Instruction Sheet TJ Series Pow'r Claw Track Jacks TJ105A, TJ105AX, TJ109S, TJ109B, TJ109LS S54703 Rev. A 08/08 TJ105A TJ105AX TJ109S TJ109LS TJ109B Warning! Use of jacks to move heavy loads involves risk of serious injury unless jacks are properly used and maintained by properly qualified, trained and supervised personnel. In no event should jack be operated by anyone who has not read, or is not strictly complying with, the operating and safety procedures and precautions contained in this manual. (Additional copies of this manual are available upon request.) 1
IMPORTANT - READ CAREFULLY This manual contains important information for the correct installation, operation and maintenance of this equipment. All persons involved in the installation, operation and maintenance of this equipment must be thoroughly familiar with the contents of this manual. To safeguard against the possibility of personal injury or property damage, follow the recommendations and instructions of this manual. Keep this manual for reference. WARRANTY STATEMENT Enerpac rail products are warranted to be free of defects in materials and workmanship under normal use for as long as the original purchaser owns them, subject to the guidelines and limitations listed. This warranty does not cover: normal wear & tear, cosmetic items, abuse, overloading, alterations, improper fluid, or use in a manner for which they are not intended. If the customer believes a product is defective, the product must be delivered, or shipped freight prepaid, to the nearest Enerpac Rail Authorized Service Center for evaluation and repair. RECEIVING INSTRUCTIONS Important! Make sure to inspect all of the components for shipping damage. If damage is found, notify carrier at once. Shipping damage will not be covered by warranty. The carrier is responsible for all loss associated to shipping damage. SAFETY Make sure to read the instructions, warnings and precautions carefully. Follow any recommended safety precautions to avoid personal injury or damage to the unit. Enerpac cannot be responsible for any damage or injury from unsafe use, lack of maintenance or incorrect operation. In the event any questions or concerns may arise, contact Enerpac or a local Distributor for clarification. Read all instructions, warnings, and cautions carefully. Follow all safety precautions to avoid personal injury or property damage during system operation. Enerpac cannot be responsible for damage or injury resulting from unsafe product use, lack of maintenance or incorrect product and/or system operation. Contact Enerpac when in doubt as to the safety precautions and operations. If you have never been trained on highpressure hydraulic safety, consult your distributor for a free Enerpac Hydraulic safety course. Failure to comply with the following cautions and warnings could cause equipment damage and personal injury. CAUTION is used to indicate correct operating or maintenance procedures and practices to prevent damage to, or destruction of equipment or other property. WARNING indicates a potential danger that requires correct procedures or practices to avoid personal injury. DANGER is only used when your action or lack of action may cause serious injury or even death. 2
JACKING SAFELY You must know the weight of what you intend to lift and choose a jack with at least 20% more capacity. Never place any part of your body under any load at any time. Jacks are meant for lifting only and should not be used to support the load for any period of time. You should obtain and be familiar with the American National Standards Institute rules that apply to hydraulic jacks (ASME ANSI B30.1). Make sure to read the instructions, warnings and precautions carefully. Follow any recommended safety precautions to avoid personal injury or damage to the unit. Enerpac cannot be responsible for any damage or injury from unsafe use, lack of maintenance or incorrect operation. In