Brano 15-00 Bedienungsanleitung

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]; inf[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

and

16t

Type

Z23

load capacity

20t

DESIGN WITH RATCHET CRANK – RK

DESIGN WITH RATCHET HANDLE-LEVER – RKP

DESIGN WITH ADJUSTABLE SUPPORT – VK

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 to be available for all responsible persons.

Keep for next usage!

Edition 8

JANUARY

2021

Registration number 1

2182

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

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

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

PACKING,

STORAGE

AND

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

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

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

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

MAIN

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

5.1 MECHANICAL DEVICE................................................................................................... 8

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

5.3 DATA ON THE PRODUCT.............................................................................................. 9

JACK

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

6.1 JACK OPERATION INSTRUCTIONS.............................................................................. 9

6.2 REST ADJUSTMENT.....................................................................................................10

6.3 RATCHET CRANK OPERATION AND THE RATCHET CRANK-LEVER .......................10

6.4 BEARING SURFACE CHECK-UP /floor, rough ground/ .................................................11

6.5 TEST PRIOR TO USE....................................................................................................11

OPERATION...........................................................................................................11

7.1 APPLICATION OF THE JACK........................................................................................11

7.2 SAFETY WORK ENVIRONMENT ..................................................................................12

CHECK-UP

THE

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

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

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

8.1.2 Daily inspection ...........................................................................................................13

8.1.3 Regular inspection.......................................................................................................13

8.1.4 Jack occasionally used................................................................................................13

8.1.5 Report on inspection....................................................................................................13

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

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

GREASING...........................................................................................................15

10.1 GENERALLY................................................................................................................15

10.2 JACK MECHANISM .....................................................................................................15

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

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

11.2 REPLACEMENT OF BRAKE INSERTS AND BRAKE ADJUSTING .............................16

11.2.1 Brake disassembly (fig. 6) .........................................................................................16

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

11.3 BEARINGS...................................................................................................................16

11.4 GENERAL INSTRUCTIONS.........................................................................................16

11.5 CHECK UP...................................................................................................................17

11.6 REPAIR........................................................................................................................17

11.7 TEST............................................................................................................................17

PUTTING

OUT

OPERATION

–

LIQUIDATION................................................17

LATED

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

FINAL

REQUIREMENTS

THE

PRODUCER

THE

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

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.

Load capacity (Q1): is the maximum permitted weight (working load limit) of a load

on the rest, by which the jack is possible to be loaded when handling on conditions

specified in this Operation Manual.

2 DEVICE PURPOSE

2.1 The rack jack type 15-00 load capacity 2,5t and 5t, 15-01 load capacity 10t and

16t, Z23 load capacity 20t in any combination of design (-RK, -RKP, -VK) and in

design for potentially explosive atmospheres -NEXP (hereinafter referred to as

product or NEXP= structurally identical product, differing in surface protection of

selected parts, marking plate material and documentation) 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 product has been designed in compliance with the requirements

stipulated by Directive 2006/42/EC of the European Parliament and of the Council, as

amended by the Czech technical regulation – Government Directive No. 176/2008

Coll., as amended, and the requirements of the harmonized Czech technical

standards ČSN EN ISO 12100 and ČSN EN 1494+A1.

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 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 operation manual and security instructions.

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

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“.

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

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 atmospher

3.2.2 When in use

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

ALWAYS make sure that the foot of the comb bar rests on the ground with the

entire contact surface.

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 After use

ALWAYS ensure the jack against incompetent use.

3.2.4 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.

3.2.5 Maintenance

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

of the jack.

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 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) A claim for defects in the product must be applied according to the

relevant provisions of the Commercial Code or the Civil Code, 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

The technical parameters of the product in the "NEXP" design for all types, load

capacities, designs correspond to the parameters of the standard product design.

E.g. product parameters 15-01-NEXP/10t correspond to product parameters 15-

01/10t.

Type-design

Load

capacity

(t)

Actuating

force on

crank

(N)

Main dimensions (mm)

Weight

(kg)

Q Q

a b b

q h

min

r Z

15-00

2,5

1,75

380

175

200

735

250

345

15-00-VK

250

15-00-RKP 380

230

15-00-VK-RKP 265

15-00

5 3,5

550

200

235

200

765

300

360

215

275

15-00-VK-RK 250

15-00-RKP 550

330

250 24

15-00-VK-RKP 285 26

15-01

540

245

290

200

795

300

320

280

15-01-VK 325

140

315

15-01-RKP 10

540

320

305

15-01-VK-RKP 10

335

140

15-01 16

11,2

730 280 315

280

77 160

900

400

320 65

Z23

800

325

330

280

150

960

400

300

Working temperature range

20°

až +5

0°

Handle in position “crank”

Handle in position “lever”

Main dimensions design - VK

Type-design

Load

capacity

)

P (mm)

R (mm)

15-01-VK

540

15-01-VK

540

15-01-VK

10 500 100 5

Main dimensions – all type

Main dimensions – design - RKP

min.

Fig.1

Fig. 2

Fig. 3

Position transport

Position lever

Position crank

Overloading safety

min.

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

oad 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 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 value 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:

Stand

ard finish:

NEXP product d

sign

Mark of the producer

Address of the producer

Product type

Load capacity

Serial numbe

Ser

ial numbe

Pro

duction year

Production year

CE marki

CE marking

Protection type symbol (IM2ExhIMb for group I, II2GExhIICT6Gb

and

II2

°C

for group II

)

6 JACK OPERATION

! WARNING

ALWAYS before installation check up thoroughly whether the jack is not

damaged.

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.

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, …).

! NOTICE

The jack safe working load on the rest is decreased by 30%.

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.

Lowering

position

Lifting

position

Neutral

position

6.2 REST ADJUSTMENT

(only design - VK).

Position of the adjustable rest can be changed in the

range given by a number of mounting positions on the

jack bar (see fig.1)

After removal of the breaking piece (2) and shifting of

the rest in the direction indicated by an arrow,

fastening pin (1). 2 get loose in the jack bar and rest

can be put out. Carry out rest fitting-on to other position

by opposite procedure.

6.3

RATCHET

CRANK

OPERATION

AND

THE

RATCHET

CRANK-LEVER

(only design – RK and – RKP).

6.3.1 Raising or lowering

Before raising hitch up the

changeover lever and set on the

mark of raising – up-arrow (see fig.5).

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.5). 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.

6.3.2 Ratchet crank-lever

The manipulation with the ratchet crank-lever during the lifting and lowering of loads

is performed in the same way as is stated in article 6.3.1 and 6.3.2.

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).

Fig. 4

Fig. 5

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