OPERATION AND

MAINTENANCE MANUAL

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Hydraulic trolley jack

Art. 0457

ORIGINAL INSTRUCTIONS
 MACHINES AND
ACCESSORIES

FOREWORD

Read this manual before operating any machinery

ORIGINAL INSTRUCTIONS
Before starting any operation it is compulsory to read this instruction manual. The guarantee
that the machine will function and perform properly is strictly dependent upon the application
of all the instructions contained in this manual.

Operator Qualification

safety in pertaining to:

a)
b)
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The operators assigned to using this machine must be supplied with all of the necessary
information and instruction and should be provided with adequate training regarding

The conditions of use of the equipment;

Foreseeable abnormal situations, pursuant to Article 73 of Legislative Decree
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81/08.
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We guarantee the Machine's conformity to the specifications and technical instructions

described in the Manual on the date of issuance and listed herein; On the other hand,
the machine may also be subject to important technical changes in the future, without
the manual being updated.

Therefore, see FERVI for information about modifications that could be implemented.

REV. 1 November 2013

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CONTENTS

1 INTRODUCTION ........................................................................................ 4
1.1 Preface..........................................................................................................................5

2 SAFETY WARNINGS .................................................................................. 6

2.1 General safety rules for machine tools ..........................................................................6
2.2 Safety regulations for jacks ..........................................................................................7
2.3 Technical support..........................................................................................................7
2.4 Other provisions ...........................................................................................................7

3 JACK DESCRIPTION .................................................................................. 8

3.1 Safety devices ...............................................................................................................9
3.2

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Identification plate and pictograms ............................................................................ 10

TECHNICAL SPECIFICATIONS ................................................................. 12

IMPROPER USE AND CONTRAINDICATIONS............................................ 13

TRANSPORTING, LIFTING AND MOVING ................................................. 14

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7 COMMISSIONING.................................................................................... 15
7.1 Unpacking instructions ............................................................................................... 15
7.2 Assembling the lifting lever ........................................................................................ 15
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7.3 Mounting the upper handle ......................................................................................... 15

8 MACHINE OPERATION............................................................................. 16
8.1 Lifting the load............................................................................................................ 17
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8.2 Lowering a load .......................................................................................................... 17

9 MAINTENANCE ........................................................................................ 18
9.1 Routine maintenance .................................................................................................. 18

10 REPLACEMENT PARTS........................................................................... 20

11 TROUBLESHOOTING ............................................................................. 22

12 WAREHOUSE STORAGE......................................................................... 23

13 DECOMMISSIONING ............................................................................. 23

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1 INTRODUCTION
This manual is delivered with the machine, and it must be regarded as an inseparable part of
it.
The manufacturer holds all ownership to material and intellectual property of this manual;
any disclosure or copying, even partial, of this publication without prior written consent is
forbidden.

The purpose of this manual is to provide the knowledge necessary for the use and
maintenance of the machine Hydraulic trolley jack Art. 0457 and create a sense of
responsibility and an understanding of the capabilities and limitations of the means entrusted
to the operator.
As the machine is entrusted to experienced and skilled operators, the following machine must
be perfectly known by the operator if you want it to be used safely and effectively.

for those who carry out these tasks. om

Operators must be properly trained and prepared, so make sure that this manual is read and
consulted by the staff responsible for commissioning, operation and maintenance of the
Hydraulic trolley jack. This is to make all operations the safest and most effective possible

Therefore, it is imperative to strictly comply with the requirements in this manual, a

necessary condition for safe and satisfactory operation of the machine.
Prior to installation and use of the Hydraulic trolley jack, authorised personnel shall:
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 carefully read this technical document;
 know which protections and safety devices are available on the machines, their location
and how they work.
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It is the responsibility of the buyer to ensure that users are properly trained, that they are
aware of all the information and instructions in this document and that they are aware of the
potential risks that exist while working with the Hydraulic trolley jack.
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The manufacturer waives any and all responsibility for damage to people and/or
things caused by non-observance of the instructions in this manual.

The Hydraulic trolley jack was designed and built with mechanical guards and safety
devices designed to protect the operator/user from possible injury. It is strictly forbidden to
modify or remove guards, safety devices and caution labels. If this must be done (for
example, for cleaning or repair), make sure that no one can use the jack.

Operators will be held fully responsible for any changes they have made to the
machine; the manufacturer will not be held responsible for any damage to persons
and/or property resulting from maintenance performed by unqualified personnel
and in a manner that differs from the operating procedures shown below.

