Groz JACK/BT/2W User manual

1
INSTRUCTION MANUAL
S2361, REV D
Hydraulic
Bottle Jack
New Improved
Welded Construction
with leakage points
reduced by 60% Viz.
Conventional Jacks.
In- built load limiting
device ensures safety
of the user.
Advance base plate
design: Forged steel
base plate provides
more stability even
under high load as
compared to cast
iron base plate jacks
available in the
market
Machined and
polished ram with
die cut threads that
reduce wear and tear
Powder coated 2
piece lifting lever rod
with pressed ends for
convenient opening
& closing of pressure
release valve
Longer life due to
internally machined
oil passages, smooth
bearing surfaces and
close tolerances.
Knurled heat treated
saddle head with
non-slip surface for
stronger grip
100% factory tested
50% safety overload
factor
Ideal for use
on heavy duty
trucks, agriculture,
construction, mining,
automotive, and
marine applications
where lifting,
pushing, spreading,
bending, pressing,
or straightening is
required.
Knurled saddle head
for non – slip grip
Machined and
polished ram
Leak proof
welded
construction
Pump
socket
Leak Proof welded
construction
Pressure
release valve
Convenient carrying
handle
Compact 2 pc
lifting lever rod
Base Plate
Load limiting
device
ORDERING INFORMATION
CAT NR. CAPACITY MIN. HEIGHT (A) LIFT HEIGHT (B) ADJUSTABLE HEIGHT (C) MAX. HEIGHT (D)
JACK/BT/2W 2 ton (1815 kg) 178mm (7") 112mm (4-13/32") 48mm (1-57/64") 338mm (13-11/32")
JACK/BT/4W 4 ton (3629 kg) 190mm (7-7/16") 118mm (4-11/16") 60mm (2-5/16") 368mm (14-13/16")
JACK/BT/6W 6 ton (3629 kg) 207mm (8-5/32") 125mm (4-59/64") 70mm (2-49/64") 402mm (15-53/64")
JACK/BT/12W 12 ton (10866 kg) 230mm (9-1/16") 155mm (6-1/16") 80mm (3-3/16") 465mm (18-5/16")
JACK/BT/15W 15 ton (13608 kg) 230mm (9-1/16") 155mm (6-1/16") 80mm (3-3/16") 465mm (18-5/16")
JACK/BT/20W 20 ton (18144 kg) 240mm (9-7/16") 150mm (5-15/16") 60mm (2-7/16") 450mm (17-11/16")
JACK/BT/32W 32 ton (29030 kg) 260mm (10-5/16") 160mm (6-5/16") — 420mm (16-9/16")
JACK/BT/50W 50 ton (45359 kg) 280mm (11") 170mm (6-11/16") — 450mm (17-11/16")
4 Ton 12 Ton 15 Ton 20 Ton 32 Ton 50 Ton

2
BEFORE USE
(Refer exploded view on page 4 & 5)
Rotate the saddle anti-clock wise to thread
up the screw extension.
i. Rotate the saddle anti-clock wise to
thread up the screw extension.
ii. Rotate the saddle clockwise to thread
down the screw extension
5. Replace worn or damaged
parts and assemblies with
GROZ authorized replacement
parts only.
** Screw extension available only in 2Ton, 4Ton, 12Ton,
15Ton & 20Ton Models
OPERATION
(A) Raising the Ram
1. Assemble the lifting lever rod. (See Fig. 1)
2. Park the vehicle with emergency brake on to
prevent unwanted vehicle movement.
3. “CLOSE” the pressure release valve by
turning it clockwise with the help of the
pressed end of the lifting lever rod, until firm
resistance is felt . (See Fig. 2 & 3)
4. Verify lift point as mentioned by the vehicle
manufacturer, center the jack saddle under
the lift point.
5. If the clearance height of the vehicle is
much more than the jack height, rotate the
saddle anti-clockwise to thread up the screw
extension to an appropriate height (See Fig.
4)
6. Insert the lifting lever rod into the pump
socket, then pump in order to raise saddle to
contact lift point. To lift, continue pumping
until load reaches desired height.
7. Immediately secure lifted load with
appropriately rated jack stands
WARNING
• This is a lifting device only!
• Immediately after lifting, support the load
with a pair of appropriately rated jack stands
• Lift only on areas of the vehicle as specified
by the vehicle manufacturer
• Do not exceed rated capacity
• Use only on hard, level surface
• Never work on, under or around a load
supported only by bottle jack
• Do not use adapters or accessories that are
not provided in the pack
• No alterations should be made to this
product
• Failure to follow these warnings may result in
personal injury and/or property damage
• If lifting lever rod is worn, operates
abnormally, or does not positively engage
the pressure release valve, STOP, discontinue
use of the jack until a factory replacement
lifting lever rod can be acquired
Fig. 2
UP
DOWN
Fig. 4
1. Before using the product, read the
instruction manual completely and
familiarize yourself thoroughly with the
product and it’s components.
2. Assemble lifting lever rod together by fitting
the smaller rod into the bigger rod.
3. Use the pressed end of the
lifting lever rod to engage
and turn the pressure release
valve
a) Turn clockwise until
firm resistance is felt to
further turning. This is
the ‘CLOSED’ pressure
release valve position
used to raise the ram
plunger. (Fig 3)
b) Turn counter-clockwise,
but not more than 1 turn
from the closed position.
This is the ‘OPEN’
pressure release valve
position used to lower
the ram plunger. (Fig
3A)
4. Check that the pump
operates smoothly and
that the screw extension
will thread up/down easily
before putting into service.
(Fig 4)
Fig. 3A
Fig. 3
A
D
C
B
Fig. 1