the event any questions or concerns arise, contact ENERPAC or a local Distributor for clarification. If you have never been trained on high-pressure hydraulic safety, consult your distributor or service center for a free Enerpac Hydraulic Safety Course. Failure to comply with the following cautions and warnings could cause equipment damage, property damage or personal injury: WARNING: Escaping oil under pressure can penetrate the skin, causing serious injury. If oil is injected under the skin, see a doctor immediately. WARNING: Wear proper personal protective gear when operating hydraulic equipment. WARNING: This jack is for lifting only!! Support the load after completing the lift by other appropriate means. Never get under a load supported by the jack. Never exceed the rated capacity of the jack. Allow at least ten percent margin of safety. WARNING: Use jack only on solid surface compatible of supporting the load and base of the jack. Always center the load on the lifting toe of the jack. If the jack is not perpendicular to the load slipping or loss of load is possible. WARNING: Use only ENERPAC hydraulic oil, or approved equivalent. Failure to heed thee warning may cause loss of load or failure of the jack resulting in property damage or personal injury CAUTION: ENERPAC CAN NOT BE RESPONSIBLE for damage or injury from unsafe use application, or maintenance of this product. READ and follow all warnings, cautions, and instructions associated with this product. Do not remove warning labels, tags, or decals. CAUTION: Fully retract the jack and protect the entire unit from external damage. Keep jack clean and store in a clean dry area. INSPECT ALL SYSTEM COMPONENTS BEFORE USE. CAUTION: Keep hydraulic equipment away from flames and heat. Excessive heat will soften packing and seals, resulting in fluid leaks. For optimum performance do not expose equipment to temperatures of 65ºC (170ºF) or higher. 3
Note: The Track Jack is shipped fully assembled, complete with oil and level bar, and is ready to use. 1.1 Before Putting A New Jack In Service: Fully extend and retract the jack without a load. This will assure that the jack is primed and oil levels are correct. 1.2 To Raise The Jack: Close the release knob by turning it clockwise until it is hand tight. Note: Over-tightening of the release knob can damage the valve seat, reducing the jack life. Never use pliers, or pipe wrenches, or tighten excessively - hand tightening is sufficient. Pump the lever socket by hand until the jack advances to, and engages with the load. At this point, the lever socket will become difficult or impossible to pump by hand. Insert the lever bar and continue pumping until you have reached the desired amount of lift. Then, remove the lever bar from the socket. Note: The jack will advance using only the lever socket under a no load or very light load condition. The lever bar provides the additional leverage for lifting heavier loads. FIGURE 1 TJ105A TJ105AX TJ109S TJ109LS TJ109B 4
1.3 To Lower The Jack: Make sure all personnel are clear, and then open the release screw knob by turning it counterclockwise. Never open the release screw knob more than two full turns. The lowering speed can be controlled with the release screw knob by opening the release knob slightly. Note: Full retraction speed is reached when the release knob is opened two full turns. Do not open the release screw knob more than two full turns. The jack can also be lowered in small increments by simply re-closing the release knob at any time during the jack's descent. 1.4 Horizontal Application The jack is fully functional when used in a horizontal position as long as the handle socket is facing upward, however the stroke will be limited to 4.5" (TJ105 models) or 9" (TJ109 models). The oil reservoir is not vented and should not leak regardless of the jack's position. 