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GRAPHIC REPRESENTATION OF SAFETY, OPERATIONAL AND RISK WARNINGS

The following boxes are designed to attract the attention of the reader / user for the proper
and safe use of the machine:

Pay attention
This highlights behavioural rules to prevent damage to the machine and/or the occurrence of
dangerous situations.

Residual Risks
This highlights the presence of dangers that cause residual risks to which the operator must
pay attention in order to avoid injury or damage to property.

1.1 Preface
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For safe and easy operation of the Hydraulic trolley jack, this manual must be read
carefully in order to acquire the necessary knowledge. In other words, durability and
performance are strictly dependent on how it is used.
Even if already familiar with the Hydraulic trolley jack, it is necessary to follow the
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instructions contained herein, in addition to the general precautions to be observed while
working.
 Acquire full knowledge of the machine.
Read this manual carefully to understand: operation, safety devices and all necessary
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precautions. All this is to allow safe use of the jack.

 Wear appropriate clothing for the job.
The operator must wear appropriate clothing, so as to prevent the occurrence of
unpleasant accidents.
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 Maintain the machine with care.

Machine operation
The machine must only be used by qualified personnel trained to use the machine by
authorized personnel.

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2 SAFETY WARNINGS

2.1 General safety rules for machine tools

Risks related to Using the Machine

Do NOT underestimate the risks related to the use of the machine and stay focused on the
work you are carrying out.

Risks related to Using the Machine

Despite the implementation of all safety devices for safe use of the machine, it is necessary to
take note of all the accident prevention requirements highlighted in various parts of this
manual.

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Risks related to Using the Machine
Every person who is responsible for the use and maintenance of the machine should first have
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read the instruction manual, particularly the chapter dealing with safety.
It is recommended that the plant safety manager get written confirmation of the above.
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Risks related to Using the Machine

 During all work phases with the machine, you should proceed with great caution in
order to avoid damage to persons, to the property or to the machine itself.
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 Please use the machine only for its expected uses (drilling or tapping).
 Don't tamper with the safety devices equipping the machine.

Risks related to Using the Machine

Before starting any work on the jack, the operator must wear the appropriate personal
protective equipment (PPE) such as protective gloves and safety shoes.

1. Always check the efficiency and integrity of the machine.

2. Keep the workplace tidy and free from hindrances; disorder causes accidents.
3. Make sure that the work environment is forbidden to children, non-employees and
animals.
4. Do not perform tasks on the machine other than those for which it was designed. Only
use the machine in the manner in which it was intended, as described in this instruction
manual.

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5. Work without disturbances.

6. Work areas must be well lit.
7. Always wear eye protection and protective gloves while working. If dust is produced,
use the appropriate masks.
8. Wear appropriate clothing. Loose clothing, dangling jewellery, long hair, etc.., can get
caught in the moving parts, causing irreparable injury.
9. Replace worn and/or damaged parts, check that the guards and protection devices work
properly before operating. If necessary, have the machine checked by the service
support personnel. Use only original spare parts.
10.Do not use the machine in areas with a risk of fire and / or explosion.
11.It is recommended that users of this publication, for maintenance and repair, have a
basic knowledge of mechanical principles and of repair technique procedures.
12.Management in charge of safety is to make sure that the staff responsible for
using the machine has read and understood this manual in its entirety.
13.The company safety manager is responsible for monitoring the company's risk

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status according to Legislative Decree no. 81/08.

2.2 Safety regulations for jacks

1. Use the Trolley Jack exclusively for lifting.
2. Before lifting, make sure the Jack is in good condition. Do not adjust the safety
valve!
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3. Place the Jack on a flat, solid and durable work surface.
4. Do not try to operate the machine at higher performance levels than those for which it
was designed, in particular regarding the magnitude of the load to be lifted. In
other words, do not load the Jack beyond its capacity.
5. If you use the Jack to lift a vehicle, lock the wheels of the vehicle with the emergency
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brake.
6. Always use a safety support, such as a tripod, to support the vehicle (load) in
case you need to work under the vehicle (load).
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2.3 Technical support

For any problems or concerns, please contact, without hesitation the Customer Service
Department of your dealer, who has competent and specialized staff, specific equipment and
spare parts.

2.4 Other provisions

IT IS FORBIDDEN TO TAMPER WITH SAFETY DEVICES
The first thing to do when starting work is to check for the presence and integrity of the
protections and the operation of the safety devices.

If any defect is encountered do not use the machine!

Even more so, it is strictly forbidden to modify or remove guards, safety devices,
labels and indication signs.

