Respirex MFC International STAKJAK KSM17 User manual

1
© MFC International
Instructions for Use
8 Bar Stak Jak Lifting Mats

© MFC International
1. IDENTIFICATION������������������������������������������������������������������������������������������������������������� 1
1.1. TYPE OF PRODUCT................................................................................................................ 1
2. PRODUCT DESCRIPTION������������������������������������������������������������������������������������������ 1
2.1. BASIC FUNCTIONS AND APPLICATION AREAS..................................................................... 1
2.2. BASIC DATA............................................................................................................................ 2
2.3. ENVIRONMENTAL CONDITIONS AND RESTRICTIONS OF USE ............................................. 2
2.4. SAFETY AND PERSONAL PROTECTIVE EQUIPMENT ............................................................ 2
3. DEFINITIONS �������������������������������������������������������������������������������������������������������������������� 3
4. PREPARATION OF PRODUCT FOR USE������������������������������������������������������������ 3
4.1. TRANSPORTATION AND STORAGE ....................................................................................... 3
4.1.1 TRANSPORT......................................................................................................................... 3
4.1.2 STORAGE ............................................................................................................................. 3
4.2. SAFETY PRECAUTIONS BEFORE USE................................................................................... 4
4.3. REMOVAL OF PACKAGING..................................................................................................... 4
4.4. DISPOSAL OF PACKAGING ................................................................................................... 4
4.6. INSTRUCTIONS AND PERIODIC TESTS REPORTS ................................................................ 4
5. INSTRUCTIONS FOR OPERATIONS��������������������������������������������������������������������� 4
5.1. RECOMMENDATIONS FOR SAFE AND EFFICIENT WORK ..................................................... 4
5.1.1. CARRYING THE STAK JAK .................................................................................................. 5
5.1.2. WORKING ENVIRONMENT .................................................................................................. 5
5.2. CHOOSING A STAK JAK......................................................................................................... 5
5.3. SYSTEM FOR STAK JAK INFLATION ...................................................................................... 6
5.3.1. PREPARATION OF STAK JAKS FOR LIFTING PROCEDURE ................................................ 6
5.3.2. WORKING WITH THE CONTROLLERS .............................................................................. 10
5.3.2.1. DUAL CONTROLLER AND SINGLE CONTROLLER WITH CONTROL LEVERS ............... 10
5.3.3. DISCONNECTING STAK JAKS........................................................................................... 10
5.4. LIFTING PROCEDURE .......................................................................................................... 12
5.4.1. LIFTING WITH A SINGLE STAK JAK................................................................................... 13
5.4.2. LIFTING WITH SEVERAL STAK JAKS, INCREASING THE LIFTING CAPACITY ................... 14
5.4.2.1 LIFTING USING TWO OR THREE STAK JAKS.................................................................. 15
5.4.3. LIFTING LOADS OF UNUSUAL SHAPE.............................................................................. 16
5.4.3.1. LIFTING OF PIPES AND PROFILES................................................................................. 16
5.4.3.2. LIFTING OF CYLINDRICAL OBJECTS ............................................................................. 16
5.4.3.3. USING A STAK JAK TO SEPARATE OR MOVE AN OBJECT ........................................... 17
5.4.3.4. FURTHER EXAMPLE APPLICATIONS FOR STAK JAKS .................................................. 18
5.5. UNEXPECTED SITUATIONS .................................................................................................. 19
5.6 OPTIONAL ACCESSORIES .................................................................................................... 20
5.7. DISPOSAL OF WASTE MATERIAL......................................................................................... 22
ContentsContents

