operation and maintenance manual fervi of the machine hydraulic trolley jack art. 0457 and create a...

OPERATION AND

MAINTENANCE MANUAL

Hydraulic trolley jack

Art. 0457

ORIGINAL INSTRUCTIONS

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MACHINES ANDACCESSORIES

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FOREWORD

Read this manual before operating any machinery

ORIGINAL INSTRUCTIONS

Before starting any operation it is compulsory to read this instruction manual. The guaranteethat the machine will function and perform properly is strictly dependent upon the applicationof all the instructions contained in this manual.

Operator Qualification

The operators assigned to using this machine must be supplied with all of the necessaryinformation and instruction and should be provided with adequate training regardingsafety in pertaining to:a) The conditions of use of the equipment;b) Foreseeable abnormal situations, pursuant to Article 73 of Legislative Decree81/08.

We guarantee the Machine's conformity to the specifications and technical instructions

described in the Manual on the date of issuance and listed herein; On the other hand,

the machine may also be subject to important technical changes in the future, without

the manual being updated.

Therefore, see FERVI for information about modifications that could be implemented.

REV. 1 November 2013

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CONTENTS

1 INTRODUCTION ........................................................................................4

1.1 Preface..........................................................................................................................5

2 SAFETY WARNINGS ..................................................................................6

2.1 General safety rules for machine tools..........................................................................6

2.2 Safety regulations for jacks ..........................................................................................7

2.3 Technical support..........................................................................................................7

2.4 Other provisions ...........................................................................................................7

3 JACK DESCRIPTION ..................................................................................8

3.1 Safety devices...............................................................................................................9

3.2 Identification plate and pictograms ............................................................................10

4 TECHNICAL SPECIFICATIONS .................................................................12

5 IMPROPER USE AND CONTRAINDICATIONS............................................13

6 TRANSPORTING, LIFTING AND MOVING.................................................14

7 COMMISSIONING....................................................................................15

7.1 Unpacking instructions ...............................................................................................15

7.2 Assembling the lifting lever ........................................................................................15

7.3 Mounting the upper handle .........................................................................................15

8 MACHINE OPERATION.............................................................................16

8.1 Lifting the load............................................................................................................17

8.2 Lowering a load ..........................................................................................................17

9 MAINTENANCE........................................................................................18

9.1 Routine maintenance ..................................................................................................18

10 REPLACEMENT PARTS...........................................................................20

11 TROUBLESHOOTING .............................................................................22

12 WAREHOUSE STORAGE.........................................................................23

13 DECOMMISSIONING.............................................................................23

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1 INTRODUCTION

This manual is delivered with the machine, and it must be regarded as an inseparable part ofit.

The manufacturer holds all ownership to material and intellectual property of this manual;any disclosure or copying, even partial, of this publication without prior written consent isforbidden.

The purpose of this manual is to provide the knowledge necessary for the use andmaintenance of the machine Hydraulic trolley jack Art. 0457 and create a sense ofresponsibility and an understanding of the capabilities and limitations of the means entrustedto the operator.

As the machine is entrusted to experienced and skilled operators, the following machine mustbe perfectly known by the operator if you want it to be used safely and effectively.

Operators must be properly trained and prepared, so make sure that this manual is read andconsulted by the staff responsible for commissioning, operation and maintenance of theHydraulic trolley jack. This is to make all operations the safest and most effective possiblefor those who carry out these tasks.

Therefore, it is imperative to strictly comply with the requirements in this manual, anecessary condition for safe and satisfactory operation of the machine.

Prior to installation and use of the Hydraulic trolley jack, authorised personnel shall:

carefully read this technical document;

know which protections and safety devices are available on the machines, their locationand how they work.

It is the responsibility of the buyer to ensure that users are properly trained, that they areaware of all the information and instructions in this document and that they are aware of thepotential risks that exist while working with the Hydraulic trolley jack.

The manufacturer waives any and all responsibility for damage to people and/orthings caused by non-observance of the instructions in this manual.

The Hydraulic trolley jack was designed and built with mechanical guards and safetydevices designed to protect the operator/user from possible injury. It is strictly forbidden tomodify or remove guards, safety devices and caution labels. If this must be done (forexample, for cleaning or repair), make sure that no one can use the jack.

Operators will be held fully responsible for any changes they have made to themachine; the manufacturer will not be held responsible for any damage to personsand/or property resulting from maintenance performed by unqualified personneland in a manner that differs from the operating procedures shown below.