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3 JACK DESCRIPTION
The Jack Art. 0457 is designed and constructed for the lifting / lowering of loads, and in
particular vehicles for the usual operations of maintenance and/or repair.
The jack must be used on supporting surfaces that are flat, smooth, and adequately strong
and hard (capable of supporting the weight of the jack plus the maximum nominal load
capacity).
The operating temperature is within the range of: –20/+50°C.
The environment must also be sufficiently illuminated so as to ensure operation in maximum
safety (at least 50 lux is recommended).

Other types of use, or the extension of use beyond that envisaged, does not
correspond to the designation attributed by the manufacturer, and therefore the
latter cannot accept any responsibility for any damage resulting therefrom.

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6 4
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5
3

1 2

Figure 1 - Overview of the device

1 Frame 5 Load-bearing saddle

2 Fixed front wheels 6 Operating pedal

3 Rear swivel wheels 7 Lever

4 Lifting arm

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The jack consists of:

 a load-bearing frame (1) with two fixed front wheels (2) and two rear swivel wheels
(3);
 a lifting unit consisting of the hydraulic cylinder and the lifting arm (4);
 a pumping unit consisting of a piston pump which is manually operated via the lever
(7) or the pedal (6);

The control system of the jack, consists of:

 the piston pump that, once operated, allows the extension of the piston rod of the
hydraulic cylinder, i.e. the lifting of the arm and the load;
 the vent valve that, once opened, allows the return of the piston rod of the hydraulic
cylinder, i.e. the lowering of the load;

3.1 Safety devices

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The main safety device present on the machines is the load limiter, consisting of a
maximum pressure valve, which protects the jack against overloading.
This valve, ensures that the pressure inside the hydraulic circuit can not exceed the fixed set
value determined by the maximum rated load capacity.

Load limiter
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 Under no circumstances should the adjustment of the maximum pressure safety valve
be carried out by the operator.
 Never tamper with the safety valve, if you are not authorised to do so!
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The load-bearing saddle on the lifting arm (Figure 2)

is made in such a way that the "gripping" of the load
is the maximum possible.
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Figure 2 - Close-up of the load-bearing saddle.

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3.2 Identification plate and pictograms

The identification plate is affixed to the lifting arm of the jack (Figure 3).

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Figure 3 - Nameplate.

The maximum rated load capacity that the jack can lift under standard conditions is
indicated on the plate, i.e. when:
 it is in good conditions of efficiency and conservation;
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 it operates within the temperature range in ambient conditions and on a flat, hard and
durable surface.

The maximum rated load capacity must never be exceeded!

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The following pictogram can be found on the lifting arm of the Jack that summarises the main
operating instructions and provides some information on the residual risks associated with the
use of the jack (Figure 4).
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Figure 4 – Attention and instruction pictograms.

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The following pictogram is located next to the pressure relief valve and indicates that the
configuration of the valve must not be changed (Figure 5).

VALVOLA DI SICUREZZA:
NON REGOLARE
SAFETY VALVE:
DO NOT ADJUST

Figure 5 - Pictogram next to the safety valve.

On the right side of the frame of the jack is a pictogram which provides additional instructions
for safe use, particularly on operation when using the jack for lifting cars or similar vehicles
(Figure 6).

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Figure 6 - Pictogram on the frame of the jack.

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4 TECHNICAL SPECIFICATIONS

Description Art. 0457

Length (mm) 800

Width (mm) 350
Height (mm) 160
Handle height (mm) 950
Minimum lift (mm) 70
Maximum lift (mm) 500
Weight (kg) 41
Loading capacity (kg)

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5 IMPROPER USE AND CONTRAINDICATIONS

The following actions described, which obviously can not cover the entire range of potential
possibilities of "misuse" of the machine, are to be considered strictly prohibited.

THE FOLLOW ARE STRICTLY PROHIBITED!:

 To lift persons and/or animals that could fall;
 To lift loads while there are people near the machine;
 To work under loads only lifted by the jack without using additional safety supports,
such as a tripod.
 To lift loads heavier than the maximum rating indicated on the plate;

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 To lift vehicles without applying the brakes to the wheels correctly;
 To lift unbalanced loads, or change their static configuration, and/or their centre of
gravity;
 To lift "dangerous" loads (molten metals, acids, radioactive materials, fragile and/or
brittle loads);
 To load the jack on uneven polished surfaces and/or surfaces that are not strong
enough to support the load (jack + maximum rated load capacity);
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 To use the jack when there is a possibility of the load moving accidentally;
 To leave the loaded jack unattended;
 To allow untrained staff to use the jack;
 To operate the jack if you are not psycho-physically fit;
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 To operate the jack without due attention;

 To operate the jack for purposes other than those for which it was designed;
 To use the jack in unforeseen environmental conditions (adverse weather conditions,
refrigerators, high magnetic fields, etc.);
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 To use the jack in potentially explosive environments;

 Use the jack in the event of insufficient light;
 To use the jack on ships at sea;
 To put the jack in contact with foodstuffs.