3
(B) Lowering the Ram
1. Raise load high enough to clear the jack
stands, then carefully remove jack stands.
2. Rotate the pressure release valve counter-
clockwise to “OPEN” position, but no more
than 1 turn, with the help of the lifting lever
rod. (See Fig. 2 & 3A). If the load fails to
lower:
c. Use another jack to raise the vehicle high
enough to reinstall jack stands.
d. Remove the aected jack and then the
stands.
e. Lower the load by turning the pressure
release valve counter-clockwise, but no
more than 1 turn.
3. After removing jack from under the load,
rotate the saddle clockwise to thread down
the screw extension (See Fig. 4) to retract it
inside the ram and then push ram and Pump
socket down to reduce exposure to rust and
contamination.
WARNING
Make certain that all personnel are clear of
the load before lowering. Control the rate of
descent of the load at all times. The more you
open the pressure release valve, the faster the
load descends
MAINTENANCE
Lubrication is critical to jacks as they support
heavy loads. Any restriction due to dirt, rust,
etc., can cause either slow movement or
extremely rapid jerks, damaging the internal
components. Follow the steps below to keep
your jack well lubricated:
1. Lubricate the ram, linkages, saddle and
pump socket with light oil.
2. Visually inspect for cracked, bent, loose, or
missing parts or hydraulic oil leaks.
3. If jack is subjected to abnormal load or
shock, remove from service and have it
examined by an Authorized Repair
Service.
4. Clean all surfaces and maintain all labels and
warnings.
5. Check and maintain oil level.
Changing Oil
Do not use brake or transmission oils, or regular
motor oil as they can damage the seals. Always
purchase and use products labelled “Hydraulic
Jack Oil”
1. Turn pressure release valve counter
clockwise to allow ram to fully retract. It may
be necessary to apply force to the saddle for
lowering. (See Fig. 3A)
2. Place the jack in vertical position with saddle
at the top.
3. With jack in level position remove oil filler
plug. Oil should be even with the bottom
of the hole. If not, top up. Do not overfill.
Always fill with new, clean hydraulic jack oil.
4. Make sure there are no air bubbles in the oil.
5. Reinstall the oil filler plug.
6. Check jack operation.
Cleaning
Periodically check the pump plunger and ram
for signs of rust or corrosion. Clean as needed
and wipe with an oily cloth
Storage
When not in use, store the jack with pump
plunger and ram fully retracted