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GRAPHIC REPRESENTATION OF SAFETY, OPERATIONAL AND RISK WARNINGS

The following boxes are designed to attract the attention of the reader / user for the properand safe use of the machine:

Pay attention

This highlights behavioural rules to prevent damage to the machine and/or the occurrence ofdangerous situations.

Residual Risks

This highlights the presence of dangers that cause residual risks to which the operator mustpay attention in order to avoid injury or damage to property.

1.1 PrefaceFor safe and easy operation of the Hydraulic trolley jack, this manual must be readcarefully in order to acquire the necessary knowledge. In other words, durability andperformance are strictly dependent on how it is used.

Even if already familiar with the Hydraulic trolley jack, it is necessary to follow theinstructions contained herein, in addition to the general precautions to be observed whileworking.

Acquire full knowledge of the machine.

Read this manual carefully to understand: operation, safety devices and all necessaryprecautions. All this is to allow safe use of the jack.

Wear appropriate clothing for the job.

The operator must wear appropriate clothing, so as to prevent the occurrence ofunpleasant accidents.

Maintain the machine with care.

Machine operation

The machine must only be used by qualified personnel trained to use the machine byauthorized personnel.

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2 SAFETY WARNINGS

2.1 General safety rules for machine tools

Risks related to Using the Machine

Do NOT underestimate the risks related to the use of the machine and stay focused on thework you are carrying out.


Despite the implementation of all safety devices for safe use of the machine, it is necessary totake note of all the accident prevention requirements highlighted in various parts of thismanual.


Every person who is responsible for the use and maintenance of the machine should first haveread the instruction manual, particularly the chapter dealing with safety.

It is recommended that the plant safety manager get written confirmation of the above.


During all work phases with the machine, you should proceed with great caution inorder to avoid damage to persons, to the property or to the machine itself.

Please use the machine only for its expected uses (drilling or tapping).

Don't tamper with the safety devices equipping the machine.


Before starting any work on the jack, the operator must wear the appropriate personalprotective equipment (PPE) such as protective gloves and safety shoes.

1. Always check the efficiency and integrity of the machine.

2. Keep the workplace tidy and free from hindrances; disorder causes accidents.

3. Make sure that the work environment is forbidden to children, non-employees andanimals.

4. Do not perform tasks on the machine other than those for which it was designed. Onlyuse the machine in the manner in which it was intended, as described in this instructionmanual.

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5. Work without disturbances.

6. Work areas must be well lit.

7. Always wear eye protection and protective gloves while working. If dust is produced,use the appropriate masks.

8. Wear appropriate clothing. Loose clothing, dangling jewellery, long hair, etc.., can getcaught in the moving parts, causing irreparable injury.

9. Replace worn and/or damaged parts, check that the guards and protection devices workproperly before operating. If necessary, have the machine checked by the servicesupport personnel. Use only original spare parts.

10.Do not use the machine in areas with a risk of fire and / or explosion.

11.It is recommended that users of this publication, for maintenance and repair, have abasic knowledge of mechanical principles and of repair technique procedures.

12.Management in charge of safety is to make sure that the staff responsible forusing the machine has read and understood this manual in its entirety.

13.The company safety manager is responsible for monitoring the company's riskstatus according to Legislative Decree no. 81/08.

2.2 Safety regulations for jacks1. Use the Trolley Jack exclusively for lifting.

2. Before lifting, make sure the Jack is in good condition. Do not adjust the safetyvalve!

3. Place the Jack on a flat, solid and durable work surface.

4. Do not try to operate the machine at higher performance levels than those for which itwas designed, in particular regarding the magnitude of the load to be lifted. Inother words, do not load the Jack beyond its capacity.

5. If you use the Jack to lift a vehicle, lock the wheels of the vehicle with the emergencybrake.

6. Always use a safety support, such as a tripod, to support the vehicle (load) incase you need to work under the vehicle (load).

2.3 Technical supportFor any problems or concerns, please contact, without hesitation the Customer ServiceDepartment of your dealer, who has competent and specialized staff, specific equipment andspare parts.

2.4 Other provisionsIT IS FORBIDDEN TO TAMPER WITH SAFETY DEVICES

The first thing to do when starting work is to check for the presence and integrity of theprotections and the operation of the safety devices.

If any defect is encountered do not use the machine!

Even more so, it is strictly forbidden to modify or remove guards, safety devices,labels and indication signs.

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3 JACK DESCRIPTION

The Jack Art. 0457 is designed and constructed for the lifting / lowering of loads, and inparticular vehicles for the usual operations of maintenance and/or repair.

