UNIT 3.

17

HYDRAULIC JACKS

There is a wide range of hydraulic jacks available, from the self contained 'bottle' jack
through to independent pump and ram units and then to trolley jacks. Although very different
in design and intended use the general principles are the same. In this unit we will
specifically consider those matters that apply to independent jacks (bottle jacks) and to pump
and ram units used for lifting.

The current Harmonised Standard for hydraulic jacks is BS EN 1492: 2000, Mobile or
moveable jacks and associated lifting equipment, which gives the specific requirements that
hydraulic jacks must meet.

PRINCIPLE OF OPERATION
Although there are wide variations in design and the materials used to manufacture hydraulic
jacks, rams and pumps, the basic principle of operation is the same. A liquid is taken from a
reservoir, forced thorough a small bore to the underside of a ram which, in turn, is forced
upward making room for further liquid to fill the space and keep the ram raised.

In hydraulic pump and rams, or jacks, the liquid is a light oil. Generally this flows easily,
offers considerable resistance to compression and is not greatly affected by changes of
temperature. So, although not strictly true, we can consider the oil to a) be incompressible, so
that when put under pressure it will flow, b) unaffected by temperature so that it will not
expand and c) if put under pressure will seek an increase in the volume of the space.

In the hydraulic jack we make the oil flow into a confined space under pressure, but as we
cannot compress the oil, the space must expand. If the space cannot expand, the weakest part
of the jack would fail, eg the seals would blow. The space is expanded as a result of the oil
pushing the ram out of the jack. In Figure 1 we see a schematic sketch of a jack showing the
principle of operation. (An independent pump and ram would be the same except the pump is
connected to the ram by a hose with the delivery non return valve in the entry port to the
ram.)

Figure 1
Principle of the Hydraulic Jack

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When the lever is depressed the small (pump) plunger is lifted. This causes oil to be sucked
from the reservoir into the area previously occupied by the plunger. The oil passes through a
filter and a non return valve (suction valve). When the lever is then raised the plunger is
lowered putting pressure on the oil, which, due to the non return valve is unable to return to
the reservoir. The oil is therefore made to flow into the large plunger chamber via another non
return valve (delivery valve).

Further pumping of the lever causes more oil to flow under pressure and, as the pressure acts
equally in the enclosed system, it seeks to expand the space available to it. This it does by
pushing the large plunger (ram) out of its chamber, the pressure in the system being greater
than the downward pressure of the large plunger and load.

To lower the jack a valve is opened (release valve) which allows the oil to return to the
reservoir. The downward action of the ram puts pressure on the oil, which, unable to return
the way it came because of the non return valves, flows back to the reservoir by this
alternative route.

If the load were too great the jack would fail due to the high internal pressure. In practice a
pressure release valve is fitted so that if the pressure builds to an amount greater than for
which the valve is set the oil is allowed to flow back to the reservoir.

Construction of Hydraulic Jacks

We should note that it is easier to ‘push’ the small (pump) plunger down rather than ‘pull’ it
up as shown in the scientific principle illustrated in Figure 1. In practice the pivot point of the
handle is positioned the opposite side of the plunger to facilitate this.

Various materials may be used in the construction of hydraulic bottle jacks, they are chosen
for their strength in compression. The most commonly used are cast iron, steel and
aluminium. Although the design varies the design principles are the same.

The body of the jack acts as the reservoir, housed within the body is the pump and return
valve. An additional feature is the pressure relief valve, which is set so as to return the oil to
the reservoir once a pre-determined system pressure is reached. This acts as an overload
safety device to prevent the lifting capacity of the jack being exceeded.

The ram and ram chamber are also housed within the jack body. With most modern jacks the
ram is fitted with some positive means of limiting the outward stroke, and so preventing the
complete ejection of the ram from the body when the load is raised.

The oil passageways are housed within the body, these may be small bore tubes or
passageways drilled within the parent material. Non return valves are fitted into the
passageways or pipe-lines. Neoprene rubber seals, ‘O’ rings and oil resistant jointing are used
to ensure the complete system is air and oil tight.