© MFC International
6. MAINTENANCE AND CLEANING ������������������������������������������������������������������������� 22
6.1. SAFETY PRECAUTIONS ....................................................................................................... 22
6.2. MAINTENANCE AND CLEANING AFTER USE....................................................................... 22
6.2.1. MAINTENANCE OF STAK JAKS AFTER USE ..................................................................... 22
6.2.1.1 REPLACING THE STAK JAK INFLATION CONNECTOR ................................................... 23
6.2.2. MAINTENANCE OF HOSES AFTER USE............................................................................ 23
6.2.3. MAINTENANCE OF THE CONTROLLER AFTER USE......................................................... 24
6.3. PREVENTIVE MAINTENANCE ............................................................................................... 24
6.3.1. CHECK-UP INTERVAL ....................................................................................................... 24
6.3.1.1. VISUAL TEST OF THE STAK JAK .................................................................................... 25
6.3.1.2. FUNCTION TEST OF THE STAK JAK .............................................................................. 25
6.3.1.3. VISUAL TEST OF PRESSURE REGULATOR & HOSES.................................................... 26
6.3.1.4. FUNCTION TEST OF PRESSURE REGULATOR .............................................................. 26
6.3.1.5. VISUAL TEST OF THE OUTLET HOSE ............................................................................ 26
6.3.1.6. FUNCTION TEST OF THE OUTLET HOSE....................................................................... 26
6.3.1.7. VISUAL TEST OF THE CONTROLLER............................................................................. 27
6.3.1.8. FUNCTION TEST OF THE CONTROLLER ....................................................................... 27
6.3.1.9. FUNCTION TEST OF PRESSURE GAUGES ON THE CONTROLLER .............................. 27
6.3.1.10. FUNCTION TEST OF THE SAFETY VALVE..................................................................... 27
6.3.1.11. HYDRAULIC PRESSURE TEST ..................................................................................... 27
6.4 SERVICE LIFE ........................................................................................................................ 27
6.5 TROUBLESHOOTING ............................................................................................................ 28
7. WARRANTY CONDITIONS��������������������������������������������������������������������������������������� 30
7.1. GENERAL CONDITIONS ....................................................................................................... 30
7.2 MANAGEMENT OF PRODUCTS ............................................................................................ 30
7.3. WARRANTY .......................................................................................................................... 30
7.4. EXCLUSION OF WARRANTY ................................................................................................ 30
7.5. MAKING A WARRANTY CLAIM............................................................................................. 31
8. STAK JAK CHEMICAL COMPATIBILITY ����������������������������������������������������������� 31
9. STAK JAK TEST REPORT ���������������������������������������������������������������������������������������� 39

1
© MFC International
1.1. TYPE OF PRODUCT
Stak Jak type -
KSM17, KSM25, KSM49 & KSM60�
Max� lifting capacity
Max. height inated
Volume
Working pressure 8 bar (116 PSI)
1.2 MANUFACTURER
MFC International Ltd
Naval Yard
Tonypandy
Rhondda Cynon Ta
CF40 1JS
Tel: [phone]
Fax: [phone]
E-mail: sales@mfc-international�com
www�mfc-international�com
This user instruction manual provides guidance on safety, operation, maintenance and parts
support for the KSM range of Stak Jak lifting mats�
2.1. BASIC FUNCTIONS AND APPLICATION AREAS
The Stak Jak is a revolutionary at-prole lifting cushion developed for vehicle and heavy-duty
lifting requirements. Primarily used in emergency rescue situations, they are also suitable for
a wide range of industrial, mining and military applications. The at prole of the Stak Jak has
several distinct advantages over traditional ovoid lifting cushions of which the most signicant
is the ability to safely stack up to three cushions together� This enables a greater lifting height
without the risk of sudden ejection or instability that can occur when stacking ovoid mats.
The most convenient source of supply for ination is from self-contained breathing apparatus
cylinders or scuba bottles. Other sources can be compressors, factory air-line supply, vehicle air
brake system, foot or hand pump (capable of supplying 8 bar (116 psi) pressure). Filters should
be used where there is a possibility of contaminated air supply.
Stak Jaks are slim line for tight space scenarios and compact storage. They are constructed
from compression-moulded neoprene that is reinforced with exceptionally tough high tensile
Polyaramid cord (DuPont™ Kevlar®) that provides strength and rigidity, yet are light enough to be
carried by just one person*. The outer, hot-vulcanised, neoprene cover features a non-slip matrix
pattern on both surfaces to increase friction and holding capability.
Stak Jaks can be inated quickly to provide an instant lift, making them ideal for use in rapid
response emergency situations. They also have a controlled deation facility if required, and can
be supplied with an optional bleed valve.
8 bar Stak Jaks are intended for lifting, lowering, positioning, separating and moving of loads
weighing up to 60,000 kg�
Stak Jak high pressure lifting bags have been independently tested and comply with the
requirements of EN 13731:2007 ‘Lifting bag systems for re and rescue service use - Safety and
performance requirements’�
*KSM17 and KSM25 can be carried by one person. KSM49 and KSM60 should be carried by two persons.
MFC International Limited
Naval Yard,Tonypandy, Rhondda Cynon Taff, CF40 1JS
T:
[phone] E:
[email protected]
www.mfc-international.com
For more products visit:
Safety Precautions
• Only use MFC approved controllers and safety valves • Keep clear of load during lift operations • Never work under a load without solid supports in place •Avoid direct contact with sharp edges and hot surface
• Ensure equipment is used by trained personnel only
• Read and understand manual before use
• Check that all equipment is serviceable before use
• Do not exceed maxium safe working pressure
MAX 3
>8
STAKJAK KSM49
49
17.5
25
893
8
49.2
41.6
33.1
25.5
17.9
0
10
20
30
40
50
60
1cm 5cm 10cm 15cm 17cm
Lifting Capacity (Tonnes)
Lifting Height
EN 13731:2007
Fig 1�1 Example Stak Jak label
1. Identication1. Identication
2. Product Description2. Product Description

