Toe Jack Instruction Manual
Contents
1. me i SSSSSSSSSSSA NS SS N Mg MG SSS DS SMSS T iv mm A 4 4 VA A 1 7 4 5 4 4 A Z 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Z 2 2 2 2 2 2 2 2 VA Z 4 V 7 4 4 4 277272227711 27 3 m 5 amp 10T HYDRAULIC JACKS PART LIST ITEM QTY 5T JACK 10T JACK DESCRIPTION 01 1 28502 28503 JACK BODY 02 1 28488 28543 COLUMN 03 1 25618 25642 SPRING RING 04 1 28487 28504 GUIDE 05 1 28481 28482 TOE 06 1 60659 60661 O RING 07 1 60160 60161 SEAL 08 1 28447 28447 PLUG 09 1 60652 60652 BS SEAL 10 1 26650 27920 DIAPHRAGM 12 1 60494 60494 EXPANDER PLUG 13 4 60300 60300 SCREW 14 1 32735 32735 LEVER 15 1 26656 26656 HAND TUBE 16 1 60174 60174 BETA PIN 17 1 28478 28478 LINK 18 2 28448 28448 SPINDLE 19 1 26668 26668 SPINDLE 20 3 60029 60029 WASHER 21 3 60046 60046 NUT 22 1 28508 28508 PUMP BARREL 23 1 28513 28513 SLEEVE 24 1 28511 28511 VALVE BODY 25 1 60654 60654 O RING 26 1 28477 28477 PISTON 27 1 60294 60294 SEAL 28 1 60582 60582 SEAL 29 2 60295 60295 SEAL 30 3 60164 60164 BALL 31 2 27047 27047 SPRING 32 2 25627 25627 STOP SCREW 33 2 28089 28089 PLUG 34 1 25631 25631 RELIEF VALVE 35 1 27592 27592 NOZZLE 36 1 60169 60169 BALL 32. the replacement or repair of defective parts We make no warranty with respect to trade accessories They are subject to the warranties of their manufacturers ANY IMPLIED OR STATUTORY WARRANTIES INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY We make no other express warranty nor is anyone authorized to make any on our behalf In compliance with 1975 Consumer Product Warranties Law HILMAN INCORPORATED 12 Timber Lane Marlboro New Jersey 07746 HILMAN SERVICE BULLETIN HTJ 25 TOE JACK NOTE Do not lift the jack unless the release valve is fully closed Lifting the jack with the release valve open will cause air to be sucked into the jack s hydraulic system causing faulty operation AIR PURGING PROCESS Use the following steps to bleed air from the jack in the event it has been accidentally lifted with the release valve open Close the release valve Pump the jack to full extension without a load Loosen the plug 1 1 16 socket on the head of the jack Allow air to bleed out until hydraulic oil starts to flow Re tighten the fill plug Check the jack for proper operation H HILMAN Toe Jack ROLLERS Inspection Certificate S WWW HILMANROLLERS COM Capacity Model Number Serial Number Manuf Date Inspected by Inspection Date Inspector s Signature Approval Stamp Models HTJ 5 HTJ 10 and HTJ 25 H
3. and to update all rules and regulations in force in these instructions with regard to all user countries concerned Consequently the user must obtain all relevant information and ensure that this information is given to operators and taken into account by them 1 GENERAL PRECAUTIONS This jack can only be used by skilled competent and trained operators This jack can only be used incompliance with the instructions given in this document Personal injury and damage to property may occur if the jack is not used in compliance with these instructions e The operator must check that the jack is in good general condition prior to using it Never use a jack on which the identification has been erased The manufacturer refuses all responsibilities for any consequences resulting from a change or a modification in the characteristics without his written approval as well as for any repair made by third parties other than himself or his accredited repair shops 2 DESCRIPTION 2 1 Identification Year models amp series no stamped on the pump board Capacity embossed on the tank 2 2 Description The package contains the jack control handle retaining pin amp these instructions Capacity Tons 5T 10T 25 T Lift mm 206 233 233 Loading height toe mm 25 25 58 Loading height head mm 368 413 470 Load on lever under full load 38 daN 40 daN 40 daN Weight 24 5 kg 34 5 kg 107 kg Lowing speed Adjustable A