The jack must be used on supporting surfaces that are flat, smooth, and adequately strongand hard (capable of supporting the weight of the jack plus the maximum nominal loadcapacity).

The operating temperature is within the range of: –20/+50°C.

The environment must also be sufficiently illuminated so as to ensure operation in maximumsafety (at least 50 lux is recommended).

Other types of use, or the extension of use beyond that envisaged, does notcorrespond to the designation attributed by the manufacturer, and therefore thelatter cannot accept any responsibility for any damage resulting therefrom.

Figure 1 - Overview of the device

1 Frame 5 Load-bearing saddle

2 Fixed front wheels 6 Operating pedal

3 Rear swivel wheels 7 Lever

4 Lifting arm

1

3

7

6

2

4

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The jack consists of:

a load-bearing frame (1) with two fixed front wheels (2) and two rear swivel wheels(3);

a lifting unit consisting of the hydraulic cylinder and the lifting arm (4);

a pumping unit consisting of a piston pump which is manually operated via the lever(7) or the pedal (6);

The control system of the jack, consists of:

the piston pump that, once operated, allows the extension of the piston rod of thehydraulic cylinder, i.e. the lifting of the arm and the load;

the vent valve that, once opened, allows the return of the piston rod of the hydrauliccylinder, i.e. the lowering of the load;

3.1 Safety devicesThe main safety device present on the machines is the load limiter, consisting of amaximum pressure valve, which protects the jack against overloading.

This valve, ensures that the pressure inside the hydraulic circuit can not exceed the fixed setvalue determined by the maximum rated load capacity.

Load limiter

Under no circumstances should the adjustment of the maximum pressure safety valvebe carried out by the operator.

Never tamper with the safety valve, if you are not authorised to do so!

The load-bearing saddle on the lifting arm (Figure 2)is made in such a way that the "gripping" of the loadis the maximum possible.

Figure 2 - Close-up of the load-bearing saddle.

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3.2 Identification plate and pictogramsThe identification plate is affixed to the lifting arm of the jack (Figure 3).

Figure 3 - Nameplate.

The maximum rated load capacity that the jack can lift under standard conditions isindicated on the plate, i.e. when:

it is in good conditions of efficiency and conservation;

it operates within the temperature range in ambient conditions and on a flat, hard anddurable surface.

The maximum rated load capacity must never be exceeded!

The following pictogram can be found on the lifting arm of the Jack that summarises the mainoperating instructions and provides some information on the residual risks associated with theuse of the jack (Figure 4).

Figure 4 – Attention and instruction pictograms.

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The following pictogram is located next to the pressure relief valve and indicates that theconfiguration of the valve must not be changed (Figure 5).

Figure 5 - Pictogram next to the safety valve.

On the right side of the frame of the jack is a pictogram which provides additional instructionsfor safe use, particularly on operation when using the jack for lifting cars or similar vehicles(Figure 6).

Figure 6 - Pictogram on the frame of the jack.

VALVOLA DI SICUREZZA:NON REGOLARE

SAFETY VALVE:

DO NOT ADJUST

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4 TECHNICAL SPECIFICATIONS

Description Art. 0457

Length (mm) 800

Width (mm) 350

Height (mm) 160

Handle height (mm) 950

Minimum lift (mm) 70

Maximum lift (mm) 500

Weight (kg) 41

Loading capacity (kg) 2000

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5 IMPROPER USE AND CONTRAINDICATIONS

The following actions described, which obviously can not cover the entire range of potentialpossibilities of "misuse" of the machine, are to be considered strictly prohibited.

THE FOLLOW ARE STRICTLY PROHIBITED!:

To lift persons and/or animals that could fall;

To lift loads while there are people near the machine;

To work under loads only lifted by the jack without using additional safety supports,such as a tripod.

To lift loads heavier than the maximum rating indicated on the plate;

To lift vehicles without applying the brakes to the wheels correctly;

To lift unbalanced loads, or change their static configuration, and/or their centre ofgravity;

To lift "dangerous" loads (molten metals, acids, radioactive materials, fragile and/orbrittle loads);

To load the jack on uneven polished surfaces and/or surfaces that are not strongenough to support the load (jack + maximum rated load capacity);

To use the jack when there is a possibility of the load moving accidentally;

To leave the loaded jack unattended;

To allow untrained staff to use the jack;

To operate the jack if you are not psycho-physically fit;

To operate the jack without due attention;

To operate the jack for purposes other than those for which it was designed;

To use the jack in unforeseen environmental conditions (adverse weather conditions,refrigerators, high magnetic fields, etc.);

To use the jack in potentially explosive environments;

Use the jack in the event of insufficient light;

To use the jack on ships at sea;

To put the jack in contact with foodstuffs.fer

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6 TRANSPORTING, LIFTING AND MOVING

The presence of the wheels, allows the jack to be transported manually in safety and comfort.