2© MFC International
2.2. BASIC DATA
Technical Data KSM17 KSM25 KSM49 KSM60
Product Code KSM17/08 KSM25/08 KSM49/08 KSM60/08
Length (cm) 52 62 84 92
Width (cm) 52 62 84 92
Inated Height (cm) 17.5 17.5 17.5 17.5
Deated Height (cm) 2.5 2.5 2.5 2.5
Packed Size (cm) 55x55x4 65x65x4 88x88x4 95x95x4
Max. Lift Capacity at Min. Lifting Height (tonne) 17.2 25.5 49.2 59.8
Max. Lift Capacity at Max. Lifting Height (tonne) 3.6 7.8 17.9 24.6
Max Flat area (cm) 24x24 34x34 56x56 64x64
Air Requirements (ltr) 305 465 893 1074
Weight (kg) 8 12 20 23
Max.Pressure (bar) 8 8 8 8
2.3. ENVIRONMENTAL CONDITIONS AND RESTRICTIONS OF USE
Stak Jak IIs are suitable for use within a temperature range of -30°C to +100°C� Between -20°C to
-30°C their use is limited to 1 hour, between +90°C to +100°C their use is limited to 30 minutes.
Never use where contact temperatures between the Stak Jak and load to be lifted are in excess
of +100°C�
Stak Jaks are NOT intended for use in potentially explosive atmospheres. For further information
please contact MFC International Ltd.
2.4. SAFETY AND PERSONAL PROTECTIVE EQUIPMENT
Always wear personal protective equipment (PPE) when working with lifting mats. Fire ghters
and rescue team members should wear appropriate PPE specied for their work role. Other users
should wear a safety helmet, goggles, gloves and protective footwear.
17.2
12.9
8.3
4.8 3.6
25.5
20.1
14.3
49.2
41.6
33.1
25.5
17.9
59.8
51.4
41.8
33.2
24.6
0
10
20
30
40
50
60
70
1CM 5CM 10CM 15CM 17CM
Lift Capacity (Tonnes)
Lifting Height
8-Bar StakJaks
KSM60
KSM49
KSM25
KSM17
7.8
9.5
Fig�2�1