2.1 Care & Storage The Track Jack requires minimal protection from rain, dust, mud or other potential contaminant's as long as the reservoir fill plug is kept closed and tight. After using the jack in any particularly dirty application where excess dirt, mud or grime has built up on the jack, it is recommended the jack be wiped down prior to storage. The jack should be stored in a clean, dry area and should always be stored fully retracted. 2.2 Hydraulic Oil Models TJ105A and TJ105AX hold approximately 25 cu. in. of oil. Models TJ109S, TJ1019B and TJ109LS hold approximately 50 cu. in. of oil. The oil should be changed approximately once a year. ENERPAC HF hydraulic oil (Model No. LX-101-1 gallon container) is highly recommended. WARNING: Do not use brake fluid or other non-approved substitute oil. Lighter weight oils may be used when ambient temperatures are below 32 F. 2.3 Adding Oil (when needed) A jack that is low on oil will lift a full load but will not extend to its full lift height (4.5" on TJ105 models, 9" on TJ109 models). As the reservoir runs dry, the lever socket becomes very easy to pump and the jack stops advancing. To add oil, first fully retract the jack and remove the fill plug. With the jack in its normal vertical position, fill the reservoir until the oil level is even with the fill hole and replace fill plug. Note: It is important that the oil level is no more or less than even with fill hole. 2.4 Changing The Oil (approximately once a year) To drain the oil, thoroughly clean the area around the fill plug. Be sure the jack is fully retracted and remove the fill plug. Lay the jack on its back side and allow the oil to drain into an appropriate receptacle through the fill plug hole. Take extra care to make sure no dirt or other contaminant's enter the reservoir while the fill hole is open. While the reservoir is empty, take the time to inspect the reservoir for contamination. If you find dirt or grime in the reservoir or if the drain oil appears dirty or feels gritty, simply flush the reservoir out with a clean flushing solvent before refilling. (Be sure to dispose of used oil in accordance to E.P.A. regulations.) Refill the reservoir using the recommended oil. With jack fully retracted and in its normal position, fill the reservoir until the oil level is even with the fill hole and reinstall fill plug. It is important that the oil level be accurate. Be sure the oil level is even with fill hole. WARNING: Do not fill the reservoir unless the jack is fully retracted. Before returning the jack to service, fully extend the jack without a load by pumping the lever socket by hand (no lever bar). If the oil is accurate, the lever socket will become impossible to pump by hand when the jack reaches its full extension. 2.5 Inspect the jack for leaks, cracks, or other damage Immediately take out of service any jack that appears to be damaged or leaking. Contact Enerpac (see contact information on last page of this document) for the name of the Enerpac Rail Authorized Service Center in your area. Have the jack serviced only at an Enerpac Rail Authorized Service Center. 5
2.6 Troubleshooting Problem Possible Cause-Solution Jack will not raise. screw is not closed. Turn clockwise until hand tight. screw not seating properly. Flush and clean release screw seat and replace check ball. Ball check in pump piston housing. Remove pump piston assembly. Flush and clean check ball seats and replace check ball. Seal failure. Have jack serviced by Enerpac Rail Authorized Service Center. Jack raises, but will not hold the load. screw not seating properly. Flush and clean release screw seat and replace check ball. Seal failure. Have jack serviced by Enerpac Rail Authorized Service Center. Jack raises, but only halfway. Jack is low on oil. Add oil as specified in Section 2.3. Jack leaks oil. Jack retracts slowly. Seal failure. Have jack serviced by Enerpac Rail Authorized Service Center. Air in hydraulic system. Remove fill plug to check oil level. Completely