Brano 15-00-CM Manuel utilisateur

BRANO a.s., 747 41 Hradec nad Moravicí

Česká republika

tel.: +420/ 553 632 303

http://www.brano-zz.cz; http://www.brano.eu;

[email protected]; [email protected]

OPERATION MANUAL

SECURITY PRINCIPLES, OPERATION AND MAINTENANCE

FOR

RACK JACK

WITH A RATCHET CRANK-LEVER

type 15-00-CM / 5t, 15-01-CM / 10t

Peruse the operation manual before using the jack. It comprehends substantial

security instructions and instructions for use, installation and maintenance of the

product. Ensure the Operation Manual to be available for all responsible persons.

Keep for next usage!

Edition 5th

APRIL

2018

Registration number

7012

CONTENT

DEFINITION...........................................................................................................................3

DEVICE

PURPOSE..............................................................................................................3

SECURITY

PRINCIPLES ....................................................................................................4

3.1 SECURITY PRINCIPLES OVERVIEW ............................................................................ 4

3.2. SECURITY PRINCIPLES ............................................................................................... 4

3.2.1 Prior to use ................................................................................................................... 4

3.2.2 When in use ................................................................................................................. 5

3.2.3 Risk analysis ................................................................................................................ 5

3.2.4 Maintenance................................................................................................................. 5

PACKING,

STORAGE

AND

HANDLING...........................................................................5

4.1 PACKING ........................................................................................................................ 5

4.2 STORAGE....................................................................................................................... 6

4.3 HANDLING...................................................................................................................... 6

MAIN

TECHNICAL

SPECIFICATIONS .............................................................................6

5.1 MECHANICAL DEVICE................................................................................................... 7

5.2. MATERIAL AND FINISH ................................................................................................ 7

5.3 DATA ON THE PRODUCT.............................................................................................. 8

JACK

OPERATION...............................................................................................................8

6.1 JACK OPERATION INSTRUCTIONS.............................................................................. 8

6.2 RAISING OR LOWERING ............................................................................................... 9

6.3 RATCHET CRANK-LEVER ............................................................................................ 9

6.4 BEARING SURFACE CHECK-UP................................................................................. 10

6.5 TEST PRIOR TO USE................................................................................................... 10

OPERATION........................................................................................................................10

7.1 APPLICATION OF THE JACK....................................................................................... 10

7.2 SAFETY WORK ENVIRONMENT ................................................................................. 11

CHECK-UP

THE

JACK ...............................................................................................12

8.1 INSPECTION ................................................................................................................ 12

8.1.1 Inspections types........................................................................................................ 12

8.1.2 Daily inspection .......................................................................................................... 12

8.1.3 Regular inspection...................................................................................................... 12

8.1.4 Jack occasionally used ............................................................................................... 12

8.1.5 Report on inspection................................................................................................... 12

8.2 INSPECTION PROCEDURE......................................................................................... 13

TROUBLE-SHOOTING......................................................................................................14

GREASING........................................................................................................................14

10.1 GENERALLY............................................................................................................... 14

10.2 JACK MECHANISM .................................................................................................... 14

MAINTENANCE................................................................................................................15

11.1 SECURITY PRINCIPLES ............................................................................................ 15

11.2 REPLACEMENT OF BRAKE INSERTS AND BRAKE ADJUSTING ............................ 15

11.2.1 Brake disassembly (fig. 6)......................................................................................... 15

11.2.2 Brake assembly and adjusting (figures 6 and 7) ....................................................... 16

11.3 GENERAL INSTRUCTIONS........................................................................................ 16

11.4 CHECK UP.................................................................................................................. 16

11.5 REPAIR....................................................................................................................... 16

11.6 TEST ........................................................................................................................... 16

PUTTING

OUT

OPERATION

–

LIQUIDATION......................................................16

DOCUMENTATION ......................................................................................17

FINAL

REQUIREMENTS

THE

PRODUCER

THE

CUSTOMER ..................17

EC DECLARATION OF CONFORMITY................................................................................. 18

1 DEFINITION

! HAZARD

Hazard: it adverts to an imminent hazardous situation, which will inflict death or

serious injury, if the operation personnel will not avoid it.

! WARNING

Warning: it adverts to a possible hazardous situation, which could inflict death

or serious injury, if the operation personnel will not avoid it.

! NOTICE

Notice: it adverts to a possible hazardous situation, which could inflict any

minor or slight injury, if the operation personnel will not avoid it. The notice can

warn against hazardous practices as well.