3
© MFC International
Stak Jaks lift evenly almost over the entire surface during ination and thanks to their construction,
also maintain the shape and size of the bearing surface
Bearing surface is the surface of the Stak Jak in contact with the load or the object to be lifted
Controller is a device that supplies, empties and monitors the lling procedure with the air.
Working pressure is the pressure in the Stak Jak during operation
Permissible pressure is the maximum ination pressure in the Stak Jak during operation,
specied by the manufacturer.
Ination connector is the connector on the Stak Jak where outlet hoses are connected
Pressure regulator or pressure reducer reduces the pressure of air supply to the specied
pressure value
Safety valve protects the entire system and releases excess pressure to unload the system
Lifting capacity* is the maximum weight that can be lifted by the Stak Jak at a specied pressure
Connection hoses connect the controller and Stak Jaks
Inlet hose is a hose between the air source and controller
Outlet Hose is a hose between the controller and Stak Jak
Contact surface is the surface of the Stak Jak that makes contact with the load at a denite
point of time during the ination procedure
*Max lifting capacity
4.1. TRANSPORTATION AND STORAGE
4.1.1 TRANSPORT
During transportation, Stak Jaks should be placed at (horizontally) or upright (vertically); bending
the Stak Jak should be avoided.
Stak Jaks that are stored in a truck compartment that is subjected to constant bumping and
vibration will eventually become damaged. It is strongly recommended that Stak Jaks are stored
in their own cushioned cartons. It is further recommended that all components are strapped
down, braced or secured within the compartment during transport.
4.1.2 STORAGE
Stak Jaks are packed in cardboard boxes; sensitive parts of the mat are additionally protected.
Whether Stak Jaks are stored in a stationary, mobile or movable facility the following conditions
apply:
Always store in a clean, dry and dust free environment away from direct sources of light, particularly
direct sunlight or intense articial light with high ultra violet content.
Avoid equipment capable of generating ozone e.g. high voltage electrical equipment.
Stak Jaks should be stored in a temperature range between +5°C to +25°C.
It is recommended that Stak Jaks are stored at (horizontally). When the Stak Jak is stored
horizontally, the ination connector should be facing forwards in a clearly visible position to
prevent damage occurring when moving.
3. Denitions3. Denitions
4. Preparation Of Product For Use4. Preparation Of Product For Use

4© MFC International
If the Stak Jak is stored vertically (upright) it is recommended xing it to a surface (e.g. a wall)
to protect against bending. The ination connector should face upwards and be covered by the
protective cap�
It is recommended that Stak Jaks are stored in their original packaging to minimise various
environmental inuences on the product during storage. Alternatively, optional PVC storage
pouches can be used, please contact MFC International Ltd for further information.
4.2. SAFETY PRECAUTIONS BEFORE USE
Always read the instructions carefully and understand safety procedures before use!
Rescue teams should participate in a training course held in conformity with internal training
rules. Other users should attend a training course organised by MFC International Ltd or an
authorised training service provider.
Never exceed the working pressure of 8 bar.
Under no circumstances should a Stak Jak be inated to working pressure whilst not under load.
Ensure Stak Jaks are protected from hot vehicle exhausts. Exhausts should be covered with a
folded re and heat resistant blanket.
Keep clear of loads which are unsupported by chocks during lifting operations.
Operators should be positioned away from the direction of anticipated thrust particularly when
making space with partially-inserted Stak Jaks.
Never work under a load without safety supports.
Do not use an outlet hose for retrieving or repositioning a Stak Jak.
Ensure all gauges are reading zero before disconnecting hose.
4.3. REMOVAL OF PACKAGING
In order to avoid damaging Stak Jaks do not use sharp objects such as knives, screwdrivers or
similar for the removal of packaging�
4.4. DISPOSAL OF PACKAGING
Packaging is made of recyclable cardboard; it should be deposited in waste bins for recycled
paper or cardboard packaging.
4.6. INSTRUCTIONS AND PERIODIC TESTS REPORTS
Instructions and periodic test reports are enclosed with every Stak Jak and retained on le at
MFC International Ltd for the shelf life of the lifting mat, i.e. 15 years.
Instructions and periodic test reports should be retained throughout the service life of the
mat.
5.1. RECOMMENDATIONS FOR SAFE AND EFFICIENT WORK
Failure to follow the instructions can put safety of users and third persons at risk and result in
signicant injury. Carefully read the instructions for operation before using the lifting mat!
WARNING! NEVER REACH UNDER A LOAD WHICH IS NOT PROTECTED BY MECHANICAL
SAFETY SUPPORTS
• Never exceed the maximum working pressure (marked on the Stak Jak).
• Never place more than three Stak Jaks on top of each other�
• Never exceed a pressure of 1 bar if no load is placed on the Stak Jak.
5. Instructions for Operations5. Instructions for Operations

