Stanley TJ12 Hydraulic Track Jack (10 Ton)

Declarations of Conformity

The Stanley TJ12 Hydraulic Track Jack has been manufactured in conformity with relevant directives and standards, including the Machinery Directive EN 2006/42/EC:2006 and EN 1494:2000+A1:2008. It also conforms to UK regulations, including the Supply of Machinery (Safety) Regulations 2008.

Table of Contents

• Safety Symbols
• Tool Stickers and Tags
• Maintenance & Care
• Operating Instructions
• Troubleshooting
• Specifications
• Pump Assembly Illustration & Parts List
• Base Illustration & Parts List

Important Information

To validate your product warranty, visit www.stanleyinfrastructure.com and navigate to the Company tab > Warranty. Note that the warranty validation record must be submitted.

Servicing Warning: This manual contains safety, operation, and routine maintenance instructions. STANLEY Infrastructure recommends that servicing of hydraulic tools, other than routine maintenance, must be performed by an authorized and certified dealer. Improper repair or service can result in serious injury or death.

Safety Symbols

Safety symbols and signal words are used to emphasize critical actions. Obey all safety messages following these symbols to avoid injury or death.

• DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
• WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in property damage.
• NOTICE: Indicates a situation which, if not avoided, will result in damage to the equipment.
• IMPORTANT: Indicates a situation which, if not avoided, may result in damage to the equipment.

Always observe safety symbols for your safety and the protection of the tool.

Enter any local safety regulations in the provided space. Keep these instructions accessible to operators and maintenance personnel.

Safety Precautions

• Comply with all safety precautions and instructions on the tool and hose stickers.
• Review precautions carefully before operating or performing maintenance.
• Supervising personnel should develop additional precautions for specific work areas and local regulations.
• The TJ12 conforms with EN 1494:2000+A1:2008 and is intended for lifting rail (railroad tracks) only.
• Users must be familiar with correct operation, maintenance, and use. Lack of knowledge can lead to injury.
• Operators must work in an area without bystanders and be aware of prohibited areas (slopes, dangerous terrain, extreme climates).
• Always wear safety equipment: goggles, gloves, head protection, and safety shoes.
• Warning: Hydraulic fluid under pressure can cause skin injection injury. Seek immediate medical attention if injured.
• Do not exceed the jack's rated capacity. Use a jack with sufficient capacity. Keep clear of lifted loads.
• Visually inspect the jack before each use for damage or leaks. Do not use damaged, leaking, altered, or poorly conditioned jacks.
• Do not put poorly balanced or off-center loads on the jack. The load can tip. Do not use in unstable or hazardous positions.
• Use the jack on flat, completely supported surfaces. Do not push or lift on the ends of the base.
• Do not lift people or loads with people on them.
• Use blocks or cribs to guard against a falling load as it is lifted.
• Ensure personnel are clear of a load before lowering or lifting.
• Lift only dead weight loads. Do not add additional weight.
• Do not use damaged, altered, or poorly conditioned jacks. Do not modify the jack in a way that affects compliance with BS EN 1494:2000+A1:2008.
• Ensure the reservoir has sufficient hydraulic fluid (ISO#15 Hydraulic Fluid). Ensure no oil contamination on the floor.
• Read and understand operating instructions, ASME B30.1, and EN 1494 safety codes.
• Ensure all safety decals and stickers are readable. Replace unreadable ones.
• Never use extreme heat to disassemble a hydraulic ram or cylinder.
• Be aware of possible "pinch points" and stay clear.
• When lifting with 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 by the carrying handle with the jack in the fully lowered position.
• End users must be trained in proper use. Fully lower the jack when work is completed.
• Remove operating levers when not in use to avoid accidental dislocation and tripping hazards.
• Ensure all personnel are clear of the load before lifting or lowering.
• DO NOT use extenders, spindles, or accessories.
• Never use the tool when working around electrified rail unless it is de-energized and you are trained. Treat all rail as live if unsure.
• The operator should always have the lifting device and load in view during movement.
• All tool repair, maintenance, and service must be performed by authorized and properly trained personnel.
• Never use the tool in an explosive atmosphere.
• Never use the tool near strong magnetic fields.
• Do not handle loads that could lead to dangerous situations (e.g., molten metal, acids, radiating material, brittle loads).
• When decommissioning, drain all hydraulic fluid and dispose of it according to regulations.
• If rated values are exceeded, use additional persons to aid in lowering.

