Jack Installation Manual
Jack Installation Manual
JACK DESCRIPTION
INSTALLATION INSTRUCTIONS
MAINTENANCE INSTRUCTIONS
CONTENTS
1. GENERAL INFORMATION 3
6. INSTALLATION INSTRUCTIONS 7
8. GENERAL INSTRUCTIONS 12
1. GENERAL INFORMATION
1.1 Range of application 1.2.5 Document terms
The use of the hydraulic lift is recommended for Reproduction of the whole or part of the specific
installations, which are subject to the standard EN 81-2. manual is not allowed, without the written approval of the
manufacturer.
IMPORTANT NOTE
2.4 Temporary storage
Temporary storage should not take place in
high humidity environments. Check all packed
1.2.4 Quality assurance and inspection components regularly, for the possible existence of
The system of quality assurance guarantees the condensed water, which could cause wear
high standards of quality provided for the complete lifts
manufactured by KLEEMANN. The quality assurance 2.5 Protection
includes all the systematically designed activities, which The state of the supplied components should be
are required for this product to harmonize with all the checked at regular intervals, if the storage is to exceed the
relevant safety regulations. suggested period. KLEEMANN will not be responsible for
All necessary documents regarding safety the failure of proper storage.
instructions, use and maintenance of lift
components, are contained within the 2.6 Protection from environmental conditions
user’s manual, supplied along with every The storage area should be dry and free of dust.
complete KLEEMANN lift and should always be at Protection against time can only be achieved through proper
the disposal of persons involved in the installation packaging and storage.
and maintenance of the lift.
1. HEXAGONAL SCREW
2. WASHER
3. RAM – SAFETY BLADE
4. PLASTIC PROTECTIVE RAM COVER
5. ALLEN Μ6x8 SCREW
6. RETAINING RING
7. SEAL BASE
7.1. WIPER
7.2. SEAL
8. Ο-RING
9. BEARING
10. BEARINGS BASE
11. RAM COVER 1
12. RAM TUBE
2
13. CYLINDER COUPLING
3
14. CYLINDER TUBE
15. DAMPING ROD
16. RAM BOTTOM ELASTIC RING
4
17. HEXAGONAL BASE
18. ALLEN SCREW Μ30x100
19. CYLINDER BOTTOM
20. CYLINDER CENTERING RING 5
7.1 6
7.2 7
8
9
10
7.1
11
12
7.2
13
6
14
8
15
16
18
17
20
19
FIGURE 3.1
1 9
2
6
10 5
5
7
3
4
FIGURE 4.1
FIGURE 5.1
Their transport should be made with the help of a belt crane and a rotating hook, with both parts of the
belt being in an open arrangement (figure 5.4).
FIGURE 5.4
In order to place the jack in the shaft, suspend it from the Π shaped parts, which are welded on the
upper part of the cylinder (figure 5.5). By following this procedure, the vertical position of the ram can be
obtained.
FIGURE 5.5
6. INSTALLATION INSTRUCTIONS
(The installation procedure is described in the car frame installation manual. A typical installation
procedure is described below)
The following steps should be taken for the correct installation of the jack:
Place the lower part of the jack on the ram pedestal (figure 6.1b), while the cylinder centering ring goes
through the hole of the bracket for the cylinder and the ram pedestal (figure 6.1a). In this way, the lower
part of the jack is aligned with the guide rails.
Support the upper part of the jack (exactly under the cylinder head) on the guide rail bracket or on the wall
(figure 6.1d) by using the ram bracket (figure 6.1c). In this way, the upper part of the jack is aligned with the
guide rails.
Check if the jack is at a vertical position and centered between the guide rails (figure 6.1e)
FIGURE 6.1c
FIGURE 6.1a
FIGURE 6.1e
21
A plastic canister is supplied with every jack and jack parts. The
plastic hose connected to the oil over flow outlets is inserted in the canister.
In this way the fluid deposited on the upper part of cylinder is removed
(figure 6.2).
Check once per month the volume of the fluid that has been removed.