5
© MFC International
• Inate the Stak Jak until a required or maximum height, or maximum working pressure is
reached.
• Improper use of Stak Jaks should be avoided. MFC International Ltd assumes no responsibility
for damage resulting from improper use of the product.
• Always use the specied PPE when working with the Stak Jak.
5.1.1. CARRYING THE STAK JAK
Carry the Stak Jak in an upright position and make sure the ination connector always faces
upwards to prevent damage in case of a fall. When carrying several Stak Jaks together they
should be placed horizontally and carried by two persons.
Larger and heavier Stak Jaks, i.e. KSM49 and KSM60 should always be carried by two persons.
5.1.2. WORKING ENVIRONMENT
TEMPERATURE OF THE OBJECT TO BE LIFTED:
Protect the Stak Jak with a thermal blanket, breboard or rubber-coated steel board if the contact
surface temperature of the object to be lifted exceeds 65°C (150°F). Temperatures exceeding
the permissible values can damage the Stak Jak. Stak Jaks preserve their lifting capacity and
material properties down to the lowest temperature permitted which is -30°C.
LIGHTING OF THE WORKING PLACE:
It is dangerous to work in low light conditions; ensure the work area is not poorly lit or in shadow.
MFC International Ltd recommend the use of additional lighting, e.g. oodlights, even during
daylight hours when visibility can be poor due to shading or cloud cover. Never use a naked ame
for lighting purposes�
PRESENCE OF AUTHORISED PERSONNEL:
Only trained personnel should prepare and lift/lower the load. Other personnel should remain
away from the area where Stak Jaks are prepared, lifted or lowered. Appropriate measures aimed
at minimizing risks that could endanger the safety of personnel and the environment, such as an
outbreak of re due to fuel leakage, should be put in place prior to carrying out lifting operations.
FIRE AREAS:
Stak Jaks may be used in a re area only after the contact temperature between the load and the
ground drops below 55°C.
5.2. CHOOSING A STAK JAK
The following data is required in order to choose an appropriate Stak Jak:
• Shape of the load
• Weight of the load to be lifted
• Required lifting height
Consider the data about the load weight and required lifting height, see Fig.2.1, in choosing an
appropriate Stak Jak�
An example of choosing:
A load of 10 t is to be lifted to the height of 150mm using one Stak Jak.
Considering Fig.2.1, the lifting capacity of KSM49 and KSM60 Stak Jaks meet the requirements.
The lifting capacity of the KSM25 Stak Jak is not sucient for reaching a height of 150 mm.
Lifting heights can be increased by stacking up to a maximum of three Stak Jaks on top of
each other; see Section 5.4.2.1. For other methods of increasing lifting height see Section 5.4.1.
Always use Stak Jaks of the same dimensions when stacking and attach restraining straps to link
the mats together�

6© MFC International
5.3. SYSTEM FOR STAK JAK INFLATION
• Stak Jaks are to be in ated solely with air, other gases should not be used. Controllers with
built-in safety valves should be used for in ation of Stak Jaks.
• Never in ate a Stak Jak without a load to more than 1 bar pressure.
• In ate the Stak Jak until the required or maximum lifting height or maximum working pressure
is reached.
5.3.1. PREPARATION OF STAK JAKS FOR LIFTING PROCEDURE
Prepare the following items for lifting loads using a Stak Jak:
1� Air source
2� Pressure regulator (if the pressure of air source exceeds 8 bar)
3� Controller
4� Outlet hoses
5� Inlet hose
6� Stak Jak
Always use the items detailed above when lifting a load using a Stak Jak.
Use only original systems for in ation speci ed by MFC International Ltd.
If compressed air contains oil, use oil separator.
Fig 5�1
5� Inlet hose
3� Controller
6� Stak Jak
lifting mats
2� Pressure regulator
4. Outlet hoses
1. Compressed-air
cylinder

7
© MFC International
Step 1: Position the Stak Jaks
Position the Stak Jak in a de ned and previously
prepared location. Follow the rules de ned in
sections 5.1 and 5.2. Use mechanical supports for
load stabilization.
Step 2: Connect outlet hoses to Stak Jak
Outlet hoses are of di erent colour to prevent
confusion during use. If several Stak Jaks are used,
connect each one with a hose of di erent colour.
Hoses are equipped with safety couplings having
dual protection.
Connect the safety coupling of the outlet hose to
the hose connector on the Stak Jak/s as shown by
the arrow, see Fig 5.3, press  rmly until it clicks into
place�
Fig 5�2
Fig 5�3
Step 3: Connect outlet hoses to controller
Fig 5�4
Connect the opposite end of the outlet hose from
the Stak Jak to the connection coupling on the
controller, see Fig 5.4. If inserted correctly, the
connection coupling clicks into place�
The outlet hoses should be entirely unrolled
without constrictions or kinks�
Step 4: Prepare the air source
A compressed-air cylinder is the most frequently used air source for Stak Jak in ation.
If a di erent air source is used make sure that:
• Inlet air pressure supplied to the controller is reduced via the regulator to a maximum of 8 bar.
• The inlet hose connector for connection to the controller should be a type 26 safety coupling.