Load capacity (Q): is the maximum permitted weight (working load limit) of a load on the jack

head, by which the jack is possible to be loaded when handling on conditions specified in this

Operation Manual.

Competent person: is the person determined by the equipment user

2 DEVICE PURPOSE

2.1 The rack jack of type 15-00-CM / 5t, 15-01-CM / 10t with modification for ISO container

(hereinafter referred to as jack) is designed entirely for manual raising, lowering and pushing

of free loads in the workplace. The load weight when raising does not have to exceed specified

permitted load capacity.

2.2 The jack by its design meets requirements provided by Directive 2006/42/EC

of the European Parliament and of the Council as amended by the Czech technical regulation –

ministerial order No. 176/2008 of the Collection of Laws as amended as well as requirements

of the ČSN EN ISO 12100 and ČSN EN 1494 harmonized technical standards.

2.3 The jack by its design meets requirements specified for the group I of devices (mine)

category M2 according to the Directive 2014/34/EU of the European Parliament and of the

Council as amended by the Czech technical regulation – ministerial order No. 116/2016 of the

Collection of Laws as amended as well as requirements of the ČSN EN 13463-1 harmonized

technical standard and complies with the conditions for use in „hazardous atmospheric

conditions 2“ environment according to the ČSN EN 1127-2 standard with the limitation

according to the national regulation – CBM (Czech Bureau of Mine) regulation No. 22/89

of Collection of Law § 232 section (1) c) up to 1,5% of mine gas accumulation.

2.4 The jack by its design meets requirements specified for the group II of devices (non-

mine) category 2 and 3 according to the Directive 2014/34/EU of the European Parliament and

of the Council as amended by the Czech technical regulation – ministerial order No. 116/2016

of the Collection of Laws as amended as well as requirements of the ČSN EN 13463-1

harmonized technical standard and complies with the conditions for use in „zone 1 and zone

21“, „zone 2 and zone 22“ environments according to the ČSN EN 1127-1 standard.

Note: 2.3 and 2.4 articles apply for jack designed for use in the environment with explosion

hazard.

3 SECURITY PRINCIPLES

3.1

SECURITY

PRINCIPLES

OVERVIEW

A hazard exists when handling loads especially in the event that the jack is not use in the right

way or is badly maintained. Whereas as a result an accident or severe injury could happen, it is

necessary to observe the special security measures when handling, assembling, maintaining

and checking the jack.

! WARNING

ALWAYS ensure the load against drop (i.e. by a stand or jack block), if you are going

to work under it.

NEVER burden the jack more than is the load capacity indicated on the jack.

NEVER jack up persons.

ALWAYS warn persons in surroundings before starting work.

ALWAYS read the operational manual and security instructions.

ALWAYS ensure the movement of load raising in one direction i.e. vertical when

manipulating with ISO containers.

ALWAYS set up the jack vertically when manipulating with ISO containers.

Bear in mind that the operation staff is responsible for faultless technique of raising loads.

nce verify all national directives, regulations and standards whether they contain other

information on safety work with your jack.

3.2.

SECURITY

PRINCIPLES

! WARNING

3.2.1 Prior to use

ALWAYS ensure the jack would be operated by physically fit, qualified and instructed

persons older than 18 years, demonstrably familiarized with the operation manual

and trained in security of work and mode of operation. The user keeps

demonstrably the registration of training persons.

ALWAYS check up the jack every day before starting work according to section 8.2. (1)

„Daily inspection“.

ALWAYS make sure that the lift is adequate for intended work.

ALWAYS respect the jack is on firm foundation.

NEVER jack up loads well set or of unknown weight.

NEVER push with the jack without knowledge of expansion forces.

NEVER use the defective or outworn jack.

NEVER use the jack without visible load capacity marking on the jack.

NEVER use the jack marked with the label „OUT OF OPERATION“.

ALWAYS consult the producer or his authorized representative any application of the jack

in nonstandard or extreme environment.

3.2.2 When in use

ALWAYS attend to the jack would stay vertically when jacking up.

ALWAYS make sure the load is fitly put on the jack.

ALWAYS pay increased attention, if the jack is drawn up to maximum position.

ALWAYS work with the jack only with manpower.

ALWAYS when jacking up loads with a weight oncoming safe working load of the hoist we

recommend the operation would be ensured by two persons owing to magnitude

of actuating forces.

NEVER use the jack for anchoring of loads.

NEVER allow the load would give rise to impacts or vibrations.

3.2.3 Risk analysis

The possible risks analysis in light of design, operation and environment of the jack appointment

is presented in freestanding document „Risk analysis“. It is possible to require the document

in service centers.

