TJ10
HYDRAULIC
TRACK JACK
Safety, OperatiOn and Maintenance
USer'S ManUaL
© 2011 Stanley Black & Decker, Inc.
New Britain, CT 06053
U.S.A.
34964 4/2013 Ver. 8
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DECLARATION OF CONFORMITY
DECLARATION OF CONFORMITY
ÜBEREINSTIMMUNGS-ERKLARUNG
DECLARATION DE CONFORMITE CEE
DECLARACION DE CONFORMIDAD
DICHIARAZIONE DI CONFORMITA
Hydraulic Tools
______________________________________________________________________
I, the undersigned:
Weisbeck, Andy
Ich, der Unterzeichnende:
Je soussigné:
Surname and First names/Familiennname und Vornamen/Nom et prénom/Nombre y apellido/Cognome e nome
El abajo firmante:
lo sottoscritto:
hereby declare that the equipment specified hereunder:
bestätige hiermit, daß erklaren Produkt genannten Werk oder Gerät:
déclare que l’équipement visé ci-dessous:
Por la presente declaro que el equipo se especifica a continuación:
Dichiaro che le apparecchiature specificate di seguito:
1. Category:
Kategorie:
Catégorie:
Categoria:
Categoria:
Track Jack
2. Make/Marke/Marque/Marca/Marca
3. Type/Typ/Type/Tipo/Tipo:
Stanley
TJ10111M, TJ10111MF, TJ10112M
4. Serial number of equipment:
Seriennummer des Geräts:
Numéro de série de l’équipement:
Numero de serie del equipo:
Matricola dell´attrezzatura:
All
Has been manufactured in conformity with
Wurde hergestellt in Übereinstimmung mit
Est fabriqué conformément
Ha sido fabricado de acuerdo con
E’ stata costruita in conformitá con
Directive/Standards
Richtlinie/Standards
Directives/Normes
Directriz/Los Normas
Direttiva/Norme
No.
Nr
Numéro
No
Approved body
Prüfung durch
Organisme agréé
Aprobado
n.
Collaudato
Machinery Directive
EN
EN
EN
2006/42/EC:2006
12100-1:2009
12100-2:2009
1492:2000+A1:2008
B30.1-2009
Self
Self
Self
Self
Self
ASTM
5. Special Provisions:
Spezielle Bestimmungen:
Dispositions particulières:
Provisiones especiales:
Disposizioni speciali:
None
6. Representative in the Union: Patrick Vervier, Stanley Dubuis 17-19, rue Jules Berthonneau-BP 3406 41034 Blois Cedex, France.
Vertreter in der Union/Représentant dans l’union/Representante en la Union/Rappresentante presso l’Unione
Done at/Ort/Fait à/Dado en/Fatto a Stanley Hydraulic Tools, Milwaukie, Oregon USA
Signature/Unterschrift/Signature/Firma/Firma
Date/Datum/le/Fecha/Data
3-22-11
Position/Position/Fonction/Cargo/Posizione
Engineering Manager
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SAFETY SYMBOLS
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair
actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equip-
ment.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
This safety alert and signal word indicate an imminently hazardous situa-
tion which, if not avoided, will result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
This safety alert and signal word indicate a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury.
This signal word indicates a potentially hazardous situation which, if not
avoided, may result in property damage or damage to the equipment.
This signal word indicates a situation which, if not avoided, may result in
damage to the equipment.
Always observe safety symbols. They are included for your safety and for the protection of the tool.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and mainte-
nance personnel.
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SAFETY PRECAUTIONS
Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and
on the stickers and tags attached to the tool and hose.
These safety precautions are given for your safety. Review them carefully before operating the tool and before per-
forming general maintenance or repairs.
Supervising personnel should develop additional precautions relating to the specific work area and local safety regu-
lations. If so, place the added precautions in the space provided.
GENERAL SAFETY PRECAUTIONS
• The user must be familiar with correct operation, maintenance, and use of the jack. Lack of knowledge can lead
to personal injury.