4. separate lever 14 from piston 26 and link 17 6 3 2 Assembly Clean all parts except the seals and the diaphragm using a degreasing product e g trichlorethylene prior to reassembling the jack then carefully dry these parts Inspect all seals which may have been nicked during disassembly Column Assembly Install seals and O rings 6 and 7 on the lifting toe 5 Lubricate the bore in the toe 5 Install toe 5 on column 2 Screw guide 4 on column 2 after having carefully cleaned threading and put a drop of strong threadlock LOCTITE on one part Remove away surplus of threadlock Lubricate the machined outer surface of the toe 5 Fit the completed assembly inside the jack body 1 Install spring ring 3 which before installation is in the shape of a straight wire with rounded ends curve it slightly and fit it through the rounded part on the edge of the slot made in jack body Hit the other end with a hammer while maintaining it firmly with pliers sampe B Pump Assembly a Install seals 27 28 and beta pin 16 on sleeve 23 then lubricate the bore of the pump in which they are fitted Caution For the stage a use a standard grease and not a silicon grease b Fit the sleeve in the pump barrel using a small hydraulic press c Install the suction valve in the body of valve 24 in accordance with the order given ball 30 spring 31 and stop screw 32 C
5. 7 1 25633 25633 SHUTTER 38 1 25632 25632 SPRING 39 1 60602 60602 SCREW 40 1 60660 60660 O RING 41 1 60171 60171 SNAP RING 42 1 25635 25635 KNOB 43 1 60603 60603 SCREW 44 1 28517 28517 WASHER 45 1 60669 60669 SCREW 46 1 60668 60668 SEAL 47 1 60653 60653 SEALING WASHER 48 1 60651 60651 CHECK VALVE 50 1 60671 60671 SNAP RING 51 1 28573 28573 FILTER 15 Exploded View 25t Toe Jack Z Ves VANA K 9 28790 06 16 25 TON HYDRAULIC JACKS PART LIST ITEM QTY 25TJACK DESCRIPTION 42 1 25635 KNOB 43 1 60603 SCREW 44 1 28517 WASHER 45 1 60669 SCREW 46 1 60663 SEAL 48 1 60651 VALVE 50 1 60671 SNAP RING 51 1 28573 FILTER 55 1 60225 SNAP RING 56 2 60838 SCREW 58 2 28084 SMALL LINK 59 1 28085 SPINDLE 60 2 26649 RAIL WHEEL 61 2 28809 SHAFT 62 2 60226 SNAP RING 63 2 26648 WASHER 65 1 30111 NOZZLE 66 1 30112 FILTER SUPPORT 67 1 30609 PIPE ITEM QTY 25T JACK DESCRIPTION 01 1 28791 BODY 02 1 26638 COLUMN 1 28802 SPRING RING 04 1 28803 GUIDE 05 1 28789 TOE 06 1 60705 O RING 07 1 160666 SEAL 08 1 28447 PLUG 09 1 60652 BS SEAL 12 1 60494 EXPANDER PLUG 13 4 60300 SCREW 14 1 28480 LEVER 15 1 28814 HANDLI
6. HILMAN Toe Jack ROLLERS Instruction Manual WWW HILMANROLLERS COM Models HTJ 5 HTJ 10 and HTJ 25 C HILMAN 12 Timber Lane Marlboro NJ 0774 Rev 03 08 26 2013 ROL tel 732 462 6277 fax 732 462 6355 s WWW HILMANROLLERS COM email sales hilmanrollers com CONTENTS GENERAL PRECAUTIONS DESCRIPTION IDENTIFICATION DESCRIPTION STORAGE HANDLING TRANSPORT STORAGE HANDLING TRANSPORT ASSEMBLY USE FIELD OF USE OPERATION SAFETY PRECAUTIONS MAINTENANCE PREVENTIVE MALFUNCTION FAILURES DISASSEMBLY ASSEMBLY DISASSEMBLY ASSEMBLY MAINTENANCE LOG CHECKS STARTUP PERIODIC SCRAPPING DIAGRAMS PARTS LISTS DISCHARGE VALVE EXPLODED VIEW PUMP EXPLODED VIEW 5t AND 10t TOE JACKS EXPLODED VIEW 25t TOE JACK PARTS LIST LIMITED WARRANTY USER AND MAINTENANCE INSTRUCTIONS FOR HILMAN TOE JACKS A IMPORTANT This guide must be read and understood before using maintaining or repairing this jack The plant manager and the operators must take the following warnings seriously e These users and maintenance instructions concern any operator using maintaining and repairing a Hilman Toe Jack The plant manager must make sure that the operator is aware of all information given in the guide and ensure that this guide is always available when the jack is being used If the jack is sold used by other plant managers or operators then these instructions must be handed over It is an impossible task to list
7. ILMAN gt Timber Lane Marlboro NJ 07746 Rev 03 08 26 2013 ROL tel 732 462 6277 fax 732 462 6355 www HILMANROLLERS COM email sales hilmanrollers com
8. NG TUBE 16 1 60174 BETA PIN 17 1 28808 SMALL ROD 18 2 28448 SHAFT 19 1 26668 SHAFT 20 3 60029 WASHER 21 3 60046 NUT 22 1 28508 PUMP BARREL 23 1 28800 SLEEVE 24 1 28511 VALVE BODY 25 1 60654 O RING 26 1 28801 PISTON 27 1 60294 SEAL 28 1 60662 SEAL 29 2 60295 SEAL 30 3 60164 BALL 31 3 27047 SPRING 32 2 25627 STOP SCREW 33 2 30607 SHUTTLE 34 1 25631 RELIEF VALVE 35 1 27592 NOZZLE 36 1 60169 BALL 37 1 25633 SHUTTER 38 1 25632 SPRING 39 1 60602 SCREW 40 1 60660 O RING 41 1 60171 SNAP RING 17 LIMITED WARRANTY We warrant each new Hilman Toe Jack sold by us to be free from manufacturing defects in normal service for a period of one 1 year commencing with delivery of the Toe Jack to the original user Our obligation under this warranty is expressly limited at our option to the replacement or repair at Hilman Incorporated Marlboro New Jersey 07746 USA or at a service facility designated by us of such part or parts as inspection shall disclose to have been defective This warranty does not apply to defects caused by damage or unreasonable use including failure to provide reasonable and necessary maintenance while in the possession of the consumer WE SHALL NOT BE LIABLE FOR CONSEQUENTIAL DAMAGES OF ANY KIND including but not limited to consequential labor costs or transportation charges in connection with