3.2.4 Maintenance

ALWAYS make possible to competent persons to carry out the regular inspection of the jack

(see chapter 8).

ALWAYS ensure slipping parts would be sufficiently greased.

At maintenance only such interventions can be done that will be in accordance with producer’s

requirements stated in the chapter 11 of this OM.

IT IS NOT PERMITTED to carry out repairs and maintenance in other manner than specified

by the producer. It concerns namely the forbiddance of using of unoriginal spare parts

or carrying out changes on the product without the approval of the producer.

4 PACKING, STORAGE AND HANDLING

4.1

PACKING

4.1.1 Jacks are supplied in assembled state in bulk in transport cases.

4.1.2 The following accompanying documentation is a part of the delivery:

a) Operation Manual

b) EC Declaration of Conformity

c) Quality and Completeness Certificates and Guarantee Certificate.

c1) Guarantee period is stated in the Guarantee Certificate.

c2) The guarantee does not apply to defects caused by infringement of the instructions

stated in the Operation Manual and defects arisen by improper using and unskilled

action.

c3) The guarantee does not apply as well to changes on the product or using

of unoriginal spare parts without the approval of the producer.

c4) Reclaiming of product defects is carried out according to applicable provisions

of commercial code eventually as amended.

d) List of service centers.

4.2

STORAGE

Store jacks in dry and clean stores void of chemical impacts and noxious fumes.

(1) Wipe away all dust, water and impurities from the jack.

(2) Grease the rack of the jack.

(3) Put the jack in a dry place.

(4) In next using follow instructions in the article 8.1.4 „Jack occasionally used“.

(5) Keep the temperature from -33°C till +70°C when storage.

Note: The product does not require any special storage position.

4.3

HANDLING

During transportation and handling, observe technical regulations and standards in force

for work with heavy loads.

5 MAIN TECHNICAL SPECIFICATIONS

Type

Load

capacity

(t)

Actuating

force on

crank-

lever

(N)

Main dimensions (mm)

Weight

(kg)

Q a b b

q h

min

r Z

15-00-CM 5 612 / 352

202

225

222

39 68 734 270

350 23

15-01-CM 10 540 / 324

263

256

222

39 68 747 300

350 39

Working temperature range

-30°to +55°

Main dimensions

r + 200

min

Position lever

Position crank

Overloading safety

Position transport

Fig.3

Producer label

Pawls

5.1

MECHANICAL

DEVICE

Safety and working life of the jack is guaranteed if it works in accordance with specified

classification.

The jack is designed for class 1Bm according to the FEM 9.511 regulation – see table 5.1. (it

corresponds to mechanism classification M3 according to the ISO 4301/1).

Average daily operating time is specified in the load diagram.

Tab. 5.1 MECHANICAL CLASSIFICATION

Load diagram

(load distribution)

Definition Load coefficient Average daily

operating time (h)

(light)

Jacks usually being subject

to the low load and only in

special cases to the

maximum load.

k≤0,50 1 - 2

(mean)

Jacks usually being subject

to the low load, but quite

often to the maximum load.

0,50< k ≤0,63 0,5 - 1

(heavy)

Jacks usually being subject

to the mean load, but

frequently to the maximum

load.

0,63< k ≤0,80 0,25 – 0,5

(very heavy)

Jacks usually being subject

to the maximum load or load

approximating to the

maximum.

0,80< k ≤1,00 0,12 – 0,25

Load diagram Load diagram Load diagram Load diagram

1 2 3 4

Percentage of operating time

5.2.

MATERIAL

AND

FINISH

5.2.1 All parts of the jack are manufactured from steel and cast iron, the brake liners from

hardened woven fabric.

5.2.2. Materials susceptible to a creation of an incentive spar within the meaning of the Annex

No.2 Article 1.3.1 to the ministerial order No. 116/2016 of the Collection of Law and the

ČSN EN 1127-2 article 6.4.4 and ČSN EN 13463-1 article 8.1 harmonized technical

standards are not used.

5.2.3. Materials with dangerous effects of static electricity within the meaning of the ČSN EN

1127-2 article 6.4.7, ČSN EN 1127-1 article 6.4.7, ČSN EN 13463-1 article 7.4.3 and

ČSN 33 2030 are not used in the jack.

5.2.4 The jack does not exceed the noise value specified in the Annex No.2 article 1.7.4 letter f

of the ministerial order No. 176/2008 of the Collection of Law

(EP and RE directive No. 2006/42/EC).

Note: Articles 5.2.2 and 5.2.3 apply for jack finish to environment with explosion risk.

