Brano Z321 Guía de instalación

BRANO a.s, 747 41 Hradec nad Moravicí

Czech Republic

tel.:+420 / 553 632 303

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

[email protected]; [email protected]

SAFETY PRINCIPLES, OPERATION AND MAINTENANCE

MANUAL

FOR

HYDRAULIC CYLINDER

type Z321

lifting capacity 25t; 50t; 100t and 200t

Read this manual carefully before using this product. The manual contains important

safety, installation, operation and maintenance instruction. Make this manual

available to all responsible persons.

Keep for further use!

Edition 3rd

MARCH

2017

Evidence number 1-52238-0-1

CONTENT

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

INTENDED

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

SAFETY

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

3.1 SAFETY SUMMARY ....................................................................................................... 4

3.2. SAFETY PRINCIPLES .................................................................................................... 4

3.2.1 Before use........................................................................................................................ 4

3.2.2 While operation............................................................................................................... 5

3.2.3 After use .......................................................................................................................... 5

3.2.4 Risk analysis.................................................................................................................... 5

3.2.5 Maintenance .................................................................................................................... 5

PACKING,

STORAGE

AND

MANIPULATION .................................................................. 5

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

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

4.3 MANIPULATION ............................................................................................................. 6

MAIN

TECHNICAL

PARAMETERS.................................................................................... 6

OPERATION

CYLINDER ............................................................................................... 7

Cylinder is supplied without the oil charge.............................................................................. 7

6.1 KONTROLA PŘED INSTALACÍ..................................................................................... 7

6.1.1 Support face..................................................................................................................... 7

6.2 CONNECTION OF CYLINDER WITH PUMP ............................................................... 7

6.3 POSITION OF CYLINDER DURING LIFTING OR LOWERING ................................ 8

6.4 LIFTING A LOAD ............................................................................................................ 8

6.5 LOWERING A LOAD....................................................................................................... 8

6.6 TEST BEFORE THE USE................................................................................................. 8

OPERATION .......................................................................................................................... 9

7.1 USE OF THE CYLINDER ................................................................................................ 9

7.2 SAFETY WORKING ENVIRONMENT .......................................................................... 9

INSPECTION

CYLINDER............................................................................................... 9

8.1 INSPECTION..................................................................................................................... 9

8.1.1 Inspection classifications................................................................................................. 9

8.1.2 Daily inspection............................................................................................................. 10

8.1.3 Regular inspection......................................................................................................... 10

8.1.4 Occasionally used hydraulic cylinder ........................................................................... 10

8.1.5 Inspection record........................................................................................................... 10

8.2 INSPECTION PROCEDURE.......................................................................................... 10

TROUBLSHOOTING........................................................................................................... 11

MAINTENANCE................................................................................................................ 11

10.1 SAFETY PRINCIPLES ................................................................................................. 11

10.2 GENERAL INSTRUCTION.......................................................................................... 12

10.3 EXCHANGE OF PISTON CUP (DISMANTLING OF PISTON) - fig. 10.3............... 12

10.4 CHECK .......................................................................................................................... 12

10.5 REPAIR.......................................................................................................................... 13

10.6 TEST .............................................................................................................................. 13

REMOVING

FROM

OPERATION

–

LIQUIDATION ...................................................... 13

DOCUMENTATION....................................................................................... 13

FINAL

REQUIREMENTS

THE

MANUFACTURER

CUSTOMER................. 13

1 DEFINITION

! DANGER

Danger: indicates the presence of a hazard, which will cause

death or severe injury if the warning is ignored.

! WARNING

Warning: indicates the presence of a hazard, which can cause

death or severe injury if the warning is ignored.

! CAUTION

Caution: indicates the presence of a hazard, which can cause

minor injury if the warning is ignored. Caution can also indicate

dangerous practices.

Lifting capacity (Q): indicates maximum mass of load (working load limit) the cylinder

is designed to support in general service under conditions given by this manual.