When lifting, the operation must be carried out by two people holding the jack on oppositesides. It is recommended, in this regard, to remove the lever for operating the pump beforelifting the jack.

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7 COMMISSIONING

7.1 Unpacking instructionsThe Jack is supplied in a cardboard box, with the lifting lever disassembled.Before disposing of the shipping carton, check you do not to throw away parts of themachine, the owner's manual or other documentation.

Standard packaging

Under no circumstances should the adjustment of the maximum pressure safety valve becarried out by the operator.Never tamper with the safety valve, if you are not authorised to do so!

7.2 Assembling the lifting leverTo assemble the lifting lever for the jack, proceed as follows:

1. Insert the lever into the hydraulic pumpcoupling on the jack, making sure toinsert the long end of the lever to the left.

2. Tighten the screw with a wing nutconnecting the coupling to the lever. Itmust be possible to rotate the lever insidethe housing.

Figure 7 - Installation of the jack lever.

Correctly mount the lever

Do not use the trolley jack until the lifting lever has been mounted properly, as described inthis paragraph.

7.3 Mounting the upper handleTo assemble the upper handle of the jack, proceed as follows:

Insert the handle into the upper part of the lever.

Use the bolt supplied with the jack to secure the handle. Insert the screw in the frontpart of the lever and attach the nut at the back. Tighten the screw using an Allenwrench.

Figure 8 - Installation of the jack handle.

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8 MACHINE OPERATION

Lifting loads

There is a risk of crushing body parts while lifting heavy loads resulting from mishandling.

Workers must be equipped with standard safety equipment, especially gloves and crushresistant safety shoes.

Lifting loads

Workers performing the lifting of loads must guide the device carefully, without abruptmovements and using the utmost care.

In particular, the jack and load must be kept under constant control during movement.

Working under loads

Working under a lifted load ALWAYS entails a residual risk of the load falling accidentally.

In this regard, IT IS STRICTLY FORBIDDEN to operate under a load lifted only by the jack.Always insert a safety support (of suitable capacity) under the load before operating below it(for example a tripod).

Periods of inactivity

After a period of inactivity, before operating the jack, pump with the jack unloaded at least 6times to ensure complete distribution of the hydraulic oil.

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8.1 Lifting the load1. Place the Jack under the load in a suitable position for lifting. In the event the load is a

vehicle, it is recommended that the operator refers to the user manual. The jack isequipped with wheels for easy positioning at the point of lifting the load.

Lifting a load

Always position the load in the central part of the load-bearing saddle, as shown in Figure 9.Use the foot pedal only when approaching the load to be lifted. Then, use the lever that allowsgreater force to be applied to the load.

Figure 9 - Positioning the load.

2. Pump the lifting lever back and forth until the desired height is reached or use the footpump to lift the load

8.2 Lowering a load

1. Lift and rotate the lifting lever clockwise toopen the lowering valve (or check valve).Visually check that the pin is moving properlywithin its housing in the coupling.

Figure 10 - Lowering of the load.

Slow and controlled lowering of the load

Turn the lift lever slowly to control the lowering of the load.

2. When the lifting arm is fully lowered, remove the Jack.

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9 MAINTENANCE

The purpose of this chapter is to provide all the information on maintenance procedures andfrequency required for the Trolley Jack.

Maintenance and repairs must be performed by qualified personnel.

9.1 Routine maintenance

INTERVENTIONFrequency

Daily Weekly Monthly

1. General visual inspection X

2. Checking nameplate readability X

3. Check for the absence of leaks X

4. General cleaning X

5. Lubrication and greasing X

6. Check the oil level and top up X

7. Bleed air from the circuit If necessary

1. General visual inspection: check the general condition of the machine, if there areany damaged or missing parts.

2. Check the readability of nameplates: plates and pictograms on the machine mustbe perfectly legible, it is therefore necessary to keep them clean and requestreplacements if they are illegible.

3. Verify the absence of leaks in the hydraulic circuit: there can be no measurableaccidental loss in the hydraulic circuit, except for slight moisture insufficient to form adrop.

4. General cleaning: cleaning is necessary to free the structure and moving parts fromthe accumulation of dust, dirt and stains caused by excess lubricants. Cleaning shouldbe done with the use of means, equipment and detergents or solvents commonly usedin the cleaning of industrial equipment.