5.3

DATA

THE

PRODUCT

Each product is equipped with the label with specified data as follows:

Standard finish:

Finish to environ

ment with explosion risk:

Mark of the producer

Address of the producer

Product type

Load capacity

Serial number

Production year

CE marking

E marking

Protection type symbol (IM2c for group I, II2GDcT85°C

for group II)

6 JACK OPERATION

! WARNING

ALWAYS before installation check up thoroughly whether the jack is not damaged (see

chapter 8.1.2).

ALWAYS before using check up thoroughly the jack (see chapter 6.5.).

ALWAYS safeguard the jack against drop at pushing or spreading out of loads (i.e. in

horizontal direction). A drop can take place when shifting the load and thereby unloading and

releasing the jack. Every such handling is necessary to be appreciated individually in terms of

safety.

NEVER the load weight or resultant pushing force on the head must not exceed the safe

working load of the jack.

6.1

JACK

OPERATION

INSTRUCTIONS

The jack is operated by the crank. Raising or lowering the load can be cut off in any lifting

height. A lowering brake and pawl system with forced mesh in the jack crank safeguard the

stability of the load position.

! NOTICE

At actuating force greater than 400N (it means when handling with the jack at the safe

load limit) the jack must be operated by 2 persons at least.

6.2 RAISING OR LOWERING

Before raising hitch up the changeover lever and set on the mark of raising – up-arrow (see

fig. 4). Carry out the raising by oscillating (eventually rotation) motion of the ratchet crank.

At the beginning of the raising before the loading of the rack jack will take place, hold

the knurled nut so that it would not be carried away by the crank at its backwards motion.

Before lowering the load, shift the changeover lever to the position on the lowering mark – down

arrow (see fig. 4). Lower down the load by oscillating (eventually rotation) motion of the ratchet

crank.

Make sure at each change of the position of the changeover lever, whether the lever gets fitly

to the socket in the ratchet crank.

First motion of the ratchet crank after reversing (after shifting of the changeover lever) is slightly

blocked. This state arises by an influence of stronger follow-through of the brake namely

at manipulation with heavier loads. In this case release the brake by more point-blank motion,

thereby you will coincidently release the ratchet crank.

6.3 RATCHET CRANK-LEVER

When raising or lowering loads the manipulation with the ratchet crank-lever is done

by the same way as it is stated in the chapter 6.2.

The ratchet crank is changed to an extended lever by folding the crank-lever handle by 90

(into

the lever position - see fig. 3). We use this position for decreasing the control force during

the manipulation with loads that are close to the nominal lifting capacity of the lifter.

The ratchet crank-lever is equipped with a safety shear pin against overloading (see fig. 3).

If the shear pin is sheared during the manipulation with a load, it is still possible to lower

the load even if the shear pin is sheared (after moving the reverse lever to the lowering

position).

! WARNING

NEVER extend the lever’s arm with a pipe or by any other method. The lever might get

damaged.

Lowering position

Lifting

position

Neutral position

Fig.4

Changeover lever

6.4 BEARING SURFACE CHECK-UP /floor, rough ground/

! NOTICE

ALWAYS make sure that the bearing surface is sufficiently firm to hold tightly supposed

loading for all time of handling. The installation must not be carried out

on the surface where it is not possible to determine the load-bearing capacity or

that is instable.

ALWAYS the operation personnel are responsible for the set-up!

6.5 TEST PRIOR TO USE

! NOTICE

(1) At first read again the previous articles of this manual and make sure that all steps were

correctly done and all parts are safety mounted.

(2) Visually check the jack and bearing surface whether they are without defects.

(3) Put to proof the jack function by the motion of the crank without loading.

(4) Carry out several jacking up and lowering with the suitable load (10% till 50% of the load

capacity). At the same time verify, whether the jack will hold firmly the load without slipping

when lowering and stopping.

7 OPERATION

7.1 APPLICATION OF THE JACK

7.1.1 The jack is multifunctional equipment with modification for ISO container destined for

manual jacking up, lowering, pushing and spreading of subjects in the workplace

determined by the user. It can be used not only in a current environment, but also

in environments with explosion risk in the event that there is the symbol of the protection

type marked on the label – see articles 2.3, 2.4 and 5.3 of this OM.

Application in horizontal position

All jacks of load capacity 5t and 10t have an opening in the foot which simplifies work when

pushing apart objects above head height. The lifter’s foot can be easily attached in the required

position by using a screw for example, without the need to use a helper (fig. 5).

Fastening by the help of the opening in foot

Fig. 5

Ce manuel convient aux modèles suivants

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