8© MFC International
Before removing the safety plug, check if the
valve on the cylinder is shut-o ; to shut-o the
valve turn it clockwise�
Unscrew the safety plug and keep it in a safe
place�
Fig 5�5
Shut-o the  ow valve on the pressure regulator
by turning clockwise�
Insert the pressure regulator into the connection
on the air cylinder and secure the locking nut
tightly, see Fig 5�7�
If the cylinder is placed on the ground, position
the valve so that it is protected from any damage.
Step 4.3: Attach the pressure regulator to the cylinder
Fig 5.7
Flow valve
Step 4.2: Connect inlet hose to pressure regulator
Connect the inlet hose connector to the inlet
air supply coupling on the pressure regulator;
see the arrow in Fig 5.6. If correctly inserted,
the coupling on the controller clicks into place�
Step 4.1: Remove the safety plug from the compressed-air cylinder
Fig 5�6
Locking nut

9
© MFC International
Step 4.4: Set the pressure regulator to the required value
Fig 5�8
Connect the inlet hose connector to the inlet air
supply coupling on the controller; see the arrow
in Fig 5.9. If correctly inserted, the coupling on
the controller clicks into place� Move the coupling
housing by 180° left or right to lock the coupling�
Fig 5�10
Release the pressure into the controller by turning
the  ow valve anti-clockwise
Step 6: Relieve the pressure regulator
Step 5: Connect the inlet hose to the controller
Fig 5�9
Open the valve on the cylinder.
Unscrew it completely then turn back by half a turn�
The pressure gauge should indicate a value of 200
or 300 bar depending on cylinder capacity.
The required working pressure is set by turning the
adjusting valve.
Observe the set value on the outlet pressure gauge
(8 bar) during value setting.

10 © MFC International
Fig 5�12
5.3.2. WORKING WITH THE CONTROLLERS
Always monitor the pressure on the respective pressure gauge, the behaviour of the Stak
Jaks and the load during ination.
If the maximum pressure is exceeded the safety valve on the controller activates and relieves the
pressure from the Stak Jak�
5.3.2.1. DUAL CONTROLLER AND SINGLE CONTROLLER WITH CONTROL LEVERS
By using a dual controller, one, two or three Stak
Jaks can be operated simultaneously. The Stak Jaks
are handled by means of a control lever under the
respective pressure gauge� When the control lever
is pushed forwards, the pressure in the connected
Stak Jak builds up. When the control lever is pulled
backwards, the pressure in the Stak Jak reduces.
When the control lever is released, it automatically
returns to its neutral position. The lling and discharge
valve is shut-o.
Fig 5�11
5.3.3. DISCONNECTING STAK JAKS
Stak Jaks and other required components are under high-pressure, extreme caution is required
when disconnecting. Disconnect the Stak Jaks as follows:
Step 1: Shut-o the valve on the compressed-air cylinder; see Fig 5.5.
Step 2: Shut-o the ow valve on the pressure regulator by turning clockwise; Fig 5.10.
Step 3: Completely release the pressure from the connected Stak Jaks by pulling the levers
of the controller backwards, see Fig 5.11.
Step 4: Completely release the air from the outlet hose and valves that are connected to
the Stak Jaks by pulling the levers of the controller backwards, then immediately empty the
Stak Jaks once again.
Step 5: Disconnect the inlet hose from the
controller by rotating the coupling housing until
the groove on the housing clicks in, see Fig
5.12. Slide the coupling housing towards the
controller and disconnect the inlet hose from
the controller.