TYPES OF HYDRAULIC JACK

Jacks are designed so that the load to be lifted sits on the head of the jack, however, to enable
objects with low jacking points to be raised some models can be fitted with a claw. This is an
attachment that has a toe. Due to the arrangement this places a leverage on the head of the
jack. As a result the maximum load that can be lifted on the toe is considerably less than that

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on the head of the jack. Other models have a screw extension in the head of the jack to enable
them to be adjusted to raise items where the jacking point is at a higher level.

Figure 2 shows some typical examples of jacks which have been designed for differing duties
and Figure 3 shows a jack fitted with a claw attachment.

Figure 2
Various Types of Jack

Figure 3
Jack with Claw Attachment

SAFETY REQUIREMENTS OF BS EN 1494

General
BS EN 1494 requires that hydraulic jacks, and pump and ram sets, are designed so that the
load is restrained and held automatically when the pumping operation stops.

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The reservoir must hold at least 10% more oil than the maximum displacement within the
system and there must be a facility for filling, or topping up, the oil level. A means must be
provided to enable any air to be bled from the system.

A device must be provided which prevents the ram being ejected from its housing cylinder.

Pressure Control
A pressure release valve must be fitted to prevent overloading. This should be set at the
lowest possible value within a tolerance range of 100% to 125% of the rated capacity.

Mechanical Strength
BS EN 1494 requires that the mechanical load bearing components, eg body, must be capable
of withstanding a load of at least 150% of the rated capacity without deformation of any part.
The materials used must be capable of the duty cycle and expected life such that they will not
fatigue or deform.

The parts and components of the jack which are subject to pressure must be designed to resist
a pressure of twice that at which the relief valve is set.

In the case of pump and ram sets, the coupling hose must be capable of sustaining three times
the set pressure of the relief valve without rupture.

Operation
The maximum effort necessary by each operative to start moving the load using the lever of a
hand pump, or using a foot pump, must not exceed 400N.

The operative must be able to regulate the speed of lowering a load. At the rated capacity the
speed of lowering must not exceed 0.15m/s.

Hydraulic jacks must be designed to operate within the temperature range of -20ºC to +50ºC.

MARKING
BS EN 1494 requires hydraulic jacks to be permanently and legibly marked with the
following minimum information:
a) Name and address of the manufacturer
b) Product identification code
c) Serial number or batch code
d) Year of manufacture
e) Rated capacity (WLL)

MANUFACTURER'S TESTS
Type Verification
BS EN 1494 requires the manufacturer of hydraulic jacks to carry out various type tests to
prove the design on one or more samples. (Note that in the case of pump and ram sets the
tests are made with the ram cylinder in the vertical position.) These include:
a) To prove the correct operation of any controls and safety mechanisms the jack must
be operated through one complete cycle in an unloaded condition.
b) The jack must be operated through one complete cycle with a load equal to the rated
capacity. The maximum operating pressure must be recorded. The load must then be
fully lowered and the speed recorded to ensure it does not exceed 0.15m/s.

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c) The jack should be fully raised with a load equal to the rated capacity and this should
be held for a period of 10 minutes. The vertical descent (creep) must not exceed 2mm.
d) The jack must be raised to 50% of its maximum operating height without a load. It
must then be back loaded with a load equal to 150% of the maximum possible load.
The load must be sustained for 15 minutes and then lowered. There must be no
permanent deformation of any part.
e) The jack must be stored at an ambient temperature of +23ºC ±5ºC for a period of at
least 12 hours. The jack should then be raised to its full working height and back
loaded to the rated capacity. This load must then be sustained for a period of at least
30 minutes. After 5 minutes of the load having been applied checks must be made of
any descent (creep). During the test a maximum creep of 2mm is permitted.
f) To test the pressure relief valve with the jack partially raised it should be subjected to
a load equivalent to that at which the relief valve would blow plus 5%. The jack must
hold this load but should not be able to raise it. Then with no load the jack should be
raised until the relief valve operates and this pressure must not exceed 125% of the
rated load.
g) At the rated capacity a test must be made to simulate the failure of a hose or pipe way
between the pump and ram cylinder to ensure the operation of the non return valve.
The load must not descend by more than 100mm.
h) The relief valve must then be neutralized and the jack raised. It must then be back
loaded to a load equivalent to the maximum possible load plus 25%. This load must
then be lowered by operation of the jack through is full stroke. There must be no
permanent deformation of any part.
i) The operating forces must be measured at the rated capacity and must not exceed
those given in the standard.
j) With no load, the jack should be raised until the travel limiting device operates. This
test must be repeated 10 times. There must be no permanent deformation of any part.

