Brano 15-00-CON-W Manuel utilisateur

translation of the original instructions for use (also applies to special designs)

BRANO a.s., 747 41 Hradec nad Moravicí

the Czech Republic

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

Type

15-00

load capacity

2,5t

and

Type

15-01

load capacity

10t

CONTAINER WALL-MOUNTED CONSTRUCTION – CON-W

CONTAINER DESIGN – CON

these versions are further available in variants:

DESIGN WITH RATCHET CRANK – RK

DESIGN WITH RATCHET HANDLE-LEVER – RKP

DESIGNED IN EXPLOSIVE ENVIRONMENTS – NEXP

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 is available for all responsible persons.

Keep for next usage!

Edition 4

JANUARY

2021

Registration number 1

55830

CONTENTS

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 ................................................................................................... 4

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

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

PACKING,

STORAGE

AND

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

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

4.2 STORAGE ........................................................................................................ 5

4.3 HANDLING ....................................................................................................... 5

MAIN

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

5.1 MECHANICAL CLASSIFICATION .................................................................... 7

5.2. MATERIAL AND FINISH.................................................................................. 8

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

JACK

INSTAL

TION............................................................................................................9

6.1 ANCHORAGE TO A STRUCTURE................................................................... 9

6.2 TEST PRIOR TO USE .................................................................................... 10

OPERATION

AND

MAINTENANCE...................................................................................10

7.1 JACK APPLICATION ...................................................................................... 10

7.2 SAFETY WORK ENVIRONMENT................................................................... 10

JACK

CHECK....................................................................................................................11

8.1 INSPECTION .................................................................................................. 11

8.1.1 Inspections types ......................................................................................... 11

8.1.2 Daily inspection............................................................................................ 11

8.1.3 Regular inspection ....................................................................................... 11

8.1.4 Jack occasionally used ................................................................................ 11

8.1.5 Report on inspection .................................................................................... 11

8.2 INSPECTION PROCEDURE .......................................................................... 12

TROUBLE-SHOOTING .....................................................................................................13

GREASING .....................................................................................................................13

10.1 GENERAL..................................................................................................... 13

10.2 JACK MECHANISM ...................................................................................... 13

MAINTENANCE ..............................................................................................................14

11.1 SECURITY PRINCIPLES.............................................................................. 14

11.2 REPLACEMENT OF BRAKE INSERTS AND BRAKE ADJUSTING............. 14

11.2.1 Brake disassembly (fig. 4).......................................................................... 14

11.2.2 Brake assembly and adjusting (figures 4 and 5) ........................................ 15

11.3 BEARINGS ................................................................................................... 15

11.4 GENERAL INSTRUCTIONS ......................................................................... 15

11.5 CHECK UP ................................................................................................... 15

11.6 REPAIR......................................................................................................... 15

11.7 TEST............................................................................................................. 15

PUTTING

OUT

OPERATION

–

DISPOSAL................................................................15

DOCUMENTATION........................................................................................16

FINAL

REQUIREMENTS

THE

PRODUCER

THE

CUSTOMER............................16

1 DEFINITION

! HAZARD

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

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

! WARNING

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

inflict death or serious injury, if the operation personnel do not avoid it.

! NOTICE

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

any minor or slight injury, if the operation personnel do 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, the

jack can be loaded by when handling it on conditions specified in this Operation Manual.

2 DEVICE PURPOSE

2.1 Rack jack type 15-00 with a load capacity of 2.5 t and 5 t, type 15-01 with a load

capacity of 10 t in the container design - CON, wall container - CON-W in any

combination of designs (-RK, -RKP) and in the design for environments with a risk of

explosion -NEXP (hereinafter referred to as the product, or NEXP = structurally identical

product, differing in the surface protection of selected parts, the material of the marking

label and documentation) is destined entirely for anchorage to structures for the purpose

of manual raising and lowering of movable parts of structures (e.g. covers or container

roofs, waste gates of water basins, screens of sewage disposal plant etc.). The weight

of a movable part of a structure when handling does not have to exceed specified

permitted load capacity of the jack.

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+A1 harmonized technical

standards.

2.3 The product has been designed in compliance with the requirements stipulated by

Directive 2014/34/EU of the European Parliament and of the Council, as amended by

the Czech technical regulation – Government Directive No. 116/2016 Coll., as amended.

