Jegs 81532 User manual

Installation Instructions for 81532 & 81533
Hydraulic Porta-Power Ram Jack Kit
4 & 10 Ton
IMPORTANT!
PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFETY INSTRUCTIONS AND WARNINGS.
USE THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED.
FAILURE TO DO SO MAY CAUSE DAMAGE TO PROPERTY AND/OR SERIOUS PERSONAL INJURY. PLEASE
KEEP THIS INSTRUCTION MANUAL SAFE FOR FUTURE USE.
1. SAFETY INSTRUCTIONS AND WARNINGS
1.1 The maximum ram capacity is 4 (10) ton. DO NOT exceed this rated capacity.
1.2 When extension tubes are used, the rated capacity is always reduced by 50% for each tube connected.
1.3 The maximum spreader capacity is 0.5 ton. And maximum ram toe and plunger toe capacity is 0.5 ton (4 ton jack
kit) or 0.8 ton (10 ton jack kit). DO NOT exceed these rated capacities when using these attachments.
1.4 DO NOT use this equipment as a vehicle lifting device or as a vehicle support.
1.5 Keep children and unauthorized persons away from the work area.
1.6 Remove loose clothing. Remove ties, watches, rings and other loose jewelry, and contain long hair.
1.7 Always wear ANSI approved safety goggles when operating the repair kit.
1.8 Keep proper balance and footing, do not overreach and wear nonslip footwear.
1.9 Only use this equipment on a surface that is stable, level, dry and not slippery, and capable of sustaining the load.
Keep the surface clean, tidy and free from unrelated materials and ensure that there is adequate lighting.
1.10 When using this equipment, open the breather valve (P09). Close it when not in use.
1.11 DO NOT allow the piston rod (R03) of ram to extend so far as to exceed the maximum ram stroke.
1.12 When coupler valves are disconnected, always use dust cap to keep the hydraulic system clean.
1.13 DO NOT drop any heavy objects onto the hose and DO NOT twist the hose. Always keep the hose clean to avoid
damage to the hose and couplers.
1.14 Keep the equipment away from heat or fire, as this may cause damage or weaken the seals.
1.15 DO NOT operate this equipment when you are tired or under the influence of alcohol, drugs or any intoxicating
medication.
1.16 DO NOT allow untrained persons to operate the equipment and DO NOT make any modifications to it.
1.17 DO NOT expose the equipment to rain or any other kind of bad weather.
1.18 Use a qualified person to maintain the equipment in good condition. Keep it clean for best and safest performance.
1.19 If the equipment is in need of repairing and/or there are any parts that need to be replaced, have it repaired by
authorized technicians and only use the replacement parts supplied by the manufacturer.
1.20 WARNING: The warnings, cautions and instructions discussed in this instruction manual cannot cover all possible
conditions and situations that may occur. It must be understood by the operator that common sense and caution
are factors which cannot be built into this product, but must be supplied by the operator.
2. SPECIFICATIONS
Rated capacity: 4 Ton 10 Ton
Rump output pressure: 56.5MPa 63MPa
Ram min height: 267mm 322mm
Stroke: 120mm 130mm
Oil being filled: 350g 500g
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3. OPERATING,INSTRUCTIONS
3.1 Connect the hydraulic ram, hose and pump unit together, ensure that you have securely fastened the couplers
before pumping.
Warning: Inspect before each use. Do not use if bent, broken, leaking, damaged components or any suspect parts are
noted and/or it has been subjected to a shock load
3.2 Open the breather valve (P09).
3.3 Firmly close the release valve (P15) by turning it clockwise.
3.4 Adjust the ram slowly to make the load coaxial with the ram.
NOTE: The pump can be used in any position from horizontal to vertical. Always keep the hose end of the pump
downward when it is not horizontal.
3.5 Pump the handle (P39) up and down to supply pressure.
3.6 When work is done, SLOWLY and CAREFULLY turn the release valve counterclockwise (never more than one
turn) to release the pressure until ram retracts to desired position.
3.7 Close the breather valve.
4. MAINTENANCE
4.1 When not in use, store the equipment in a dry location with the pump piston (P34) and the ram fully retracted.
4.2 Periodically check the ram and pump piston for signs of rust or corrosion. Clean exposed areas with a clean oiled
cloth.
Warning: Never use sandpaper or abrasive material on these surfaces!