2 INTENDED PURPOSE

2.1 Hydraulic cylinder type Z321, lifting capacity 25t; 50t; 100t and 200t (further only

cylinder) is designed solely for lifting and lowering free loads of big weight in vertical

direction by the help of manual pump at normal atmospheric condition on a workplace.

Weight of load during lifting must not exceed nominal lifting capacity.

2.2 Design of the cylinder meets requirements given by Directive of European

Parliament and Council 2006/42/EC as amended by the Czech technical regulation –

Government regulation no. 176/2008 Collection of law as amended and requirements

of harmonized Czech technical standards ČSN EN ISO 12100 and ČSN EN 1494+A1.

2.3

Výrobek svým provedením vyhovuje požadavkům stanoveným Směrnicí

Evropského parlamentu a Rady 2014/34/EU ve znění českého technického předpisu –

nařízení vlády č. 116/2016 Sb. v platném znění. Výrobek je proveden jako zařízení

IM2c dle ČSN EN 13463-1:2009 a ČSN EN 13463-5:2012. Splňuje podmínky pro

použití v důlním prostředí „nebezpečné atmosférické podmínky 2“

dle ČSN EN 1127-2.

2.4Výrobek svým provedením vyhovuje požadavkům stanoveným Směrnicí

Evropského parlamentu a Rady 2014/34/EU ve znění českého technického předpisu –

nařízení vlády č. 116/2016 Sb. v platném znění. Výrobek je proveden jako zařízení

II2GDcT85°C dle ČSN EN 13463-1:2009 a ČSN EN 13463-5:2012. Splňuje

podmínky pro použití v prostředí „zóna 1 a zóna 21“, “zóna 2 a zóna 22“

dle ČSN EN 1127-1.

Note: Articles 2.3 and 2.4 are valid for type of construction of hydraulic cylinder for

explosive environment.

3 SAFETY PRINCIPLES

3.1

SAFETY

SUMMARY

Danger exists particularly when the cylinder is not used properly or is poorly

maintained. Since an accident or serious injury could result, special safety precautions

apply to the operation with the hydraulic cylinder during its use, maintenance and

inspection.

! WARNING

NEVER work under lifted load or close to it.

NEVER lift more than lifting capacity shown on cylinder.

ALWAYS make sure the ground is firm enough to support safely fully loaded cylinder

and all lifting operation.

ALWAYS keep sufficient spacing from the load.

ALWAYS let people around to know when lift is about to begin.

ALWAYS read the operation manual and safety instructions.

Remember proper rigging and lifting techniques are the responsibility of the operator.

eck all applicable national directions, regulations and standards for further

information about the safe use of your hydraulic cylinder.

3.2.

SAFETY

PRINCIPLES

! WARNING

3.2.1 Before use

ALWAYS ensure physically strong, qualified and instructed persons elder 18 years of

age, knowing this manual and trained in safety conditions and way of work

operate the cylinder.

ALWAYS check the cylinder every day, prior starting the work according to the article

8.2.(1) „Daily inspection“.

ALWAYS make sure the lift is sufficient for intended operation.

ALWAYS ensure load against unwanted motion.

ALWAYS make sure the cylinder stands on firm ground.

ALWAYS make sure the cylinder stands vertically.

ALWAYS use recommended pumps and connection houses only.

NEVER use damaged or worn cylinder.

NEVER use cylinder without visible marking of the lifting capacity on it.

NEVER use a cylinder marked by the label „OUT OF SERVICE“.

ALWAYS consult use of the cylinder in non-standard or extreme conditions with

manufacturer or the authorised representative.

3.2.2 While operation

ALWAYS make sure the load is properly placed on a cylinder.

ALWAYS pay attention not to exceed maximum height of lift marked by the red

groove on a piston.

ALWAYS after lifting a load ensure the piston of the cylinder by the nut.

ALWAYS underlay load, if you intend to work on it.

ALWAYS pay a special attention to a cylinder, if piston is released to maximum

position

(marked by the red groove on a piston).