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6 TRANSPORTING, LIFTING AND MOVING

The presence of the wheels, allows the jack to be transported manually in safety and comfort.
When lifting, the operation must be carried out by two people holding the jack on opposite
sides. It is recommended, in this regard, to remove the lever for operating the pump before
lifting the jack.

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7 COMMISSIONING
7.1 Unpacking instructions
The Jack is supplied in a cardboard box, with the lifting lever disassembled.
Before disposing of the shipping carton, check you do not to throw away parts of the
machine, the owner's manual or other documentation.

Standard packaging
Under no circumstances should the adjustment of the maximum pressure safety valve be
carried out by the operator.
Never tamper with the safety valve, if you are not authorised to do so!

7.2 Assembling the lifting lever

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To assemble the lifting lever for the jack, proceed as follows:

1. Insert the lever into the hydraulic pump

coupling on the jack, making sure to
insert the long end of the lever to the left.
2. Tighten the screw with a wing nut
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connecting the coupling to the lever. It
must be possible to rotate the lever inside
the housing.
Figure 7 - Installation of the jack lever.
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Correctly mount the lever

Do not use the trolley jack until the lifting lever has been mounted properly, as described in
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this paragraph.

7.3 Mounting the upper handle

To assemble the upper handle of the jack, proceed as follows:
 Insert the handle into the upper part of the lever.
 Use the bolt supplied with the jack to secure the handle. Insert the screw in the front
part of the lever and attach the nut at the back. Tighten the screw using an Allen
wrench.

Figure 8 - Installation of the jack handle.

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 MACHINES AND
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8 MACHINE OPERATION

Lifting loads
There is a risk of crushing body parts while lifting heavy loads resulting from mishandling.
Workers must be equipped with standard safety equipment, especially gloves and crush
resistant safety shoes.

Lifting loads
Workers performing the lifting of loads must guide the device carefully, without abrupt

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movements and using the utmost care.
In particular, the jack and load must be kept under constant control during movement.

Working under loads

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Working under a lifted load ALWAYS entails a residual risk of the load falling accidentally.
In this regard, IT IS STRICTLY FORBIDDEN to operate under a load lifted only by the jack.
Always insert a safety support (of suitable capacity) under the load before operating below it
(for example a tripod).
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Periods of inactivity
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After a period of inactivity, before operating the jack, pump with the jack unloaded at least 6
times to ensure complete distribution of the hydraulic oil.
If necessary, bleed the air.

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8.1 Lifting the load

1. Place the Jack under the load in a suitable position for lifting. In the event the load is a
vehicle, it is recommended that the operator refers to the user manual. The jack is
equipped with wheels for easy positioning at the point of lifting the load.

Lifting a load
Always position the load in the central part of the load-bearing saddle, as shown in Figure 9.
Use the foot pedal only when approaching the load to be lifted. Then, use the lever that allows
greater force to be applied to the load.

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Figure 9 - Positioning the load.
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2. Pump the lifting lever back and forth until the desired height is reached or use the foot
pump to lift the load
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8.2 Lowering a load

1. Lift and rotate the lifting lever clockwise to

open the lowering valve (or check valve).
Visually check that the pin is moving properly
within its housing in the coupling.

Figure 10 - Lowering of the load.

Slow and controlled lowering of the load

Turn the lift lever slowly to control the lowering of the load.

2. When the lifting arm is fully lowered, remove the Jack.

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9 MAINTENANCE
The purpose of this chapter is to provide all the information on maintenance procedures and
frequency required for the Trolley Jack.
Maintenance and repairs must be performed by qualified personnel.

9.1 Routine maintenance

Frequency
INTERVENTION
Daily Weekly Monthly
1. General visual inspection X
2. Checking nameplate readability X
3. Check for the absence of leaks
4. General cleaning
5. Lubrication and greasing
6. Check the oil level and top up
7. Bleed air from the circuit
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X

If necessary
X
X
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1. General visual inspection: check the general condition of the machine, if there are
any damaged or missing parts.
2. Check the readability of nameplates: plates and pictograms on the machine must
be perfectly legible, it is therefore necessary to keep them clean and request
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replacements if they are illegible.