11
© MFC International
Step 6: Dismount the pressure regulator
Unscrew the locking nut on the pressure regulator and detach the regulator from the compressed-
air cylinder, see Fig 5.7.
Step 7: Attach the safety plug on the compressed-air cylinder, see Fig 5.5.
Step 8: Disconnect the outlet hoses from the
controller by pushing the hose connector
towards the controller. Slide the coupling
housing backwards towards the controller.
Release the hose from the coupling.
When outlet hoses are disconnected, the pressure
automatically releases from the hoses�
Step 9: Remove the Stak Jaks from the work area and keep them in an easy accessible
place.
WARNING! Never remove Stak Jaks by pulling on the outlet hoses.
Fig 5�13
Step 10: Disconnect outlet hoses from the lifting
bag by pushing the hose coupling towards the
Stak Jak. Slide the hose coupling sleeve collar
backwards away from the Stak Jak and release
the hose; the plug of the Stak Jak automatically
jumps out of the coupling.
Fig 5�14

12 © MFC International
A mechanical safety support should be rm enough to withstand the load. It should be placed on
a solid surface to minimise the possibility of slipping.
Lifting capacity (tonne) is highest at the beginning of the lifting procedure when the lifting height
is at its lowest (Fig 5.15). For the lifting capacity depending on the lifting height see Fig.2.1.
5.4. LIFTING PROCEDURE
Before starting work, check the location where the Stak Jak is to be positioned.
Remove any sharp objects such as glass fragments or other foreign particles to avoid damaging
the Stak Jak. Never lift with a Stak Jak that is in contact with any sharp metal edges, nails, screws
or similar that may puncture, abrade or otherwise damage the Stak Jak.
If a Stak Jak is to be used where a danger of slipping exists due to:
• oil spillages
• chemicals that could aect the properties of rubber
• ice or snow
spread some sand or other granulated material between the Stak Jak and the surface to increase
friction or use a breboard as protection.
If the Stak Jak is used on non-consolidated or soft terrain place a rm support, e.g. a breboard,
under the Stak Jak to assure stability during lifting and prevent possible slipping of the load or
the Stak Jak itself�
WARNING! A mechanical safety support MUST be used in all lifting operations. Never work under
a load that is only supported by means of an inated Stak Jak.
Position the bag in a prepared location or on a built support, see Fig 5.15.
WARNING! Certain parts of the load may not be xed to the main load to be lifted. Any
loose parts should be secured or removed. Under no circumstances should loose parts be
supported by an inated Stak Jak in order to lift the main load.
BEARING
SURFACE
LOAD
Fig 5�15
Fig 5.15: Mechanical safety support and bearing surface

13
© MFC International
5.4.1. LIFTING WITH A SINGLE STAK JAK
If only one Stak Jak is available and the gap between the ground and the object to be lifted
exceeds 70mm, build a rm and suciently high support to a point that just allows enough space
to insert an uninated Stak Jak.
LOAD
UNINFLATED STAK JAK
Fig 5�16
Build a safety support on each side of the load to a point where it is impossible to insert another
level (Fig 5.16). Follow this process to minimize the height from which the load may drop in the
event of an abrupt air loss from the Stak Jak�
Position the Stak Jak on the middle of the support so that its ination connector is facing forwards.
Make sure that the area of Stak Jak’s upper surface within the four white squares (the bearing
surface) makes contact with the underside of the load. If the Stak Jak is not positioned centrally
beneath the load the bearing surface may be reduced, this can cause the load to slip away during
ination and may lead to a sudden and uncontrolled ejection of the Stak Jak.
Slowly inate the Stak Jak to reach the required height and simultaneously add lateral safety
supports, see Fig 5�17�
The uppermost support must be suciently solid to prevent shifting or collapse during ination
when the Stak Jak takes up its shape�
LOAD
ADDITIONAL LATERAL SUPPORTS ADDED
Fig 5�17
Do not inate the Stak Jak whilst adding lateral safety supports.
Once the nal lift height has been reached, carefully deate the Stak Jak to allow the load to rest
fully on the lateral safety supports. If a working space is required under the point of lifting, remove
the Stak Jak and the support(s) beneath it.
When working under a load, the load should be stabilised and the Stak Jak completely
deated.