9. S REMEDIES The hand tube is slack and Try without load to find Bleed as in paragraph 6 3 2 E the jack does not lift the load out if it is the same Otherwise Replace the diaphragm The hand tube rises after each The check valve leaks Retry after pumping several times time it is pumped under no load If this continues replace it The jack does not lift up nor The load is too high Check the weight of the load check hold the load whether it is stuck somewhere or hooked onto something The relief valve is not Tighten it by hand then retry fully tightened If the fault continues Replace the relief valve The hand tube is exceptionally The pump piston is Replace it hard to move twisted The valve is seized Replace it The hand tube is exceptionally Insufficient oil in the Adjust the quantity of oil refer to hard to move and the jack does diaphragm paragraph 6 3 2 E not lift normally 6 3 Disassembly Assembly These operations should only be carried out by skilled mechanics trained in the maintenance of hydraulic equipment using appropriate tooling 6 3 1 Disassembly Follow the instructions below in the given order to disassemble your unit fully A Jack draining a Lift the jack up and maintain the column 2 extended by putting a block between the base and the toe 5 b Remove plug 8 c Drain oil contained in the jack body 1 B Pump disassembly Remove spindle 19 Remove lever assembly 14 p
10. aution After the ball 30 has been fitted hit it with a hammer using a soft steel drift to peen its seat and provide good sealing d Tighten the valve body 24 to the pump barrel 22 after having installed O ring 25 and filter 51 using snap ring 50 e Fit check valve 48 in the pump barrel 22 Install the bleed valve in the pump barrel 22 in the following order spring 31 ball 30 then stop screw 32 g Fit seals 29 after having coated them with silicon grease Also coat the bore in the jack body in which the pump is mounted 9 10 Relief valve assembly a Assemble spring 38 shutter 37 ball 36 and nozzle 35 b Lubricate O ring 40 and fit it c Install relief valve 34 on the pump and fit snap ring 41 D Final Assembly of the jack 5 t and 10 t onl Position the jack vertically and hold the column in extended position Fit diaphragm 10 in the tank of body 1 Fill the diaphragm with 5 CL of oil Install pump assembly in its housing in the body During this operation make sure to not damage seals 29 A mallet is used for this assembly operation inserting a wooden shim on the top flat surface of the pump You can also buy a special tool for the assembly e Tighten screws 13 f Fill the jack body 1 through the top port until the oil flows out by the port of plug 8 g Tighten plug 8 on the related seal 9 h Fill the cavity of the piston wi
11. by hand Check that there are no visible signs of an oil leak Check that the barrel toe and base are not deformed or cracked Check that the pump operates normally when not loaded B Yearly The frequency of this check should be shortened if the jack is used very frequently e Check that all nuts screws and plugs are tightened Adjust if necessary e When the jack is not under load pump up to full travel distance until the release value operates No signs of leaks should be found signs of oil on the column or the piston is normal Release the pressure and inspect the column for signs of impacts scratches as well as straightness Replace the column if defective e Lower the jack by hand Check that there are no friction points slight vibrations are normal e Examine carefully all external parts of the jack Barrel deformation cracks impact marks Pump lever deformation excessive clearance in pins replace pins if an excessive clearance is found Toe deformation cracks Base deformation cracks e Inthe event of doubt especially regarding cracks do not hesitate in replacing or carrying out any pertinent inspection to check the part e All defective parts must be replaced and most of all not straightened out heated or welded e Part replacement must be in accordance with the instructions given under disassembly assembly paragraph 6 3 6 2 Malfunction Failures FINDINGS CAUSES TEST