Tool Stickers and Tags

The TJ12 is equipped with various stickers and tags for safety and identification:

• Manual Sticker (P/N-88348)
• Crushing Hazard Sticker (P/N-31064)
• Stanley Sticker (P/N-73679)
• Importer Sticker (P/N-88345)
• CE Sticker (P/N-28322)
• UKCA Sticker (P/N-88724)
• Railroad Help Desk Sticker (P/N-73680)

Information such as Model Number, Serial Number, pressure rating (7250 PSI/500 Bar), and year of manufacture are stamped on the bottom left side of the base.

Maintenance & Care

General Protection

• Store the Track Jack upright in a protected area, away from elements, abrasive dust, and damage.
• Do not exceed the rated use temperatures of -4°F to 122°F (-20°C to 50°C).
• Use only recommended repair and replacement parts.
• Do not use the jack for unintended applications.
• Use the carrying handle for transport; do not carry by the jack handle.

Cleaning

• Keep the jack free from dirt daily or at each shift change.
• Clean jacks exposed to rain, sand, or grit-laden air before each use.
• Clean and re-lubricate exposed screw threads as necessary.
• Keep the cylinder clean and retract the piston when not in use.
• Ensure operating lever and loadbearing surfaces are free of slippery material or fluids.
• Keep tool labels and stickers legible.

Hydraulic Fluid

The Track Jack holds approximately 28 oz (820 cc) of ISO#15 Hydraulic Fluid.

DANGER: Do not use brake fluid or other non-approved substitute fluids. Lighter fluids may cause jack failure under load.

A jack low on hydraulic fluid may still lift a full load but not to full height. The handle will become easier to pump as the fluid level drops.

Adding Oil:

1. Fully retract the plunger.
2. Ensure the relief valve is closed.
3. Remove the fill plug (item #3).
4. Fill the reservoir with new, clean ISO#15 Hydraulic Fluid. Fill to the bottom of the threads on the fill plug hole.

WARNING: DO NOT OVERFILL OR UNDERFILL THE RESERVOIR AS THIS MAY DAMAGE THE JACK.

Annual Fluid Change

Change hydraulic fluid annually for proper operation.

To drain the fluid:

1. Clean the area around the fill plug.
2. Remove the fill plug and lay the jack on its back to drain fluid into a receptacle.
3. Dispose of used hydraulic fluid according to Environmental Protection Agency regulations.
4. Prevent dirt or contaminants from entering the reservoir. Check fluid for contaminants; flush if necessary.
5. Refill the reservoir with recommended hydraulic fluid. Stand the jack upright with the piston retracted. Fill to the bottom of the threads on the fill plug hole.
6. Before returning to service, fully extend the piston without a load. The pump handle should become difficult to pump as the piston reaches full extension.
7. Replace the plug.
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 and replace any damaged parts.

Purging Air

Air trapped in the hydraulic system can be removed by following these steps:

1. Ensure the plunger is fully retracted.
2. Pry out the cap.
3. Loosen (Do Not Remove) the capscrew under the cap in the top of the plunger.
4. Place the jack in a suitable fixture to prevent plunger extension while purging air.

DANGER: The fixture used must withstand the full ten-ton force of the jack.

5. Add hydraulic fluid if necessary.
6. Pump the handle until oil comes up through the thread area of the capscrew.
7. Tighten the socket head capscrew to 10-12 ft. lbs./14-16 Nm. Replace the cap.
8. Top off the reservoir with hydraulic fluid. Ensure the plunger is fully retracted before filling.

Pressure Relief Setting

The pressure relief is factory-set and should not be altered. Contact STANLEY for any issues with the relief setting.

WARNING: Never attempt to alter the pressure relief setting. Doing so could result in death, serious injury, or equipment damage.

WARNING: To avoid personal injury or equipment damage, all repair, maintenance, and service must be performed by authorized and properly trained personnel.

Inspecting the Track Jack for Damage or Leakage

1. Before each use, visually inspect the jack for leaks, cracks, or other damage.

DANGER: Never use a damaged track jack. Immediately take out of service any jack that appears to be damaged or leaking and replace any damaged parts.

Illustration showing Cap, Retaining Ring, Lifting Toe, and arrows indicating inspection points.

2. Once a month, remove the retaining ring and lifting toe. Thoroughly inspect the back, front, and sides for damage or cracks, paying special attention to the indicated areas.

Operating Instructions

DANGER: Ensure all personnel are clear of the load before attempting to raise or lower the jack. Serious injury or death could result from improper use.

Preparation Procedures

• Before putting a new Track Jack into service, or after extended periods of non-use, perform a visual inspection for bent, broken, cracked, missing, or worn components (see “Inspecting the Track Jack for Damage or Leakage” on page 11).
• Ensure hydraulic fluid and lubricant levels are correct.
• Fully extend and retract the jack without a load to ensure it is primed and operating properly.
• Note: TJ12 is rated for use at temperatures between -4°F - 122°F (-20°C - 50°C).