raise and lower jack. Re-install plug when complete. Enerpac Worldwide Locations e-mail: info@enerpac.com internet: www.enerpac.com Africa China Germany, Austria Middle East, Turkey and Spain and Portugal ENERPAC Middle East FZE Actuant China Ltd. and Switzerland Caspian Sea ENERPAC Office 423, JAFZA 15 1F, 269 Fute N. Road ENERPAC GmbH ENERPAC Middle East FZE Avda. Los Frailes, 40 Nave C & D P.O. Box 18004 Waigaoqiao Free Trade Zone P.O. Box 300113 Office 423, JAFZA 15 Pol. Ind. Los Frailesanzo De Arriba Jebel Ali, Dubai Pudong New District D-40401 Düsseldorf P.O. Box 18004 (Madrid) Spain United Arab Emirates Shanghai, 200 131 China Willstätterstrasse13 Jebel Ali, Dubai Tel: +34 91 661 11 25 Tel: +971 (0)4 8872686 Tel: +86 21 5866 9099 D-40549 Düsseldorf United Arab Emirates Fax: +34 91 661 47 89 Fax: +971 (0)4 8872687 Fax: +86 21 5866 7156 Germany Tel: +971 (0)4 8872686 Tel: +49 211 471 490 Fax: +971 (0)4 8872687 Fax: +49 211 471 49 28 Australia, New Zealand Actuant Australia Ltd. Block V Unit 3 Regents Park Estate 391 Park Road Regents Park NSW 2143 (P.O. Box 261) Australia Tel: +61 297 438 988 Fax: +61 297 438 648 Brazil Power Packer do Brasil Ltda. Rua dos Inocentes, 587 04764-050 - Sao Paulo (SP) Tel: +55 11 5687 2211 Fax: +55 11 5686 5583 Toll Free in Brazil: Tel: 0800 891 5770 vendasbrasil@enerpac.com Canada Actuant Canada Corporation 6615 Ordan Drive, Unit 14-15 Mississauga, Ontario L5T 1X2 Tel: +1 905 564 5749 Fax: +1 905 564 0305 Toll Free: Tel: +1 800 268 4987 Fax: +1 800 461 2456 Technical Inquiries: techservices@enerpac.com Actuant China Ltd. (Beijing) 709B Diyang Building Xin No. 2 Dong San Huan North Rd. Beijing City 100028 China Tel: +86 10 845 36166 Fax: +86 10 845 36220 Central and Eastern Europe, Greece ENERPAC GmbH P.O. Box 300113 D-40401 Düsseldorf Willstätterstrasse13 D-40549 Düsseldorf Germany Tel: +49 211 471 490 Fax: +49 211 471 49 28 France, Switzerland francophone ENERPAC, Une division de ACTUANT France S.A. ZA de Courtaboeuf 32, avenue de la Baltique 91140 VILLEBON /YVETTE France Tel: +33 1 60 13 68 68 Fax: +33 1 69 20 37 50 India ENERPAC Hydraulics (India) Pvt. Ltd. Office No. 9,10 & 11, Plot No. 56, Monarch Plaza, Sector 11, C.B.D. Belapur Navi Mumbai 400614, India Tel: +91 22 2756 6090 Tel: +91 22 2756 6091 Fax: +91 22 2756 6095 Italy ENERPAC S.p.A. Via Canova 4 20094 Corsico (Milano) Tel: +39 02 4861 111 Fax: +39 02 4860 1288 Japan Applied Power Japan Ltd. Besshochou 85-7 Saitama-shi, Kita-ku, Saitama 331-0821 Japan Tel: +81 48 662 4911 Fax: +81 48 662 4955 All Enerpac products are guaranteed against defects in workmanship and materials for as long as you own them. For your nearest authorized Enerpac Service Center, visit us at www.enerpac.com Russia and CIS (excl. Caspian Sea Countries) Actuant LLC Admiral Makarov Street 8 125212 Moscow, Russia Tel: +7-495-9809091 Fax: +7-495-9809092 Singapore Actuant Asia Pte. Ltd. 37C, Benoi Road Pioneer Lot, Singapore 627796 Tel: +65 68 63 0611 Fax: +65 64 84 5669 Toll Free: +1800 363 7722 Technical Inquiries: techsupport@enerpac.com.sg South Korea Actuant Korea Ltd. 3Ba 717, Shihwa Industrial Complex Jungwang-Dong, Shihung-Shi, Kyunggi-Do Republic of Korea 429-450 Tel: +82 31 434 4506 Fax: +82 31 434 4507 The Netherlands, Belgium, Luxembourg, Sweden, Denmark, Norway, Finland and Baltic States ENERPAC B.V. Galvanistraat 115, 6716 AE Ede P.O. Box 8097, 6710 AB Ede The Netherlands Tel: +31 318 535 911 Fax: +31 318 525 613 +31 318 535 848 Technical Inquiries Europe: techsupport.europe@enerpac.com United Kingdom, Ireland Enerpac Ltd Bentley Road South Darlaston, West Midlands WS10 8LQ, United Kingdom Tel: +44 (0)121 50 50 787 Fax: +44 (0)121 50 50 799 USA, Latin America and Caribbean ENERPAC P.O. Box 3241 6100 N. Baker Road Milwaukee, WI 53209 USA Tel: +1 262 781 6600 Fax: +1 262 783 9562 User inquiries: +1 800 433 2766 Inquiries/orders: +1 800 558 0530 Technical Inquiries: techservices@enerpac.com 02/08/08