4
PART LIST (2 TON)
REF. NO. DESCRIPTION QTY.
1Round wire snap ring 1
2Rectangular ring 2
3 O-Ring 1
4Ram assembly 1
5Bowl washer 1
6 O-Ring 1
7Round wire snap ring 1
8Base Welding Parts 1
9Oil Plug 1
10 Steel Ball bearing Ø6mm 1
11 Release valve assembly 1
12 Plastic Plug 1
13 Safety Valve 1
EXPLODED VIEW (2 TON)
REF. NO. DESCRIPTION QTY.
14 Spring 1
15 Spring Holder 1
16 Steel Ball bearing Ø3mm 1
17 Steel Ball bearing Ø5mm 2
18 Bowl washer 1
19 Pump Plunger Assembly 1
20 Reuseable cotter pin Ø1.2 X 18 mm 2
21 Pin 2
22 Handle socket assembly 1
23 Handle assembly 1
24 Spring 1
25 Seal Kit 1

5
PART LIST (4 TON, 12 TON & 20 TON)
REF. NO. DESCRIPTION QTY.
1Round wire snap ring 1
2Rectangular ring 2
3 O-Ring 1
4Piston rod assembly 1
5Bowl washer 1
6 O-Ring 1
7Round wire snap ring 1
8Cylinder 1
9Oil filler Plug 1
10 Steel Ball 6mm 1
11 Pressure release valve assembly 1
12 Plastic Plug 1
EXPLODED VIEW (4 TON, 12 TON & 20 TON)
REF. NO. DESCRIPTION QTY.
13 Adjusting screw assembly 1
14 Spring 1
15 Spring Holder 1
16 Steel Ball 3mm 1
17 Steel Ball 5mm 2
18 Bowl washer 1
19 Pump Plunger Assembly 1
20 Cotter pin 2
21 Pin 2
22 Pump socket assembly 1
23 Lifting lever rod assembly 1
1
7
8
9
10
11
19
18
17
20
21
22
23
15
16
14
13
12
2
2
3
4
5
6

6
PART LIST (15 TON)
REF. NO. DESCRIPTION QTY.
1Roundwire snap ring 1
2Rectangular ring 2
3 O-Ring 1
4Ram assembly 1
5Bowl washer 1
6 O-Ring 1
7Roundwire snap ring 1
8Base welding parts 1
9Oil plug 1
10 Steel ball bearing Ø6mm 1
11 Release valve assembly 1
12 plastic plug 1
EXPLODED VIEW (15 TON)
REF. NO. DESCRIPTION QTY.
13 Safety valve 1
14 Spring 1
15 Spring holder 1
16 Steel ball bearing Ø3mm 1
17 Steel ball bearing Ø5mm 2
18 Bowl washer 1
19 Pump plunger assembly 1
20 Reusable cotter pin Ø1.2X18mm 2
21 Pin 2
22 Handle socket assembly 1
23 Handle assembly 1
24 Seal kit 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17 20
24
21
22
23
18
19

7
PART LIST (32 TON & 50 TON)
REF. NO. DESCRIPTION QTY.
1Roundwire snap ring 1
2Rectangular ring 2
3 O-Ring 1
4Piston rod assembly 1
5Bowl washer 1
6 O-Ring 1
7Roundwire snap ring 1
8Cylinder 1
9Steel ball 6mm 1
10 Pressure Release valve assembly 1
11 Plastic plug 1
EXPLODED VIEW (32 TON & 50 TON)
REF. NO. DESCRIPTION QTY.
12 Adjusting screw assembly 1
13 Spring 1
14 Spring holder 1
15 Steel ball 3mm 1
16 Bowl washer 1
17 Pump plunger assembly 1
18 Oil filler plug 1
19 Cotter pin 3
20 Pin 2
21 Pump socket assembly 1
22 Lifting lever rod assembly 1
1
2
2
3
4
7
8
9
10
11
12
13
14
15
16
18
19
20
21
22
5
6