The product has been designed as IM2ExhIMb equipment pursuant to EN ISO

80079-36:2016 and EN ISO 80079-37:2016. It complies with the conditions stipulated

for use in mining environments classed as “hazardous atmospheric conditions 2”

pursuant to ČSN EN 1127-2.

2.4 The product has been designed in compliance with the requirements stipulated by

Directive 2014/34/EU of the European Parliament and of the Council, as amended by

the Czech technical regulation – Government Directive No. 116/2016 Coll., as amended.

The product has been designed as II2GExhIICT6Gb, II2DExhIIICT85°CDb

equipment pursuant to EN ISO 80079-36:2016 and EN ISO 80079-37:2016. It complies

with the conditions stipulated for use in environments classed as „zone 1 and zone 21“,

“zone 2 and zone 22“ pursuant to ČSN EN 1127-1.

Note: Articles 2.3 and 2.4 apply to NEXP product design.

3 SECURITY PRINCIPLES

3.1

SECURITY

PRINCIPLES

OVERVIEW

A hazard exists when handling movable parts of structures 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.

! VAROVÁNÍ

ALWAYS ensure the raised part of the structure against drop (e.g. by brace rod), if

you intend to work under it.

NEVER jack up persons.

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

ALWAYS warn persons in surroundings before starting work.

ALWAYS read the operation manual and security instructions.

Bear in mind that the oper

ation staff is responsible for faultless technique of raising.

Hence 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, familiarized with the operation

manual and trained in security of work and mode of operation.

ALWAYS check up the jack every day before starting work according to Section 8.2.

(1) „Daily inspection“.

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.

ALWAYS check that the product is grounded through the ground terminal when

working in an explosive atmosphere

ALWAYS wipe off any dust before handling the product in an explosive atmosphere

3.2.2 When in use

ALWAYS make sure the jack is properly mounted in equipment construction.

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

ALWAYS work with the jack only with manpower.

ALWAYS we recommend with respect to actuating forces the jack operation is

ensured by two persons when handling parts of structures the weight of

which approximate to safe working load of the hoister.

NEVER use the separate jack (not mounted in the structure for which it is destined)

to handling free loads

NEVER allow the lifted part of the structure would give rise to impacts or vibrations.

NEVER leave the loaded jack without supervision or other securing of a raised part

of the structure.

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.

ALWAYS ensure slipping parts (except the brake) are sufficiently greased.

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

producer’s requirements stated in the chapter 11 and 14 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“.

4.3

HANDLING

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

for work with heavy loads.

5 MAIN SPECIFICATIONS

Specifications

Type-design Load

capacity

(t)

Lift

(mm)

Actua-

ting

force

crank

(

Range of

opera-

ting

tempera-

ture

Weight

rack

L = 660

(kg)

Weight

rack

L = 970

(kg)

Weight

rack

L = 1200

(kg)

15-00-CON-W 2,5 345 - 850

380

-20

+50

12,8 15,2 17,0

CON

11,4

13,8

15,6

15-00-CON-W 5 360 – 850

550 22,1 25,6 28,5

CON

19,0

22,5

25,4

CON

10 345 – 825

540

15-01-CON 33 38 43

Dimensions

Type-design Load

capacity

A B C E d L

15-00-CON-W 2,5 320 80 250 180 13 660,

970, 1200

CON

150

15-00-CON-W 5 350 80 300 190 13 660,

970, 1200

CON

160

CON

490

300

660,

970, 1200

15-01-CON - - 195 -

Fig.1 Product design – CON-W

Fig.2 Product design – CON

5.1

MECHANICAL

CLASSIFICATION

Safety and working life of the jack is guaranteed providing that 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.

5.2.2. Materials inclinable to creation of an incendiary spark in terms of the annex

No. 2 article 1.3.1 to the ministerial order No. 116/2016 of the Coll. of Laws and

the ČSN EN 1127-2 article 6.4.4 ČSN EN 1127-1 article 6.4.4 and EN ISO 80079-

36 article 6.4.2.1 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, EN ISO 80079-36 article

6.7 and ČSN ČSN CLC/TR 60079-32-1 are not used in the chain block.

5.2.4 The jack does not exceed the noise values specified in the Annex No.1 article

1.7.4.2 letter u 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 3 apply to NEXP product design.