4.3 A coating of light lubricating oil to pivot points, axles and hinges will help to prevent rust and assure that pump
assemblies move freely. Periodically lubricate the pivot points, axles and hinges with a light lubricating oil as
needed.
4.4 With ram fully lowered, set pump unit in its normal, level position. Remove the oil filler screw (P07) to check the
hydraulic oil level. If it is not adequate add high quality hydraulic jack oil as necessary.
Warning: DO NOT use brake fluid or any other improper fluid and avoid mixing different types of oil when adding
hydraulic oil.
4.5 To ensure best performance and longer equipment life, replace the complete hydraulic oil at least once a year. With
ram fully lowered, remove the oil filler screw (P07) and drain the oil into a suitable container. Ensure that no dirt
gets into the system. Set the pump in its normal level position, fill with approved hydraulic jack oil, then replace the
oil filler screw (P07).
Note: Dispose of hydraulic oil in accordance with local regulations.
4.6 When equipment efficiency drops, purge away air from hydraulic system: Tum the release valve counterclockwise
by 1-1/2 tums, with ram fully retracted and release valve open, pump the handle rapidly for 10-20 times.
4.7 It is recommended that an annual inspection be done by qualified technicians.
5. TROUBLESHOOTING
Symptom
Possible Causes
Corrective Action
Ram won't lift load
Release valve not tightly closed
Overload condition
Air trapped in system
Firmly close release valve
Remedy overload condition
Purge away air from system
Ram won't maintain load
Release valve not tightly closed
Hydraulic unit malfunction
Firmly close release valve
Replace ram and/or pump
Ram won't lower after unloading
Reservoir overfilled
Linkages binding
Drain oil to proper level
Clean & lubricate moving parts
Ram won’t extend to full stroke
Oil level low
Add hydraulic oil
Poor performance
Oil level low
Air trapped in system
Add hydraulic oil
Purge away air from system
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Part No.
Description
Qty
Part No.
Description
Qty
01
Case
1
10
Rubber head
1
02
Tube
5 (4)
P01
Valve block
1
03
Flat base
1
P02
Oil filter
1
04
Ram toe
1
P03
O-ring
2
05
Plunger toe
1
P04
Reservoir
1
06
Wedge head
1
P05
Tie rod
1
07
V-base
1
P06
Nylon ring
1
08
Male connector
1
P07
Oil filler screw
1
09
Serrated saddle
1
P08
Sealing
1
P09
Breather valve
1
P41
Screw
1
P10
Screw
1
P42
Screw
1
P11
O-ring
4
P43
Spring
1
P12
Pump foot
1
P44
Ball
1
P13
Ball
2
R01
Cover
1
P14
O-ring
1
R02
Circlip
1
P15
Release valve
1
R03
Piston rod
1
P16
Hydraulic hose
1
R04
Circlip
1
P17
Coupler
1
R05
Bushing
1
P18
Hose dust cover
1
R06
Nylon ring
1
P19
Ball
1
R07
Sealing ring
1
P20
Ball cap
1
R08
Circlip
1
P21
Spring
1
R09
Nut
1
P22
Screw
1
R10
Spring
1
P23
O-ring
1
R11
Screw
1
P24
Screw
1
R12
Protection cap
1
P25
Screw protector
1
R13
Ring for ram
1
P26
Screw
1
R14
Cylinder
1
P27
Nylon ring
1
R15
Screw
1
P28
Sealing ring
1
S1
Pin
1
P29
O-ring
1
S2
Circlip
2
P30
Nylon ring
1
S3
Movable jaw
1
P31
Screw
1
S4
Spring
1
P32
O-ring
1
S5
Fixed jaw
1
P33
Nylon ring
1
S6
Piston
1
P34
Piston
1
S7
Cup seal
1
P35
Pin
1
S8
O-ring
1
P36
Retaining ring
2
S9
End cap
1
P37
Pin
1
S10
Coupling ring
2
P38
Handle socket
1
S11
Coupling bolt
2
P39
Handle
1
S12
Dust cap
2
P40
Handle sleeve
1
6. PARTS LIST
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R01
R12 R02
R09
R13 R03
R10
R04
R11
R05
R06
R14
R07
R15 R08
S10
S11
P11
S12
S12
S4 P11
S11
S10
S2
S9
S8
S1
S7
S6
S3
S2
S5
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