NEVER use cylinder for permanent underlying of loads.

NEVER allow the load, causes impacts or vibrations.

3.2.3 After use

NEVER leave lifted load without attendance and without ensuring the piston against

self downturn by the nut.

3.2.4 Risk analysis

The analysis of possible risk in turn of design, operation and environment of the

hydraulic cylinder application is mentioned in freestanding document “Risk analysis”.

This document can be required in service centres.

3.2.5 Maintenance

ALWAYS let qualified personnel inspect the cylinder regularly.

Only such interventions can be done when maintaining that are in compliance with

requirements of the manufacturer specified in the chapter 13 of this manual.

It is not allowed to provide repairs and maintenance in a different way then specified

by the manufacturer. It is especially prohibition of use of no original parts or providing

changes of product without the agreement of manufacturer.

4 PACKING, STORAGE AND MANIPULATION

4.1

PACKING

4.1.1 Cylinders are supplied assembled with hydraulic liquid, free loaded 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) Certificates of Quality and Completeness and Guarantee Card

c1) Guarantee period is stated in the Guarantee Card.

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

instructions stated in this Operation Manual and defects occurred owing to

improper use and unskilled intervention.

c3) The guarantee does not apply also to any modifications on the product

without a written approval of the manufacturer.

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

of commercial code eventually as amended.

4.2

STORAGE

Store jacks in dry and clean stocks free of chemical influences and vapors.

(1) Remove from jack all dust, water and impurities.

(2) Push piston into the initial (lowered) position.

(3) Store the cylinder so as the piston was in vertical position.

(4) During further use follow instructions of the article 8.1.4 „Occasionally used jack“.

4.3

MANIPULATION

Follow the valid technical regulation and standards and standards for work with heavy

loads.

The hydraulic jack is not portable by women and persons under 18 years of age.

5 MAIN TECHNICAL PARAMETERS

Type

Lifting

capacity

(t)

Lift

(mm)

Operating

pressure

(MPa)

Swept

volume

( l )

Range of

working

temperatu

Connecting

screw

(mm)

Weight

(kg)

Z321

25 145

0,56 -10°C

+50°C

M18 x 1,5

50 145 1,4 40

100 145 2,23 87

200 145 4,55 190

5.1 DATA ON PRODUCT

Every product is fitted with a label with specified data as follows:

Standard design: Design for explosive environment:

Manufacture’s identification Manufacture’s identification

Address of the manufacturer Address of the manufacturer

Type of product Type of product

Pressure Pressure

Serial number Serial number

Year of production Year of production

CE marking CE marking

Symbol of protection type (IM2c for group I , II2GDcT85°C for

group II)

5.2. MATERIAL AND DESIGN

5.1.1 All parts are made of steel.

5.1.2. There are no materials inclinable to spark ignition used in construction of the

cylinder by course of amendment no. 2 article 1.3.1 of Government regulation

no. 116/2016 Collection of law and harmonized technical standards ČSN EN

1127-2 article 6.4.4, ČSN EN 1127-1 article 6.4.4 and ČSN EN 13 463-1 article

8.1.

5.1.3. Materials with dangerous effects of static electricity in terms of 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 cylinder.

5.1.4 Plastics (high pressure hoses, pressure liquids) used in operation of cylinder in

explosive environment according to the article 2.3 and 2.4 of this manual must

meet ČSN EN 1127-2 article 6.4.7, ČSN EN 1127 – 1article 6.4.7, ČSN EN

13463-1 article 7.4.3, ČSN 33 20 30 and for use in mining environment § 185

paragraph (1) Czech mining office no. 22/89 Collection of law as amended.

6 OPERATION OF CYLINDER

Before installation carefully check the cylinder, whether is not damaged.

Cylinder is supplied without the oil charge.

6.1

CHECKING

BEFORE

THE

INSTALLATION

6.1.1 Support face

! WARNING

ALWAYS make sure the support face is firm enough to support assumed load for the

whole time of manipulation. Installation must not be carried out on the surface

we cannot check the loading capacity or is unstable

ALWAYS the user is responsible for positioning the cylinder!