14 © MFC International
5.4.2. LIFTING WITH SEVERAL STAK JAKS, INCREASING THE LIFTING CAPACITY
Lifting capacity can be increased by positioning two Stak Jaks side by side and simultaneously
inating, see Fig 5.18. The new capacity is double that of a single Stak Jak.
Example:
The capacity of combined Stak Jaks KSM17 and KSM17 side by side and simultaneously inated
amounts to 34 t, i.e. capable of lifting a load of 34 t.
Fig 5.18: Two Stak Jaks placed side by side to increase the lifting capacity.
LOAD = 34 t
Stak Jak KSM17 Stak Jak KSM17
Fig 5�18
Lifting height can be increased by stacking one Stak Jak on top of the other, see Fig 5.19 and
sections 5.4.2.1 and 5.4.2.2. The total lifting height of such a combination equals the sum of
lifting heights�
Lifting capacity does not increase by stacking 2 or 3 Stak Jaks one on top of the other;
only lifting height increases. The load capacity of the combination equals the capacity of a
single Stak Jak.
LOAD
BEARING SURFACE
Fig 5�19
Fig 5.19: Combined Stak Jaks to increase lifting height
WARNING: If the required lifting height cannot be determined, choose the biggest Stak Jak
available that can be placed under the load.
Example:
A combination of Stak Jaks KSM17 (17.5 cm) and KSM17 (17.5 cm) stacked one upon the other
enables a total lift height of 35 cm�

15
© MFC International
5.4.2.1 LIFTING USING TWO OR THREE STAK JAKS
A MAXIMUM of THREE Stak Jaks may be combined to increase lifting height. If lifting with
two or three Stak Jaks to achieve a higher lift, only use Stak Jaks of the same dimensions.
When combining Stak Jaks to increase lifting height, place the Stak Jaks on top of each other
and make sure that all connectors are facing forwards, see Fig 5.20. Attach the restraining straps
and connect the Stak Jaks together using the karabiner clips to prevent slipping.
Set up the safety support and base for the Stak Jak, follow the procedure for working with a Stak
Jak, see section 5�4�1�
Fig 5�20: Combining Stak Jaks to increase lifting height
When using a combination of 2 or 3 Stak Jaks on top of each other, the order of in ation is always
1, 2 and 3 (lower bag  rst) see Fig 5.21, to ensure maximum stability during the lift of the load.
2 Stak Jaks combined
3 Stak Jaks combined
Fig 5�21
1
2
1
2
3

16 © MFC International
Fig 5.22: Supporting the Stak Jak with a breboard when
lifting proles or pipes
5.4.3. LIFTING LOADS OF UNUSUAL SHAPE
5.4.3.1. LIFTING OF PIPES AND PROFILES
A problem arises when the load does not rest over the entire lifting surface of the Stak Jak.
Moreover, the Stak Jak may become damaged if it bends or is overloaded with angular, jagged
or sharp-edged loads.
Insert a breboard or similar between the Stak Jak and the load to allow the lifting force to evenly
distribute over the entire lifting surface, see Fig 5.22.
Fig 5�22
5.4.3.2. LIFTING OF CYLINDRICAL OBJECTS
Larger cylindrical objects such as tanks cannot be lifted using a single Stak Jak. If the load
is not rmly fastened it will roll away as soon as the Stak Jak begins to inate.
For this reason, two Stak Jaks are used for lifting of cylindrical objects, placed one at each side
of the object, see Fig 5.23. Make sure that Stak Jaks are inated evenly and simultaneously.
Fig 5�23
Fig 5.23: Lifting large cylindrical loads

17
© MFC International
5.4.3.3. USING A STAK JAK TO SEPARATE OR MOVE AN OBJECT
Stak Jaks can be used for separating and moving objects horizontally. Position one face of the
Stak Jak against a bar, a pillar or another rm and rigid object; position the opposite face against
the object to be moved.
Thin-walled objects, e.g. sheet metal panelling, may bend or rupture due to the Stak Jak’s
pressure. To prevent damage occurring, insert a thick breboard or similar between the
Stak Jak and the object to be moved, this will distribute the moving force over a greater
surface area, see Fig 5.24.
FIRM-FIXED LOAD
MOVING OBJECT
Fig 5�24
Fig 5.24: Moving or separating objects