5. Lubrication and greasing: it is necessary to lubricate the moving parts of the jack,namely:

the pins, hinges and levers of the pumping system; the wheel axle pins.

6. Check the oil level and top up: check the oil level and if necessary top up withhydraulic mineral oil for lifting devices.

Fully lower the pump and the lifting arm. Place the jack in a vertical position with the front wheel fixed upwards. Unscrew the oil cap. Add hydraulic mineral oil. Fill up to the bottom edge of the opening. Bleed the air in accordance with the instructions given in paragraph 7. Screw on the hydraulic oil cap.

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Type of hydraulic oil

When you top up the hydraulic oil only use the oil type recommended by the manufacturer.Do not use brake fluid or engine oil.

7. Bleed air from the hydraulic circuit: To remove any air bubbles in the hydraulicsystem of the jack, which could reduce its efficiency, follow these instructions:

Pump several times unloaded and performseveral complete lifting cycles to removethe air from the circuit.

Bleed the air by moving the oil fill cap onthe pump body.

Figure 11 – Bleeding the air

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10 REPLACEMENT PARTS

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Part No. Description PartNo.

Description

0457/01 1 Saddle casing 0457/24 2 Elastic washer 8

0457/02 1 Load-bearing saddle 0457/25 1 Pin

0457/03 1 Lifting arm 0457/26 1 Pump housing

0457/04 1 Lever with handle 0457/27 4 Elastic washer 14

0457/05 1 Cotter pin 4 x 50 0457/28 2 Screw M12 x 25

0457/06 1 Rotation pin 0457/29 1 Screw M6 x 20

0457/07 2 O-Ring 0457/30 1 Washer 10

0457/08 2 Return spring 0457/31 1 Valve

0457/09 2 Nut M18 0457/32 1 Valve opening plate

0457/10 2 Spring lock washer 0457/33 1 Washer 6

0457/11 2 Washer 0457/34 1 Elastic washer 6

0457/12 2 Plain bearing 0457/35 1 Nut M6

0457/13 2 Front wheel 0457/36 2 Locking pivot

0457/14 1 Front wheels shaft 0457/37 2 Nut M12

0457/15 1 Support shaft 0457/38 2 Washer 12

0457/16 1 Right plate 0457/39 1 M8 wing nut

0457/17 1 Left plate 0457/40 2 Washer 16

0457/18 2 Washer 20 0457/41 2 Nut M16

0457/19 2 Nut M20 0457/42 1 Lever coupling shaft

0457/20 2 Washer 14 0457/43 2 Rear wheel

0457/21 2 Nut M14 0457/44 1 Lever coupling

0457/22 1 Tools support 0457/45 1 Lever coupling screw

0457/23 2 Screw M8 x 16fervi.

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11 TROUBLESHOOTING

The following table shows the type of defect / problem, possible causes, and possibleremedies for the malfunction.

The table is a useful aid for the maintenance technician when looking for problems with themachine.

Fault Cause Solution

The jack does not lift theload.

The check valve is notproperly closed.

Close the check valve.

The jack lowers whenpressure is applied.

The check valve is notproperly closed.

Close the check valve.

The lifting lever fails to raiseunder the weight of the load.

The valves are not closedproperly, or there is a

foreign body in the valves.

Clean the valves.

Lower the piston rod of thejack, close the check valve,

raise the jack's piston rod withyour hands and then open the

check valve and lower thepiston rod quickly.

The pump is weak. Low oil level. Add hydraulic oil.

The oil leaks from the tank. Tank overflow. Remove the excess oil.

The jack does not lift to themaximum height.

Air bubbles in the hydrauliccircuit.

Purge air in the hydrauliccircuit.

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12 WAREHOUSE STORAGE

If the machine has to be stored and preserved for a period of time, to avoid damage and / ordeterioration proceed as follows:

Keep the lifting arm lowered and the coupling for the lever;

Keep the vent valve slightly unscrewed;

Lubricate all parts of the jack;

Store the jack indoors in a dry location.

13 DECOMMISSIONING

If the jack is to be scrapped, its parts must be disposed of separately.

Respect the environment!

Contact a specialist centre for the collection of metallic materials.

The structure of the jack is made from steel while some seals are made from polymericmaterial.

The pump and the tank contain hydraulic oil.

In this regard, divide the materials according to their nature, employing specialist companieswhich are authorised for their disposal, in accordance with the requirements of law.

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operation and maintenance manual fervi of the machine hydraulic trolley jack art. 0457 and create a...

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