NEVER allow the weight of the load or total piston thrust exceeds nominal lifting

capacity.

6.2

CONNECTION

CYLINDER

WITH

PUMP

Cylinders are determined for use in connection with manual hydraulic pump type

HP03L, HP05L or HP07L. Pump association depends on swept volume of cylinder.

Recommended association of pump to cylinder describes the following tablet:

Capacity

cylinder

(t)

Number of connecting

cylinders (pcs)

Association of pump -

type

Swept

volume (l)

25 1 HP 03L 0,56

2 HP 05L

50 1 HP 03L 1,4

2 HP 05L, HP 07L

100 1 HP 03L 2,23

2 HP 05L, HP 07L

200 1 HP 05L, HP 07L 4,55

Cylinders are connected with pump by the help of high pressure hoses of type 4SP

DKOS/DKOS about inner diameter 6mm. Hoses are supplied as the separate product

in basic length 2m or in other length to 6m according to wish of the customer. Hoses is

fitted on both ends with screw M18 x 1,5mm.

! CAUTION

During use of long hoses connection between pump and hydraulic cylinder is

necessary ALWAYS judge individually, whether amount of oil in houses do not limit

use of hydraulic cylinder lift.

Note: 10m of hose of inner diameter 6mm represent cca 0,3l oil.

6.3 POSITION OF CYLINDER DURING LIFTING OR LOWERING

During lifting or lowering of load the bottom of cylinder shall sit on firm a large enough

so as to avoid sinking of the cylinder. Pay attention the cylinder stand vertically. Axes

of piston can be diverted at max. about 3°.

! WARNING

ALWAYS make sure the jack stands vertically during lifting.

6.4 LIFTING A LOAD

Before lifting a load make sure the piston

nut is not screwed up to prevent its full

insertion into the cylinder. Piston shall be in

its initial (lower) position.

Lifting is provided by the oscillatory motion

of the hand lever of the pump. Instructions

for operating the pump are stated in

separate manual that is delivered to each

pump. After finishing the lifting ensure

piston against self-dropping by the nut - see

fig. 6.5.

! WARNING

ALWAYS before lifting make sure, the piston matrix does not prevent its full insertion

into the cylinder.

ALWAYS pay attention during lifting so as not exceed maximum height of lift.

NEVER lift piston of cylinder over red marked groove, which is under screw

of piston!!

ALWAYS ensure the piston by the matrix after termination of lifting.

6.5

LOWERING

LOAD

Before lowering a piston, at first slightly lift up the piston by several pendulum motions

of the hand lever and then unscrew the piston matrix to its top position.

Lowering the piston and speed of lowering control by releasing the screw of the drain

valve thanks to slide on hand lever. Before lowering the piston in dusty environment

we recommend to clean up the surface of the piston.

6.6 TEST BEFORE THE USE

! CAUTION

(1) Visually check the cylinder and support area, whether they are without defects.

(2) At first, look again at the previous articles of this manual and make sure that all

steps were done correctly and cylinder is correctly connected with appropriate

pump.

(3) By the move of pump lever check the function of the cylinder without a load.

(4) Provide several lifting and lowering with a suitable load (10% up to 50% capacity).

(5) At the same time check the cylinder and pump, whether at interruption keep load

without a drop of piston.

(6) Check, whether there is no outflow of oil due to the leakage.

Fig. 6.5

7 OPERATION

7.1 USE OF THE CYLINDER

Cylinder is intended for vertical lifting and lowering of heavy loads under normal

condition on workplace. It is operated by the help of separately delivered pump and

connecting hoses. Can be used by organisations as well as the private persons.

As work with heavy loads can pose unexpected danger, it is necessary to follow all

“Safety principles” according to the chapter 3.

