1. Choose the right ram:
You must know the weight of what you intend to lift and choose a ram with at least 20% more capacity. Be aware of possible load shift requiring more capacity at any particular lifting point.
2. Check each component:
Check each component before you set up your hydraulic system. Do not use damaged or worn components. Turn them in for repair or replacement.
3. Safety instructions:
Read all warning labels and instructions. Operating instructions must be understood before using equipment. Never remove labels from equipment. Replace missing, worn or damaged labels.
Always wear safety goggles and protective clothing when using hydraulic equipment.
4. Fully support each jack or ram at its base:
Every jack or ram, whether used individually or in a system, should be completely supported on a solid, firm, non-sliding foundation capable of supporting the load.
5. Fill oil reservoirs with cylinder retracted:
Fill pump to recommended level. Only fill when connected cylinder is fully retracted.
6. Know how your hydraulics work:
Do not use extensions or cheater bars on hydraulic jacks or hand pumps to raise a load.
7. Centre the load on the lifting point:
The load must be centred on the ram, or equally distributed on multiple rams. Off-centre loading can result in the ram slipping out and loss of the load.
8. Distribute load evenly when using multiple rams:
For multiple ram lifts, you must be able to determine the location and number of lifting points that will allow the load to be evenly distributed to all the rams. This is called load balance. Size, centre of gravity and load geometry must be considered in order to correctly determine load balance.
9. Support load:
Place blocking or cribbing under the load as you raise it. Each time you raise it higher, insert more blocking. Position yourself in a manner that will keep you clear of the load, and will not allow your hands or other body parts between the load and the cribbing.
10. Do not use rams as permanent supports:
Hydraulic rams are not meant to be used as permanent supports, but are designed to lift and lower. If you need to hold the load for any length of time, cribbing or Betex locknut cylinders should be used.
11. Connecting the hydraulics:
When making connections with quick couplers, make sure the couplings are fully engaged. Threaded connections, such as fittings, gauges, etc., must be securely tightened and leak free.
Never use excessive tightening force that may distort the fittings or strip the thread profile.
12. Avoid extreme heat or weld splatter:
Weld splatter will damage plunger rods and hoses.
Hydraulic fluid can ignite if vaporized or exposed to high temperatures.
13. Disconnecting the hydraulics:
Never attempt to disconnect hydraulic hoses, fittings or couplers under pressure. Unload the ram, open the release screw on the hand pump and shift or open all hydraulic controls several times. If the system includes a gauge, double check the gauge to ensure pressure has been completely released.
14. Do not carry or drag pumps and rams by their hoses:
Dragging or carrying rams or pumps by a connected hose can damage the couplers and hoses.
Using damaged couplers and hoses can be dangerous.
15. Keep hydraulic hoses free of obstructions:
Do not drop sharp or heavy objects on hose. Keep hose out of heavy traffic areas. Avoid internal damage to hose wire strands. Applying pressure to a damaged hose may cause it to rupture. Avoid sharp bends and kinks when routing hydraulic hoses.
Selecting the right setup
STEP 1: Choose a hydraulic cylinder that suits the application best. What you need to consider:
1. How many cylinders are required for this application?
What push or pull tonnage is required per cylinder?
Note: always choose a cylinder with a tonnage rating of 20% or more than what is required.
2. Does the cylinder need to be massive or hollow?
3. What stroke length is required?
4. Does the cylinder need to fit within limited-clearance work areas? What is the installation phase?
5. Must the cylinder push, pull or both?
– Single acting cylinders push
– Double acting cylinders push and pull
6. Is the weight of the cylinder important and affecting material choice: steel or aluminium?
• Cylinders with swivel caps are available if the cylinder needs to withstand off-center loads.
(JLLC series, NSSS 10, 25 ton)
• Locking collars are available if the lifted load needs to be supported for longer periods of time.
STEP 2: Choose a hydraulic pump, that matches the selected cylinder, consider:
1. Do you prefer a hand, foot, air, or electric powered pump?
2. How much oil capacity is required? (= oil capacity x no. of cylinders)
3. How fast must the pump be?
4. What is the frequency of the application?
5. Single- or double-acting?
6. Is the weight of the pump important?
7. Available air- or electric supply?
STEP 3: Choose necessary hydraulic accessories, consider:
1. Required hose length and number
2. Coupling sets for coupling and uncoupling
3. Gauge with T-adapter
4. Manifold valve
5. Extra hydraulic oil