• Operator must start in a work area without bystanders. The operator must be familiar with all prohibited work
areas such as excessive slopes and dangerous terrain conditions..
•
Always wear safety equipment such as goggles, gloves, head, and safety shoes at all times when operating the
tool.
• Warning: Hydraulic fluid under pressure could cause skin injection injury. If you are injured by hydraulic fluid,
get medical attention immediately.
• The total load lifted or supported by the jack must never exceed the rated capacity. Excess pressure can result in
personal injury. Use a jack with sufficient capacity to lift a load. Keep clear of lifted loads.
• Inspect each jack before each usage or shift to prevent unsafe conditions from developing.
• Properly support the jack.
• Do not put poorly balanced or off-center loads on the jack pad or jack. The load can tip and cause personal in-
jury. Do not use in unstable or hazardous positions.
• The jack must be used on flat surfaces to be able to carry the load correctly. The base must be completely sup-
ported. Do not push or lift on the ends of the base.
• Do not lift people, or loads with people on them.
• As the load is lifted, use blocks or cribs to guard against a falling load.
• To help prevent personal injury, do not allow personnel to go under, or work on, a load before it is properly
cribbed or blocked. All personnel must be clear of a load before lowering or lifting.
• Lift only dead weight loads. Do not add additional weight to a lifted load.
• Do not use jacks that are damaged, altered or in poor condition.
• The reservoir must have sufficient hydraulic fluid to fully stroke the jack. Use only approved hydraulic fluids.
• Read and understand the operating instructions in this manual, and the ASME B30.1 and EN 1494 safety code for
jacks.
• Users must ensure that all safety related decals and stickers are whole and readable. Replace those which become
unreadable.
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SAFETY PRECAUTIONS
GENERAL SAFETY PRECAUTIONS CONTINUED:
• Never use extreme heat to disassemble a hydraulic ram or cylinder. Metal fatigue can lead to unsafe conditions.
• Be aware of possible "pinch points" of the jack, and stay clear to avoid personal injury.
• When lifting with the edge of the lifting toe, place a wedge between the load and the top of the lifting toe to
avoid bending the cylinder column.
• Carry the jack only by the carrying handle. Make sure the jack is in the fully lowered position.
• End users must be trained in the proper use of the jack..
• Remove operating levers when not in use to avoid accidental dislocation of the jack, and reduce the tripping
hazard.
• Make sure all personnel are clear of the load before lifting or lowering.
• DO NOT use extenders unless authorized by a qualified person.
• Never use this tool when working around electrified rail unless it is de-energized or you have been properly
trained to work on electrified rail. If you are not sure the rail is live or not, you must treat it as being live and
dangerous to life.
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TOOL STICKERS AND TAGS
WARNING DECAL - P/N 28788
(Shown smaller than actual size)
Indicates that users should read
the manual before using the
product.
RAILROAD HELP DESK - P/N 25610
The following information is found on the base
of the Track Jack.
•
•
•
•
Model Number
Capacity
Maximum Pressure
Date
CRUSH HAZARD - P/N 31064
P/N 28788
P/N 25610
P/N 31064
P/N 05152
STICKER LOCATIONS
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MAINTENANCE & CARE
GENERAL PROTECTION
ADDING FLUID WHEN NEEDED
Store the Track Jack in an upright position, in a place
where it is protected from the elements, abrasive dust,
and damage.
A jack that is low on hydraulic fluid can lift a full load,
but not to the full lift height. As the reservoir begins to
run dry, the lever socket becomes very easy to pump,
and the jack stops lifting. To add oil:
Use only recommended repair and replacement parts
and materials specified in the Parts List section of this
manual.
1. Fully retract the plunger.
2. Remove the fill plug.
Do not use the jack for applications it was not designed
for.
3. Fill the reservoir with new, clean fluid (use ISO#15
Hydraulic Fluid) to a level 1/8 inch below the bot-
tom of the fill plug hole.
Use the carrying handle to transport the Track Jack from
location to location. Do not carry the Track Jack by
inserting the jack handle in the socket.