7.2 SAFETY WORKING ENVIRONMENT

! WARNING

(1) The operating staff of the hydraulic cylinder must be demonstrably familiarized with

this operation manual, must observe applicable safety and hygienic regulations

and must be qualified for operation of this equipment.

(2) The operating staff should be equipped with protective footwear and gloves for

work with the jack.

(3) When operating by more persons ALWAYS there must be determined one worker

trained with safety of work responsible for manipulation with the cylinder.

(4) The operating staff must have a clear and unobstructed view of the whole working

area before starting the work. When it is not possible, one or more persons must

help to supervise in the nearby area of the hydraulic cylinder.

(5) The operating staff must check, whether the entire work place is safe and whether

there is as possibility of escaping from this area in case of endanger, before

starting to operate the cylinder.

(6) During the work with the cylinder the suitable distance of the operating staff from

the load must be kept. It is prohibited to lift or lower bulky loads preventing to keep

sufficient safety distance.

8 INSPECTION OF CYLINDER

8.1

INSPECTION

8.1.1 Inspection classifications

(1) Initial inspection: precedes first use. All new or repaired hydraulic cylinders shall be

inspected by a responsible qualified person to ensure the qualified fulfillment of

requirements of this operation manual.

(2) Inspection procedures of hydraulic cylinders operated regularly are generally

divided into two classifications based on the intervals at which should be performed.

The intervals depend on the condition of the critical components of the hydraulic

cylinders and the degree of the wear and tear, deterioration or malfunction. The two

general classifications are herein classed as daily and regular ones. The respective

intervals are defined as follows:

(a) Daily inspection: visual inspection, carried by the operator, designated by the

user on the beginning of each use.

(b) Regular inspection: visual inspection carried out by the qualified person

designated by the user.

1) normal operation – once per year,

2) heavy operation – twice per year

3) special or infrequent operation – according to the recommendation of the qualified

person at first usage and according to the directions of the qualified person (workers of

maintenance).

8.1.2 Daily inspection

Regarding parts such as those recommended in the section 8.2(1) „Daily inspection“

verify, whether the girder clamp is without any defect. Provide this inspection also

during operation in the interval between regular inspections. Qualified employees will

determine whether any defect or damage can constitute a hazard and whether more

detailed inspection is necessary.

8.1.3 Regular inspection

Complete inspections of the hydraulic jack perform as recommended regular

inspections. These inspections may be performed with the hydraulic jack in its normal

location. Recommended regular inspection specified in the section 8.2(2) shall be

performed under the supervision of qualified persons that will determine, whether it is

necessary to repair the girder clamp. These inspections shall include the requirements

of the daily inspection as well.

8.1.4 Occasionally used hydraulic cylinder

(1) Hydraulic cylinder, which has been idle for a period of one month or longer but less

than one year, remit to the inspection conforming to the requirements of the section

8.1.2 before follow-up putting it into operation.

(2) The hydraulic cylinder, which has been idle for a period of one year, remit to the

inspection conforming to the requirements of the section 8.1.3 before follow-up putting

it into operation.

8.1.5 Inspection record

Always keep the record of the performed tests, repairs, inspections and maintenance

of the girder clamp. Dated inspection records perform in time intervals specified in the

section 8.1.1 (2) (b) and such records store in an accessible place designated by the

user.

Defects discovered by the inspection or reported during work must be announced to

person responsible for safety designated by the user.

8.2 INSPECTION PROCEDURE

(1) Daily inspection (carried out by the operation start or a qualified person)

PART INSPECTION

METHOD

LIMIT/CRITERIA

FOR DISCARDING

REMEDY

1. Function of the

cylinder

2. Check of piston

matrix.

3. Connection with a

pump.

By testing.

By screwing.

Visually.

Slow or no movement

of piston during

lifting.

Matrix cannot be

screwed up.

Oil leakage in the

place of thread.

Exchange of piston

cup.

----------

Note: This defect can be

caused by the failure of

the pump – see manual

for pump.

Clean the tread of

matrix and piston and

lubricate.

Tighten nut of hose or

repair.

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