12. djustable Adjustable Use temperatures 0 C 50 C 0 C 50 C 0 C 50 C Dimensions mm A 547 627 582 642 930 1115 B 371 451 371 451 640 825 131 134 D 200 196 330 E 115 120 226 F 55 55 90 G 206 233 233 H 25 25 58 90 90 90 J 93 93 160 K 130 170 270 L 368 574 413 646 470 703 Safety Devices In plant pre set limiter Control handle used to immediately stop lowering 3 HANDLING TRANSPORT STORAGE 3 1 Storage e Store jacks retracted in a dry place 3 2 Handling transport e Jacks should only be handled using the handle provided for this purpose Avoid carrying jacks using the jacking lever e Do not drop or throw jacks Impacting the outside of the control lever may deform the piston making the pump unusable e Before transporting jacks wedge them so as to stop them from hitting surrounding items e Make sure Pressure release knob is in Closed position to avoid air being drawn into hydraulic circuit 4 ASSEMBLY The only assembly operation required is to fit the hand tube on the pump lever then to insert the safety pin 5 USE 5 1 Field of use The jacks from Hilman Rollers are designed for handling objects lifting or moving loads from a sufficiently resistant and stationary location for examples concrete floor using the toe or the head of the jack The 5 and 10 Ton jacks can be used either vertically or horizontally The 25 Ton Jack can be u
13. erations so that it cannot slide or tip over block travelling plant and apply brakes Never use jacks to lift loads when personnel are standing on it Always set up the operation so that if an unforeseen failure occurs it does not cause injury to the operator or damage to the environment Never lift up a load with the end of the toe or cause this situation after the toe has been moved The toe must be fully fitted in place and the thrust point of the load must never be further away from the barrel than the place where the logo is embossed on the toe Do not under any circumstances tamper with the adjustment of the jack s internal relief valve screw Do not add additional load to a lifted load Keep clear of lifted loads When lifting by the toe wedge the head of the jack on the load to avoid bending the column Refer to sketch Never lift up a load on the edge of the head of the jack The load must always cover the top to contact the hatched area shown below Lifting a load with several jacks is always a difficult operation that has to be carefully prepared and supervised Pay special attention to the transfer of the load during lowering and lifting operations The total capacity of the jacks used must be appreciable greater than the load to be lifted 6 MAINTENANCE IMPORTANT NOTE Use only original HILMAN spare parts 6 1 Preventive A Before each use Check that all plugs and screws are tightened
14. iston 26 and link 17 from the pump Remove 4 screws 13 Separate the pump from the tank by rotating it 1 6 of a turn using two M 10 screws in the tapped holes of screw 13 Remove diaphragm 10 from the tank drain it and wipe it with a clean cloth only for 5t and 10t f Remove protector diaphragm cogo L Column disassembly a Remove spring ring 3 using a pair of pliers Scrap it b Remove the column 2 toe 5 and guide 4 assembly from complete column 2 c Heat guide 4 200_C which was fitted with glue before unscrewing it d Remove toe 5 O rings 6 and seals 7 D Pump disassembly a Remove valve body 24 b Remove suction valve located at the bottom of valve body 24 by unscrewing stop screw 32 Remove filter 51 located at the bottom of the valve body c Remove the bleed valve located on the top part of pump barrel 22 by consecutively unscrewing plug 33 and screw 32 d Remove check valve 48 if it has to be replaced e Remove handle 42 f Remove snap ring 41 before unscrewing the relief valve 34 g Extract sleeve 23 using a press h Remove seals 27 28 29 and 46 E Discharge valve disassembly WARNING This operation is not be carried out if you do not have the equipment required to calibrate the available jack Loosen nozzle 35 to access ball 36 shuttle 37 and spring 38 F Lever disassembly Remove spindles 18 to