FIGURE 6.2
FIGURE 6.3
6.3 FIRST RUN OF THE RAM
The first run of the ram should be at low speed so that the o-
ring of the ram used to protect it while transferred (figure 6.4, Νο 21),
could be placed in the groove (B) at the bottom of the ram.
FIGURE 6.4
2
2
2 2
LOWER RAM
ΚΑΤΩ
PARTΤΜΗΜΑ
ΕΜΒΟΛΟΥ
FIGURE 7.1 FIGURE 7.2
Make a visual check for dust on the thread of the ram and clean it if required.
Take the upper set of the split jack and follow the steps below:
Remove the upper yellow plastic cover with the blade.
Place the jack supporting blade (figure 7.3) by screwing it with the
hexagonal screw on the ram without tighten it
Suspend the upper part of the jack from the Π shaped parts as
shown on figure 7.3
Move it close to the lower set. Pay attention to the position of the
suspended set in order to be absolutely vertical
Unscrew the yellow plastic cover of the upper set (No.3, figure 7.4).
FIGURE 7.3
Do not remove the black protective semi-rings yet (No4, figure 7.5). They function as a distance ring in
order to have coaxiality of the ram with the cylinder.
By using two screws, hold the screw nut in a higher position than the area
where are going to work, and place the screw clamp (figure 7.6), by gripping
the upper jack.
Screw the upper and the lower ram connection screw (Νο8, figure 7.6) on
the upper thread, up to the point of 2 turns before the end.
The connection screw must be screwed to the upper ram so that the
round A will be visible (figure 7.6) 10
Place the o-ring on the female ring of the split (Νο10, σχήμα 7.6).
For jack types KZL (185 210) use a permanite flange instead of an o-
8
ring we (figure 7.8α, No12)
FIGURE 7.6 A
FIGURE 7.6
Lower the upper ram until it approaches the lower ram, about
5mm before they make contact.
Start turning carefully the screw No 8 on the female thread of
the lower ram.
When it screws 3-4 turns, add to the surface of the screw the
special glue that goes with the set of the split jack (see figure
7.7). Place glue at the thread of the screw and at the surface
that is indicated by the arrows (figure 7.6). This glue supports
and seals as well.
The surfaces that glue is going to be placed on should be
thoroughly cleaned beforehand.
FIGURE 7.7
We aim to seal, because, during the lifting of the jack and due to high oil pressure, if the area of the
screw-connection is not sealed, it gets filled up with oil, which will overflow when the connection lifts out
of the cylinder. This may be misleading, thinking that there is an overflow from the seals of the jack.
When you make sure that the surface is absolutely smooth at the area of the connection, clean it of borings
or glue remains, and remove the plastic black semi-rings from the upper and the lower cylinder.
Lower the upper set up to the point where it touches the lower set.
Loose the screws that hold the screw nut, turning it low, and very carefully start screwing the screw nut on
the lower set.
If a jam occurs during screwing, unscrew 1-2 turns, check the coaxiality of the two sets and continue
carefully. You must go through with screwing. DO NOT use a hammer for striking during clamping. Manual
strength is adequate.
For jack types KZL (185 210) instead of a split screw nut, there are
two flanges (figure 7.8a, 11a, 11b) welded on the end of each cylinder,
through which the assembly of the cylinder connection is possible. The
flanges are connected with screws and a permanite flange is placed
between them (No12).
FIGURE 7.8a
3. The next part involves, before suspending it, screwing the FIGURE 7.10
3 3-4 turns
- 4 στροφές
The jack should not remain on a horizontal position before installation. It is advisable to stabilize it on a vertical
position. If for any reason the jack should remain horizontal before installation for a long period of time, all of the
seal components must be replaced. The reason is that deformation will definitely occur at the point where it was
pressed by the ram when it was on a horizontal position.
Switch the main power supply off and then close the ball valve between
valve block and jack.
At first using a nail-claw, take off the retaining ring very carefully (figure
9.1).
FIGURE 9.1
19
FIGURE 9.4
Replace the seals required and re-assemble in the same order. Each time an
extraction of the head of the jack for a seal change takes place, the o-
ring must be replaced, since friction with the cylinder coupling destroys
them (figure 9.3 & 9.4).