3. Verify the absence of leaks in the hydraulic circuit: there can be no measurable
accidental loss in the hydraulic circuit, except for slight moisture insufficient to form a
drop.
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4. General cleaning: cleaning is necessary to free the structure and moving parts from
the accumulation of dust, dirt and stains caused by excess lubricants. Cleaning should
be done with the use of means, equipment and detergents or solvents commonly used
in the cleaning of industrial equipment.
5. Lubrication and greasing: it is necessary to lubricate the moving parts of the jack,
namely:
 the pins, hinges and levers of the pumping system;
 the wheel axle pins.
6. Check the oil level and top up: check the oil level and if necessary top up with
hydraulic mineral oil for lifting devices.
 Fully lower the pump and the lifting arm.
 Place the jack in a vertical position with the front wheel fixed upwards.
 Unscrew the oil cap.
 Add hydraulic mineral oil. Fill up to the bottom edge of the opening.
 Bleed the air in accordance with the instructions given in paragraph 7.
 Screw on the hydraulic oil cap.

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Type of hydraulic oil

When you top up the hydraulic oil only use the oil type recommended by the manufacturer.
Do not use brake fluid or engine oil.

7. Bleed air from the hydraulic circuit: To remove any air bubbles in the hydraulic
system of the jack, which could reduce its efficiency, follow these instructions:

 Pump several times unloaded and perform

several complete lifting cycles to remove
the air from the circuit.
 Bleed the air by moving the oil fill cap on
the pump body.

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Figure 11 – Bleeding the air
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10 REPLACEMENT PARTS

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No
Part No. Description Part Description
.
0457/01 1 Saddle casing 0457/24 2 Elastic washer 8
0457/02 1 Load-bearing saddle 0457/25 1 Pin
0457/03 1 Lifting arm 0457/26 1 Pump housing
0457/04 1 Lever with handle 0457/27 4 Elastic washer 14
0457/05 1 Cotter pin 4 x 50 0457/28 2 Screw M12 x 25
0457/06 1 Rotation pin 0457/29 1 Screw M6 x 20
0457/07 2 O-Ring 0457/30 1 Washer 10
0457/08 2 Return spring 0457/31 1 Valve
0457/09 2 Nut M18 0457/32 1 Valve opening plate
0457/10
0457/11
0457/12
0457/13
0457/14
2
2
2
2
1
Spring lock washer
Washer
Plain bearing
Front wheel
Front wheels shaft
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0457/33
0457/34
0457/35
0457/36
0457/37
1
1
1
2
2
Washer 6
Elastic washer 6
Nut M6
Locking pivot
Nut M12
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0457/15 1 Support shaft 0457/38 2 Washer 12
0457/16 1 Right plate 0457/39 1 M8 wing nut
0457/17 1 Left plate 0457/40 2 Washer 16
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0457/18 2 Washer 20 0457/41 2 Nut M16

0457/19 2 Nut M20 0457/42 1 Lever coupling shaft
0457/20 2 Washer 14 0457/43 2 Rear wheel
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0457/21 2 Nut M14 0457/44 1 Lever coupling

0457/22 1 Tools support 0457/45 1 Lever coupling screw
0457/23 2 Screw M8 x 16

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11 TROUBLESHOOTING
The following table shows the type of defect / problem, possible causes, and possible
remedies for the malfunction.
The table is a useful aid for the maintenance technician when looking for problems with the
machine.
Fault
The jack does not lift the
load.
The jack lowers when
pressure is applied.
The lifting lever fails to raise
under the weight of the load.
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The pump is weak.
The oil leaks from the tank.
The jack does not lift to the
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maximum height.
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MACHINES AND
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Cause Solution
The check valve is not
Close the check valve.
properly closed.
The check valve is not
Close the check valve.
properly closed.
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The valves are not closed
properly, or there is a
foreign body in the valves.
Clean the valves.
Lower the piston rod of the
jack, close the check valve,
raise the jack's piston rod with
your hands and then open the
check valve and lower the
piston rod quickly.
Low oil level. Add hydraulic oil.
Tank overflow. Remove the excess oil.
Air bubbles in the hydraulic Purge air in the hydraulic
circuit. circuit.
MACHINES AND
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12 WAREHOUSE STORAGE
If the machine has to be stored and preserved for a period of time, to avoid damage and / or
deterioration proceed as follows:
 Keep the lifting arm lowered and the coupling for the lever;
 Keep the vent valve slightly unscrewed;
 Lubricate all parts of the jack;
 Store the jack indoors in a dry location.

13 DECOMMISSIONING

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If the jack is to be scrapped, its parts must be disposed of separately.

Respect the environment!

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Contact a specialist centre for the collection of metallic materials.

The structure of the jack is made from steel while some seals are made from polymeric
material.
The pump and the tank contain hydraulic oil.
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In this regard, divide the materials according to their nature, employing specialist companies
which are authorised for their disposal, in accordance with the requirements of law.
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