WARNING
CLEANING
Do not overfill or underfill the reservoir
as this may damage the jack.
Establish a routine to keep the jack as free from dirt as
possible – daily, or at each shift change, for example.
ANNUAL FLUID CHANGE
Jacks exposed to rain, sand, or grit-laden air should be
cleaned prior to each use.
Regardless of usage, the Track Jack hydraulic fluid
should be changed annually to ensure proper operation
of the jack. To drain the fluid:
Exposed screw threads should be cleaned and re-lubri-
cated as necessary.
Keep the cylinder clean at all times. Keep the piston
retracted when not in use.
1. Thoroughly clean the area around the fill plug.
2. Remove the fill plug and lay the Track Jack on its
back to allow the fluid to drain from the fill hole into
an appropriate receptacle.
Operating lever and load-bearing surfaces should be
free of slippery material or fluids.
Keep tool labels and stickers legible.
3. Dispose of the used hydraulic fluid in accordance
with Environmental Protection Agency regulations.
HYDRAULIC FLUID
4. Make sure dirt or other contaminants do not enter
the reservoir while the fill plug is removed. When
drained, check the fluid for contaminants. If the
fluid appears gritty or dirty, flush the reservoir with
clean hydraulic fluid before refilling.
The Track Jack holds approximately 28 ounces/820 cc
cubic inches of hydraulic fluid in its reservoir.
DANGER
5. Refill the reservoir with the recommended hydraulic
fluid. Stand the jack upright, and with the piston
fully retracted, fill the reservoir until the fluid level
is 1/8 inch below the bottom of the fill plug.
DO NOT USE BRAKE FLUID OR OTHER
NON-APPROVED SUBSTITUTE FLUIDS.
LIGHTER WEIGHT FLUIDS MAY CAUSE
THE JACK TO FAIL UNDER LOAD.
6. Before returning the jack to service, fully extend the
piston without a load by pumping the pump handle
without the long extension handle. If the fluid level
is correct, the pump handle will become almost im-
possible to pump by hand as the piston reaches full
extension. Replace the plug.
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MAINTENANCE & CARE
7. It may be necessary to bleed air out of the cylinder.
See instructions below for purging air.
8. Inspect the jack for leaks, cracks, or other damage.
DANGER
Immediately take out of service any
jack that appears to be damaged or
leaking.
PURGING AIR
Air trapped within the jack hydraulic system can be
removed by performing the following steps.
1. Make sure the plunger is fully retracted.
2. Pry out the cap on top of the unit.
3. Loosen (Do Not Remove) the capscrew under the
cap located in the top of the plunger.
4. Place the jack in a suitable fixture to prevent the
extension of the plunger while purging air.
DANGER
The fixture used to prevent extension
of the plunger while purging air must
be able to withstand the full ten ton
force of the jack.
5. Add hydraulic fluid to the reservoir if necessary. See
instructions above for adding fluid.
6. Pump the handle until oil comes up through the
thread area of the capscrew in the plunger.
7. Tighten the socket head capscrew to 10-12 ft.
lbs./14-16 Nm.
8. Top off the reservoir with hydraulic fluid. NOTE:
Make sure the plunger is fully retracted before filling
the reservoir.
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OPERATING INSTRUCTIONS
DANGER
WARNING
MAKE SURE THAT ALL PERSONNEL ARE CLEAR
OF THE LOAD BEFORE ATTEMPTING TO RAISE
OR LOWER THE JACK. SERIOUS INJURY OR
DEATH COULD RESULT FROM THE IMPROPER
USE OF THIS TOOL.
Use only the recommended length jack
handle. DO NOT use longer handles or
extenders.
5. Remove the jack handle from the handle socket once
the load reaches its desired height.
PREOPERATION PROCEDURES
6. Crib or block the load to prevent accidently drop-
ping the load.
Before putting a new Track Jack into initial service,
or after an extended period of being unused, perform
a visual inspection for bent, broken, cracked, missing
or worn components. Ensure the hydraulic fluid and
lubricant level is correct. Fully extend and retract the
jack without a load to ensure that the jack is primed and
operating properly.