If you want to change the bearings, using the extractor and the spanner once
again, take off the bearings base (figure 9.5) and replace them.
ΕΣΟΛΚΕΑΣ
In case the ram is light and it rises up, we stabilize it by means of a bracket, as seen at figure 9.8
Pump
ΑΝΤΛΙΑ
Rupture valve
Βαλβίδα ασφαλείας
CYLINDER
Κύλινδρος
Κοχλίας ρύθμισης
Adjusting screw
Pump
ΑΝΤΛΙΑ
Τρελό ρακόρ
Pipe fitting
Βαλβίδα ασφαλείας
Rupture valve
Μούφα κυλίνδρου
Oil inlet
CYLINDER
Κύλινδρος
H
Adjusting
Κοχλίας screw
ρύθμισης
FIGURE 10.2
FIGURE 10.3
L1 = L2
L1 L2
1/4''
The ¼’’ hose that connects the two rupture valves is installed around the wall shafts (as shown
in figure 10.4).
FIGURE 10.4
10.3 TESTING INSTRUCTIONS
Only skilled or authorized personnel should carry out changes in settings. A precondition for testing the
pipe rupture valve is that the lift must be working properly, without any faults. Before testing the pipe
rupture valve, make sure that there are no people or materials in the lift shaft.
2nd MODE
1. With the car parked (at the highest landing), switch the controller’s mains off and the power unit’s
ball valve off.
2. On the valve block a red circular switch can be found (figure 10.3). By turning it c - clockwise the
residual pressure in the system will be reduced to zero. Leave the switch as soon as the gauge reads zero
pressure (normally the switch closes by itself)
3. Using an allen Νο 5 key remove the down valve flange (figure 10.3), located on the face of the valve
block (it contains adjustments “7” and “9”)
4. Remove the down spool, located right behind the down flange, inside the valve block (use one of the
four screws of the flange, by screwing temporarily at the back of the small piston, so that you can pull it).
6. Fix the down flange back into position. At this stage, the whole assembly is controlled by the power
unit’s ball valve. If we open the ball valve, we cause a rapid descent.
7. Open the ball valve with great pre-caution (keep hands on the ball valve’s lever)
8. Almost immediately (0,5 up to 1,5 m after the initiation of down movement), the valve should be
triggered. If so, follow the steps as described below:
Close the ball valve
Bring valve block’s residual pressure down to zero
Remove down flange
Place the down spool and adjustment’s “9” spring back into position and after put the down flange
back
9. In case that the valve is not triggered immediately, then close the ball valve immediately and
proceed to the adjustment of the valve according to the flow diagrams.
MANUAL
LOWERING
DOWN FLANGE
Νο7
FIGURE 10.3
When the car speed reaches the 130 % of nominal, the rupture valve will be activated and the car will stop.
The car must come to rest within 3-5 meters.
If it does not, immediately switch off the main switch for the lift control system and repeat the test.
By releasing the “+” key of C-HANDTERMINAL, the maximum feedback value will appear and the car will
continue the normal descent until it stops to the lower stop.
After the pipe rupture valve has closed, pressure can again build up between the block and the pipe rupture
valve, causing the pipe rupture valve to reopen. If the hose/pipe is actually burst, the pipe rupture valve would
remain closed. Very slight leakage through the pipe rupture valve is permissible.
The pipe rupture valve has been successfully tested
The system is once again ready for use
KL 10 3/4'' KL 10 1''
30 30
29 29
28 28
27 27
Η (mm)
Η (mm)
26 26
25 25
24 24
23
23
22
22
60 70 80 90 100 110 120 130 140 150 160
60 70 80 90 100 110 120 130 140 150 160
(l/min)
(l/min)
KL 10 1 1/4'' KL 10 1 1/2''
36 36
35 35
34 34
Η (mm)
Η (mm)
33 33
32 32
31 31
30 30
190 210 230 250 270 290 310 330 350 370 390 190 210 230 250 270 290 310 330 350 370 390
(l/min) (l/min)
KL 10 - 2''
49
47
45
43
H (mm)
41
39
37
35
250 280 310 340 370 400 430 460 490 520 550 580
(l/min)
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