Manufacturing Tests and Examination

On completion of manufacture each hydraulically operated jack must be subject to:
a) An operational test with no load through the full range of the travel motion.
b) A dynamic test with a load equal to the full rated capacity lifted through the full range
of the travel motion.
c) A check to ensure the correct setting and functioning of the pressure relief valve.
d) Thorough examination.

USE OF HYDRAULIC JACKS

Before we consider the matters to be taken into account during the examination, we will take
a look at the use of hydraulic jacks and the damage and defects that can occur due to misuse.
Full details of the safe use of hydraulic jacks is given in Section 12 of the LEEA Code of
Practice for the Safe Use of Lifting Equipment, which you should also study.

In operations using more than one jack, care must be taken to ensure that the load is evenly
balanced and that the operation of the jacks is in unison. Failure to observe this requirement
will result in some of the load transferring to one of the jacks and possibly overloading it.

The floor onto which the jack sits must be level and even so that the jack does not rock or tilt
as this can cause the body to be unevenly loaded and distort or crack. It is also possible for
the jack to 'kick out' damaging the ram, extension threads, body casing and other components.

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Similarly, care must be taken to prevent the jack 'kicking out' or toppling due to an oblique
thrust, eg caused by incorrect packing, uneven loading, unstable load etc. This can cause
damage to the ram, seals etc.

Care must be taken not to extend the jack up to or beyond its maximum. Whilst modern jacks
have positive stops to prevent the ram being ejected from the cylinder, over extension can
cause the ram to become bent. Older jacks may not have a positive stop and the ram could be
ejected.

To ensure the correct operation of valves, and that tubes and passageways do not become
restricted, the oil must be kept clean. Dirty/emulsified oil may result in excessive pressure
being developed leading to the failure of seals and 'O' rings etc.

EXAMINATION
Hydraulic jacks fall under the heading of 'lifting equipment' in modern legislation and
therefore should be examined by a competent person at periods not exceeding twelve months.

The requirements for load tests to be made as part of the examination will vary dependent on
the circumstances, although some testing under load will be essential. Similarly the extent to
which it may be necessary to dismantle and clean the jack will also vary with the
circumstances. We will consider these matters. Further, some organisations have laid down
procedures for dealing with these matters, which their employees will need to follow. It must,
however, be understood that these matters are the responsibility of the competent person
making the examination and that he may be held to account to justify his decisions.

During the examination, the general appearance and operation of the jack should be checked
and a functional test made to ensure the correct and smooth operation. The following should
also be checked:
a) Oil patches or obvious leaks, particularly during the operation of the jack. This is
usually due to failed seals or 'O' rings but may also be a sign of cracked jack body.
b) The jack fails to lift or after a short period of movement the load rises and falls with
each stroke of the lever. When operation ceases the load begins to lower on its own.
These may be due to blown seals or non return valves not operating correctly and can
be caused by dirty/emulsified oil, or due to scored, nicked or otherwise damage to the
ram face.
c) The ram fails to lower, fully retract or lowering is jerky. Usually due to
dirty/emulsified oil causing valves to stick, but may be due to other damage. Similarly
the release valve may be difficult to operate or fail to release the load.
d) Cracks, dents and mechanical damage to the body and base and/or base distorted.
e) In the case of jacks with claw attachments, the claw does not sit on the head of the
jack correctly, the claw is cracked, distorted or otherwise damaged.

The examination of a hydraulic jack will always include some form of test, usually with a
load imposed on the jack. Functional tests, with a light load will be helpful in confirming the
correct function of the jack. A load test at the rated capacity, lifted through the full range of
lift, then held for a period of time will help to reveal faults and defects within the hydraulic
system, eg leaking seals or valves not operating correctly, which might not otherwise be
apparent.

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