8
REPAIR AND SPARE PARTS PROGRAMME
Refer Exploded View
Repair Kit Consist of
For 2, 4, 12, 20 Ton:
Seal Kit:
S. NO. DESCRIPTION PART LIST REF. N0. QTY.
a. Roundwire Snap Ring 1 1
b. Rectangular Ring 2 2
c. O- Ring 3 1
d. Bowl Washer 5 1
e. O- Ring 6 1
Oil Filler Kit:
a. Oil Filler Plug 9 1
b. Steel Ball 6 mm 10 1
For 32, 50 Ton:
Seal Kit:
S. NO. DESCRIPTION PART LIST REF. N0. QTY.
a. Roundwire Snap Ring 1 1
b. Rectangular Ring 2 2
c. O- Ring 3 1
d. Bowl Washer 5 1
e. O- Ring 6 1
Oil Filler Kit:
a. Oil Filler Plug 18 1
b. Steel Ball 6 mm 9 1
REPLACEMENT OF SEAL KIT (COMMON FOR ALL)
1. Remove the Roundwire snap
ring (1) from the top using
a scriber.
2. Use the pump socket
assembly to lift the piston
rod assembly.
3. Pull out the piston rod
assembly completely from
the cylinder by hand.
4. Drain out the hydraulic jack
oil from cylinder.
5. Open the pressure release
valve assembly (11) to
remove the Steel Ball (10
in 2, 4, 12, 20 Ton and 9 in
32, 50 Ton) and drain out
residual hydraulic jack oil.
6. Remove the rectangular ring
(2), O-Ring (3) from the top
of the piston rod assembly
by hand.
7. Use a scriber to remove the
bowl washer (5) and O-Ring
(6) from the bottom of
piston rod assembly.
8. Replace the old parts with new parts
(roundwire snap ring, rectangular ring,
O-Ring, bowl washer & O-Ring) from the
repair kit in the following manner:
• Bowl Washer and
O-Ring assembly to be
attached to the bottom.
• Rectangular Ring (Flat),
O-Ring and Rectangular
Ring (Taper) in bottom
up order from the top.
9. Reinsert the steel ball and
slightly tighten the pressure
release valve assembly.
10. Refill the cylinder with clean
and fresh hydraulic jack oil.
11. Push the piston rod
assembly completely into
the cylinder. A scriber can
be used to set the rings in
the cylinder.
12. Completely tighten the
pressure release valve
assembly.
CAUTION
• Make sure not to lose/
misplace the Steel Ball while
draining hydraulic jack oil
out of pressure release valve
assembly.
Steel Ball

99
PROBLEM CAUSE SOLUTION
Jack will not lift load Pressure release valve not tightly closed Ensure pressure release valve is tightly closed
Overload condition Remove overload condition
Jack will lift, but not maintain
pressure Pressure release valve not tightly closed Ensure pressure release valve is tightly closed
Overload condition Remove overload condition
Hydraulic unit malfunction Contact Authorized Service Station
Jack will not lower after unloading Reservoir overfilled Ensure load is removed, then drain fluid to proper
level
Poor lift performance Fluid level low Ensure proper fluid level
Jack will not lift to full extension Fluid level low Ensure proper fluid level
TROUBLE SHOOTING
DISPOSAL
The components or the used products must be given to companies that specialize in the disposal and
recycling of industrial waste.

10

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Groz Engineering Tools (P) Ltd.
Groz Net Industries
Village Kherki Daula, National Highway-8,
Gurugram-122001, Haryana, INDIA
Tel [phone]
Fax [phone]
E-Mail [e-mail]
Url www.groz-tools.com
The GROZ name, GROZ logo and the mark are
trademarks of GROZ Engineering Tools (P) Ltd., India
GROZ WARRANTY POLICY
Groz makes all eorts to ensure that its products meet the highest standards of quality and durability and warrants to the original purchaser its
range of products for a period of 12 months from Groz Invoice date, against defects in materials and workmanship. If the Groz product is part of a
set, only the portion that is defective is subject to this warranty.
This warranty does not apply to damage due directly or indirectly, to misuse, abuse, wear and tear, negligence or accident, repairs or alterations
outside Groz plants, or to lack of maintenance. Groz shall in no event be liable for death, injuries to persons or property or for incidental, contingent,
special or consequential damages arising from the use of its products. It is upto the user to determine suitability and safety of the product for their
intended use, and the user assumes all risks and liability herewith.
In no event, shall Groz’s liability exceed the invoiced cost of the product In case of identification of defect covered under this warranty, the same
must be notified in writing to Groz /Groz designated authorized service location. Proof of purchase date must accompany the complaint. Groz
reserves the right to call back the faulty unit, all charges including transportation prepaid. On verification of the defect, the unit will be repaired or
replaced with a new or reconditioned product or part of equal utility or a full refund given at Groz’s discretion. The repaired /replaced units will be
returned to the user freight prepaid, using most economical freight carrier. However if determined that the defect resulted from causes not within
the scope of the warranty, then the cost of returning the product would be to buyer’s account.