LOWERING A LOAD
1. Make sure all personnel are clear of the load.
2. Remove cribbing or blocking if used.
3. Open the release valve by turning it counterclock-
wise (open slowly).
RAISING A LOAD
1. Before using the Track Jack, make sure that it is set
on a firm surface capable of bearing the intended
load.
DANGER
Lowering speed is controlled by opening the
release valve more or less. DO NOT open the
valve more than two full turns.
2. Make sure the release valve is closed, by turning it
clockwise until it is hand tight.
4. When the load reaches the desired level, close the
release valve by turning it clockwise until it is hand
tight.
DANGER
Overtightening the release valve can damage
the valve seat. DO NOT use pliers or wrenches
to tighten the release valve.
HORIZONTAL OPERATION
The Track Jack can also be used horizontally to separate
two items, as long as it is placed with the handle socket
facing upwards.
3. Pump the handle by hand until the toe lift or head
lift plate rises to and engages the load.
1. Place the Track Jack base against the largest, heavi-
est, or otherwise least moveable of the two items.
DANGER
2. Close the release valve by turning it clockwise until
hand tight.
Make certain that the lifting toe is fully
engaged on the load, and the entire jack is
stable, before proceeding further.
3. Pump the handle socket by hand until the lifting toe
or the head of the lifting toe firmly engages the more
moveable of the two items.
4. Insert the jack handle fully into the handle socket
and pump until the desired lift has been obtained.
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TROUBLESHOOTING
4. Make sure personnel are clear of all items being
jacked before attempting to move anything.
WARNING
5. Insert the jack handle into the handle socket and
pump until the desired separation has been obtained.
NEVER LIFT OR LOWER A LOAD HEAVIER THAN
THE LOAD RATING OF THE JACK. DAMAGE
TO THE JACK OR LOAD COULD RESULT FROM
IMPROPER USE OF THIS TOOL.
6. Remove the jack handle from the socket once the
moveable load reaches its desired separation.
PUMPING HANDLE
7. To free the jack, open the release valve by turning it
counterclockwise. When the lift plate is clear, close
the release valve.
A pumping handle is included with the Track Jack is de-
signed with a 4:1 safety factor. DO NOT use the pump-
ing handle for any other purpose. DO NOT substitute
other material for use as a pumping handle.
TROUBLESHOOTING
If symptoms of poor performance develop, the following chart can be used as a guide to correct the prob-
lem.
Because the Track Jack can be used for many different applications, this information is general in nature
and does not address specific uses.
PROBLEM
CAUSE
CORRECTION
Jack will not raise
Close the valve
A) Release valve not closed
Have jack serviced by a qualified
B) Release valve ball not
seating properly
technician
C) Seal failure
Have jack serviced by a qualified
technician
Jack raises but will not hold
Release valve ball not seat-
ing properly
Have jack serviced by a qualified
technician
Relief valve set too low or
Malfunctioning
Seal failure
Have jack serviced by a qualified
technician
Jack only raises part way
Hydraulic fluid level is low
Add hydraulic fluid
Jack leaks hydraulic fluid
Seal failure
Have jack serviced by a qualified
technician
Jack retracts slowly
Air in the hydraulic system
Air in the hydraulic system
Purge air from the hydraulic system
Purge air from the hydraulic system
Jack raises, but pulses and
hesitates
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SPECIFICATIONS
Performance
Maximum Lift ........................................................................................................................8.9 in. /226 mm
Maximum Load.................................................................................................................... 10 tons/9070 kg
Pump Displacment ...............................................................................46 cu. in/7.5 cc stroke, single speed
Advance rate per stroke ..........................................................................................................14 in./3.6 mm
Pressure at rated load.............................. 7300 psi/500 bar Model TJ10, (7150 psi/493 bar Model TJ10M)
Maximum pump handle effort...................................................................................................80 lbs./355 N
Dimensions and Weight
Baseplate Size..............................................................................................................6 x 11 in./15 x 28 cm
Lift Toe Width and Depth .............................................................................................2-1/2 x 3/63 x 76 mm
Height (retracted) ..........................................14.5 in//37 cm Model TJ10, (14.75 in/37.5 cm Model TJ10M)
extended ......................................................23.4 in./59 cm Model TJ10, (23.56 in/60 cm Model TJ10M)
Net Weight (less oil) .................................................. 43 lb/20 kg Model TJ10, (44 lb/20 kg Model TJ10M)
Lever Bar Length ..................................................................................................................... 36 in./ 80 cm
Hydraulic Requirements
Reservoir Capacity .................................................................................................................. 28 oz/820 cc
Recommended Fluid ................................................................................................ISO #7 Hydraulic Fluid.