5.3

DATA

THE

PRODUCT

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

Standard finish:

NEXP produc

t de

sign

Mark of the producer

Address of the producer

Product type

Load capacity

Serial number

Production year

CE marking

Protection type symbol (IM2ExhIMb for group I, II2GExhIICT6Gb

and

II2

°C

for group II)

6 JACK INSTALLATION

! WARNING

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

NEWER the weight of the jacked up structure or resulting pushing (pulling) force on

the rack bar have to exceed the safe working load of the jack.

The NEXP product must be installed in such a way as to prevent creeping charges.

Charging mechanisms stronger than manual friction must be avoided at the installation site

A NEXP product when used in a mine or other environment where the product could

collide with falling, flying… objects (rock, stones…) must be protected to minimize the

likelihood of a collision (sufficiently dimensioned cover, …).

6.1

ANCHORAGE

STRUCTURE

6.1.1 Product design – CON-W:

Two grips on the coating with holes for screws M12 (2,5t load capacity) or M16

(5t ,10t load capacity) and holes at the ridge bar ends with ∅25 mm (2,5t load

capacity) or ∅30 mm (5t,10t load capacity) serve for mounting to a structure.

6.1.2 Product design – CON:

The manufacturer of the equipment, in which the jack will be used, specifies the

assembly method for the structure. The jack anchorage to the equipment as a

rule represents an intervention to the jack design (e.g. welding very grip,

mounting of other parts on the jack).

! NOTICE

Any guarantee does not apply to the jack modified according to Article 6.1.2,

unless the modification type is negotiated and approved by the manufacturer.

ALWAYS we recommend consulting a technical department of the jack manufacturer

the type of intended modification.

6.1.3 Installation of jack with respect to rack load.

When installing the – CON and – CON-W rack jacks it is essential to assure that

the load on the jack is in the right direction. The pressure (tension) load on the

rack must always act in the direction from the handle hub to the catches (see

diagram), and never the other way round.

– tensile load

– pressure load

6.1.4 Documentation:

Method of the container jack anchorage and eventual jack modifications are

necessary to be documented by drawing documentation and stress analysis.

The equipment manufacturer has to elaborate the operation manual to the

equipment, in which the jack is used.

! WARNING

The jack anchorage to a structure must be solved so that the ridge bar is not

stressed by bend. Loading only by simple pulling or pushing forces is permitted.

Maximum force on the jack must not exceed maximum load capacity of the jack.

6.2 TEST PRIOR TO USE

! NOTICE

(1) At first go over again the previous Articles of this Operation Manual and make sure

that all steps were well done and all parts are safely mounted.

(2) Inspect visually the jack and anchoring in the structure whether they are without any

defect.

(3) Test the function of the jack by crank motion.

(4) Jack up and consequently lower the movable part of the structure. At the same time

verify whether the jack holds the load without slipping when lowering and stopping.

7 OPERATION AND MAINTENANCE

7.1 JACK APPLICATION

7.1.1 The jack is a single purpose device destined entirely for anchorage to structures

with the purpose of manual jacking up and lowering of movable parts of structures.

It can be used not only in 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.

7.1.2 The jack is operated by a crank. Jacking up and lowering of a structure can be

interrupted in any lift height. A lowering brake and pawls system with forced mesh

in the crank ensure position stability.

7.1.3 By reason that the work with heavy loads can constitute unexpected hazard it is

necessary to follow all „Security principles“ according to Chapter 3 of this OM.

7.2 SAFETY WORK ENVIRONMENT

! WARNING

(1) The operating personnel must be demonstrably acquainted with this Operation

Manual; they must adhere to valid security and hygienic regulations and must be

qualified for operation of this equipment.

(2) When working with the jack the operation staff must be equipped with gloves and

appropriate footwear.

(3) When operating by more persons always one worker must be determined who is

trained in safety at work and is responsible for jack handling.

(4) Before starting the work, the operation staff must check up whether all work area is

safety and whether there is a possibility of eventual escape from the environment of

jeopardy.

(5) With a product load capacity of 2,5t and 5t, the cover with the product casing is not

sufficiently dimensioned in terms of "breakthrough", therefore any cover that could

cause a collision with gears must be repaired or replaced. If the product collides with

a falling, flying (object (rock slide…) that could sufficiently damage the covers, work

must be stopped immediately and the product inspected.

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