
5.2.3 To stop the jack from lowering the load, close the release valve (clockwise).
The release valve should not be closed abruptly (except in an emergency) since
this shock loads the hydraulic system
5.2.4 After use, the jack should be stored with the load piston and pump piston
both fully retracted.
6.0 Maintenance
IMPORTANT:
Check oil level 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
Model
No.
Collapsed
Height
(mm)
Stroke
(mm)
Extended
Height
(mm)
Travel/Pump
Stroke
(mm)
Max.
Handle
Effort (kg)
Weight
without
Handle (kg)
DRJ-10 10 83.3 373 225 598 4.5 36 20.2
* Nominal Jack Capacity in ton - see kN values for actual capacity
Jack Capacity
(ton*/kN)

Instruction Manual
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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
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
WARNING: Always add oil with cylinder fully retracted or the system will contain more
oil than the reservoir can hold
6.1.1 Open release valve.
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 to a level 3 mm below the bottom of the
filler hole.
6.1.5 Bleed air from system if necessary.
6.1.6 Close the release valve.
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 6.1.3 (above).
6.2.2 Remove the saddle (#12 –Parts Breakdown).
6.2.3 Loosen but do not remove the bolt (#10) located at the top of the piston rod
(#2)
6.2.4 Use a press to prevent the cylinder extending while removing air.
DANGER: The press must be able to withstand the full ten ton force of the jack
6.2.5 Add hydraulic fluid (Step 6.1.4), if required.
6.2.6 Pump the handle until oil and air bubbles escape from the threaded area of
the bolt. Wipe and continue pumping until air is removed (air bubbles are no
longer seen).
6.2.7 Tighten the bolt (#10) and replace the saddle (#12).
6.2.8 Recheck that cylinder is fully retracted.
6.2.9 Add hydraulic fluid (Step 6.1.4), if required.
6.2.10 Close the relief valve.
6.2.11 Wipe up any spilled fluid and reinstall the oil filler plug.

Instruction Manual
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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 and the pump rods
both 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
Item Description Part No. Qty Item Description Part No. Qty
1 Body combination ZAM1817 1 13 C type ring ZAM1826 1
2 Piston rod ZAM1818 1 14 Spring assembly ZAM1827 1
3 Stop-ring ZAM1819 1 15 Toe ZAM1828 1
4 O-ring* ZAM1820 1 16 Removable handle ZAM1829 1
5 Back-up ring* ZAM1821 1 17 Pump assembly ZAM1830 1
6 O-ring* ZAM1822 1 18 Bolt ZAM1831 2
7 Back-up ring* ZAM1546 1 19 Bolt ZAM1832 1
8 Dust ring* ZAM1823 1 20 Plug ZAM1833 1
9 Washer* ZAM1803 2 21 Back-up ring* ZAM1834 2
10 Bolt* ZAM1824 2 22 O-ring* ZAM1835 2
11 Copper liner ZAM1825 1 23 Bolt ZAM1836 1
12 Load cap ZAM1117 1 24 Bolt ZAM1837 1
Repair kit ZAM1867 1

Instruction Manual
DRJ-10 Rail Jack - V1.2 www.durapac.com Page 10 of 10
Items marked with a * are contained within a standard Repair Kit.
Serial, model and part numbers need to be quoted when ordering parts.
Items marked with a * are contained within a standard Repair Kit.
Serial, model and part numbers need to be quoted when ordering parts.
8.1 Pump Assembly
Item Description Part No. Qty Item Description Part No. Qty
1 Pump housing ZAM1838 1 16 O-ring ZAM1853 1
2 Bolt ZAM1839 2 17 Release valve ZAM1854 1
3 Bolt ZAM1840 2 18 C ring ZAM1855 6
4 Reservoir ZAM1841 1 19 Plug-3 ZAM1856 1
5 Reservoir bladder ZAM1842 1 20 O-ring* ZAM1857 1
6 Filter ZAM1843 1 21 Back-up ring* ZAM1858 1
7 Check valve ZAM1844 1 22 Dust ring* ZAM1859 1
8 Safety valve ZAM1845 1 23 Pump rod ZAM1860 1
9 Bolt ZAM1846 2 24 Handle splint ZAM1861 2
10 Steel ball ZAM1847 2 25 Plug-2 ZAM1862 1
11 Outlet valve ZAM1848 1 26 Plug-1 ZAM1863 1
12 Bolt ZAM1849 1 27 Handle socket ZAM1864 1
13 Plug ZAM1850 2 28 Washer ZAM1865 1
14 Spring ZAM1851 1 29 Fixing frame ZAM1866 1
15 Bolt ZAM1852 1 30 Steel ball ZAM1273 1
Repair kit ZAM1868 1