Standards................................................................................................................. ASME B30.1, EN 1494
NOTE: Weights, dimensions and operating specifications listed on this sheet are subject to change with-
out notice. Where specifications are critical to your application, please consult the factory.
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BASE ILLUSTRATION
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PUMPASSY ILLUSTRATION
NOTE: Item descriptions which
are preceded by a item number
may be ordered individually.
NOTE: Item descriptions which are
preceded by a symbol are only available
in their respective repair kits.
Manifold Assembly P/N-34873
Includes all items shown except
pump handle 34870.
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PARTS LIST
TJ10
*TJ10M
ITEM
1
P/N
QTY
DESCRIPTION
Cap
Pumping Handle
Pipe Plug
Capscrew
Relief Valve Assy
Manifold
Capscrew
ITEM
1
P/N
QTY
DESCRIPTION
Cap
52805
65924
01219
10888
34849
56629
00769
31064
1
1
2
4
1
1
4
1
52805
52806
52807
52809
52812
52813
01219
56518
52824
52827
52830
56521
31064
05152
28788
25610
56601
1
1
1
1
1
1
2
4
1
1
1
4
1
1
1
1
1
16
28
29
40
46
49
50
3
6
Lifting Toe
Stop Ring
Plunger
Base, (Model TJ10111M)
Pumping Handle
Pipe Plug
Capscrew
Seat Assy
Relief Valve Assy
Manifold
Capscrew
Sticker, Crush Hazard
Sticker, Stanley Logo
Sticker, Manual Composite
Sticker, Help Desk
Base (Narrow), (Model
TJ10112M)
11
14
16
28
29
38
40
46
49
50
52
56
57
58
Sticker, Crush Hazard
52
56
57
59
05152
28788
25610
34852
1
1
1
1
Sticker, Stanley Log
Sticker, Manual Composite
Sticker, Help Desk
Piston
59
52819
1
Piston
NOTE: When ordering parts make sure to check the (Model Number)
on your track jack to distinguish between a TJ10 and TJ10M*.
*KITS FOR MODEL TJ10111M & TJ10112M ONLY
KITS FOR MODEL TJ10111 & TJ10112 ONLY
P/N
DESCRIPTION
P/N
DESCRIPTION
Manifold Assy
56629
Manifold Assy
56629
56528
Spring Kit
56522
56523
56524
56525
56526
56527
Cylinder Repair Kit
34872
34858
34851
34853
34848
34845
Cylinder Repair Kit
Carry Handle Repair Kit
Reservoir Repair Kit
Beam & Piston Repair Kit
Pump Repair Kit
Carry Handle Repair Kit
Reservoir Repair Kit
Beam & Piston Repair Kit
Pump Repair Kit
Release Valve Repair Kit
Release Valve Repair Kit
* "M" Models Begin With S/N 5000.
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REPAIR KITS
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NOTES
TJ10 User Manual ► 17
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Stanley Hydraulic Tools
3810 SE Naef Road
Milwaukie, OR 97267-5698 USA
Phone: (503) 659-5660
Fax: (503) 652-1780
Copyright© 2009 The Stanley Works
To fill out a Product Warranty Recording form and for information on your warranty visit
Stanleyhydraulic.com and select the Warranty tab.
(Note: the warranty recording form must be submitted to validate the warranty).
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