Raising a Load

1. Ensure the Track Jack is set on a firm surface capable of bearing the intended load.
2. Make sure the Spindle (item 41) is closed by turning it clockwise until hand-tight.

DANGER: Overtightening the spindle (item 41) can damage the valve seat. DO NOT use pliers or wrenches to tighten.

3. Pump the handle until the toe lift or head lift plate rises and engages the load.

Illustration showing Head Lift and Toe Lift.

DANGER: Make certain that the lifting toe is fully engaged on the load, and the entire jack is stable, before proceeding further.

4. Insert the jack handle fully into the handle socket. Pump until the desired lift has been obtained.

WARNING: Use only the recommended length jack handle. DO NOT use longer handles. See “Specifications” on page 15.

5. Remove the jack handle from the handle socket.
6. Crib or block the load to prevent accidental dropping of the load.

Lowering a Load

1. Make sure all personnel are clear of the load.
2. Remove cribbing or blocking, if used.
3. Slowly open the spindle (item 41) by turning it counterclockwise.

DANGER: Lowering speed is controlled by opening the Spindle more or less. Open slowly to control the lowering speed. Caution: Opening the Spindle too much will cause the load to drop quickly.

4. When the load reaches the desired level, close the spindle by turning it clockwise until it is hand tight.

Horizontal Operation

The Track Jack can be used horizontally to separate two items, with the handle socket facing upwards.

1. Place the Track Jack base against the largest, heaviest, or least moveable of the two items.
2. Close the spindle (item 41) by turning it clockwise until hand tight.
3. Pump the handle socket by hand until the lifting toe or head of the lifting toe firmly engages the more moveable of the two items.
4. Make sure personnel are clear of all items being jacked before attempting to move anything.
5. Insert the jack handle into the handle socket. Pump until the desired separation has been obtained.
6. Remove the jack handle from the socket.
7. To free the jack, open the spindle by turning it counterclockwise. When the lift plate is clear, close the spindle.
8. The operator must watch the lifting device and the load during all movements.

WARNING: 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.

Pumping Handle

A pumping handle is included with the Track Jack. DO NOT use the pumping handle for any other purpose. DO NOT substitute other material or use a longer handle than specified in “Specifications” on page 15.

Troubleshooting

Specifications

Performance

• Maximum Lift: 8.8 in. / 22.3 cm
• Maximum Load: 10 tons / 9,072 kg
• Pump Displacement: 46 cu. in. / 7.5 cc stroke, single speed
• Advance rate per stroke: 0.160 in. / 4.0 mm
• Pressure at rated load: 7250 psi / 500 bar (Model TJ12)
• Maximum pump handle effort: 75 lbs. / 34 kg

Dimensions

• Baseplate Size TJ12111S: 6.000 x 11 in. / 15 x 28 cm
• Baseplate Size TJ12112S Narrow: 4.500 x 11 in. / 11.4 x 28 cm
• Weight: 45 lbs / 19.5 kg
• Lift Toe Width and Depth: 2-1/2 in x 3 in. / 63 mm x 76 mm
• Height (Retracted): 14.7 in. / 37.3 cm
• Height (Extended): 23.500 in. / 597 mm
• Net Weight (with oil) no handle: 45 lb / 20.4 kg
• Pump Handle Length (p/n-52813): 36 in. / 91 cm

Hydraulic Requirements

• Reservoir Capacity: 28 oz / 828 cc
• Recommended Fluid: ISO #15 Hydraulic Fluid
• Standards: ASME B30.1, EN 1494:2009

Note: This product does not exceed 70 dBA per ISO 11201.

Note: Weights, dimensions, and operating specifications are subject to change without notice. Consult the factory for critical specifications.

Repair Kits

• Cylinder Repair Kit (Includes Items: 1, 7, 19, 21, & 27 thru 31): 56522
• Reservoir Repair Kit (Includes Items: 25, 26 and 35): 56524

Illustration of Pump Handle Assembly (P/N-52813).

Pump Assembly Illustration & Parts List

This section provides an illustration and parts list for the pump assembly. Refer to page 13 for Cylinder Repair Kit & Reservoir Repair kit details.

* DENOTES PART IN SEAL KIT (P/N-72735)

Illustration showing the pump assembly with numbered parts corresponding to the list. Also shows the TJ12111S and TJ12112S Narrow Base models, with a callout for Model #, Serial # location.

Base Illustration & Parts List

This section provides an illustration and parts list for the base assembly. Refer to page 15 for Repair Kit details.

* DENOTES PART IN SEAL KIT P/N-72735

Illustration showing the base assembly with numbered parts corresponding to the list. Also shows the TJ12111S model with a callout for Model #, Serial # location.