15. lve has operated 5T 10T On toe 0 500 daN 5 000 daN 10 000 daN On head 1000 daN 7 000 daN 13 000 daN Calibration on the head is less significant as it depends on efficiency which varies from one jack to another IF THESE VALUES ARE NOT OBTAINED If they are lower the jack may be used knowing that it can lift up a smaller load If they are greater replace the discharge valve 6 4 Maintenance Log Reminder The user is bound to keep a maintenance log up to date Article R 233 12 in order to ensure operator safety 7 CHECKS STARTUP PERIODIC These checks are mandatory in all countries in EEC In France decree 93 41 Users dated 11 01 93 and law dated 9 06 93 set down the conditions Other texts laws or decrees passed or to be passed since the printing of these instructions will supersede the former mentioned 8 SCRAPPING When a jack becomes old or when damage occurred likely to be a source of risk the user MUST eliminate the equipment i e ensure that it cannot be used To this end refer to paragraph 6 3 e Drain the jack paragraph 6 3 1 A e Remove the relief valve paragraph 6 3 1 Df 11 DISCHARGE VALVE Plan No 28087 12 EXPLODED VIEW PUMP NG X y Iz TRY WS POLL OA f NI YY 0 ms 4 NU TM S Oi m OK HM Plan No 28086 13 EXPLODED VIEW 5t AND 10t TOE JACKS Ptan ion irra 1816 ILLA LY vj Sl Va
16. sed only vertically The body can be positioned in relation to the toe and the base so as to be able to lift objects in restricted areas The toe must always be located above the base so that it can fold into it when the jack is closed see sketch 5 2 Operation Lifting e Turn the release valve knob in a clockwise direction until it is snug i e Closed Position e Pump by moving the jacking in a up and down motion e Lifting stops as soon as the jacking lever is no longer moved Lowering e Slowly loosen the release valve knob by turning it in a counter clockwise direction i e Open Position The more the knob is loosened the faster the load will be lowered e Stopping is instantaneous when the knob is tightened Note When jack is not under a load it is necessary to press on its head to lower it CAUTION It is strictly forbidden to unscrew parts other than the control handle except during a maintenance operation 5 3 Safety precautions Lifting loads is dangerous operation The personnel must be skilled trained and experienced in this type of operation Never exceed the maximum recommended limit Make sure that load bearing points are resistant and stable ground load etc prior to carrying out any operation Only work on flat surfaces Always put a wedge between the floor and the load prepare it before starting the lifting operation Make sure that the load remains stable during all lifting op
17. th oil i Fit lever assembly grease the pins and open discharge valve 1 4 of turn j Lower the jack and purge it with the bleed valve ball in using a rod Continue until the bubble escape by the bleed port k Tighten plug 33 on related sealing washer 47 D Final Assembly of the jack 25 t onl Position the jack vertically and hold the column in extended position Fill the jack body through the top port Tighten plug 8 on related seal 9 by the hand Open the discharge valve Lower the jack Remove plug 8 and fill the jack with oil First of all remove filter Rep A Push the bleed located under the filter Rep A Continue until the bubbles escape by the bleed port Tighten plug 8 on related seal 9 Fill the cavity of the piston with oil Fit lever assembly grease the pins Lift the jack to the top if the lever becomes slack or does not lift normally restart to the stage a AT gt 07590200759 E Testing Carry out the checks described in paragraph 6 1 B after assembly Furthermore if the discharge valve was removed it would be necessary to check that the calibration of the valve did not change For this a load sensor compression will be fitted e As far as possible between the toe and a sufficiently strong enough item e Otherwise between the head and sufficiently strong enough item This sensor should indicate the following values when the jack is actuated and the discharge va
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