HomeMy WebLinkAboutAtlas 9KOH 9000lbs Capacity Two-Post Overhead Lift Manualas 9KO-H
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:._ Read this entire manual before operation begins.
-Record below the following information which is located on the serial number
data plate.
Serial No.
`` Model No.
Date of Installation
Contents
Important Information . . . . . . . . 4
9KOH Specifications . . . . . . . . . 6
Installation Requirements . . . . 9
Installation Procedure . . . . . . . . .11
Lift Lockout/Tagout Procedure . . . . . 22
Operating Instructions. . . . . . . . .24
Safety Procedures. . . . . . . . . . .26
Troubleshooting . . . . . . . . . . . . 30
Illustrated Parts Breakdown . . . . . . 33
Parts List . . . . . . . . . . . . . . . 34
Warranty . . . . . . . . . . . . . . 37
Important Information
I. Any freight damage must be noted on the freight bill before signing and
reported to the freight carrier with a freight claim established. Identify the
components and check for shortages. If shortages are discovered, please
contact the Distributor / Sales Rep. in your area for service.
2. Consult building owner and / or architect's plans when applicable to
establish the best lift location! The lift should be located on a relatively
level floor with 4 in. minimum thickness, 3000-psi concrete slab that has
been properly cured. There can be no cracks in the slab within _36 in.
of the base plate location, and no seams in the foundation within 6
in. of its location! Remember: any structure is only as strong as the
foundation on which it is located!
IMPORTANT! Make sure you have extra help or heavy duty
lifting equipment when unloading and assembling the lift.
3. Please read the safety procedures and operating instructions in this manual
before operating lift. Keep this manual near lift at all times. Make sure all
operators read this. manual.
4. The lift should be located on a relatively level floor of less than 3 degrees
slope. If slope is questionable, consider a survey of the site and/or the
possibility of pouring a new level concrete slab.
5. Make sure you have enough area and ceiling height to install lift. (See Lift
Specifications)
6. Never raise a car until you have double checked all bolts, nuts and hose
fittings.
7. Always lower the lift onto the locks before going under the vehicle.
8. -Never allow anyone to go under the lift when raising or lowering.
This is a vehicle lift installation/operation manual and no attempt
is made or implied herein to instruct the user in lifting methods
particular to an individual application. Rather, the contents of this
Important Information 9KOH 4
manual are intended as a basis for operation and maintenance of the
unit -as it stands alone or as it is intended and anticipated to be used in
conjunction with other equipment.
Proper application of the equipment described herein is limited to the
parameters detailed in the'specifications and the uses set forth in the
descriptive passages. Any other proposed application of this equipment
should be documented and submitted in writing to the factory for
examination. The user assumes full responsibility for any equipment
damage, personal injury, or alteration of the equipment described in
this manual or any subsequent damages.
CAUTION!!
ENSURE THAT ALL CABLE SHEAVES, BEARINGS, AND SHAFTS ARE
SUFFICIENTLY LUBRICATED. ALSO, THE CORNERS OF EACH COLUMN
SHOULD BE LIGHTLY GREASED WITH QUALITY TYPE LITHIUM GREASE
PRIOR70 OPERATING THE LIFT. LUBRICATE ALL ON AN ANNUAL BASIS.
Motors and all electrical components are not sealed against the weather
and moisture. Install this lift in a protected indoor location. Failure
by the owner to provide the recommended shelter could result in
unsatisfactory lift .performance, property damage, or personal injury.
This lift is an 9,000 lb. capacity, 2-Post Lifts. The locking latch system is very
similar to an,extension ladder. The locking latch- is in contact with the latch rack.
As the lift rises the locking latch drops into place. The Locking latch engages in
latch rack in 3" increments starting at about 16" from the ground. The locking
latches must be manually disengaged for the lift to lower. The locking latch is
released by pulling the Release Cable raising the latch up off the latch rack.
Once the raise button is pressed, the latch will automatically reengage after
approximately 3" of travel. Heavy bearings and heavy-duty leaf chains are used
throughout the lift. The work is done with the heavy-duty. chain connected to a
2-1/2" cylinder, driven by an electric / hydraulic pump.
Important Information 9KOH
9KOH! Specifications
Capacity
9,000 lbs. (2,250 lbs per Arm)
Rise Time
60 Seconds
Overall Height
142"
Overall Floor Width
134-1/4"
Maximum Lift Height
74" (with adapters 80-1/2)
Minimum Pad Height
4"
Between Columns
109-3/4"
Column Size
7-1/4" x 11-1/8"
Drive Thru
. 4"
Motor
2H P, 2 8 - 230 VAC, 1 PH
9KOH Specifications 9KOH 6
SKOH Specifications 9KOH 7
Asymmetrical- Arm configuration
•— 60" (1829mm) minimum to -
nearest obstruction or bay.
T V' (2134mm) minimum to
I nearest wall.
I . I i
" (3353mm)
um to nearest
)struction
" (3963mm)
im to nearest
�struction
NOTE: Lift can be :installed so power unit can column can be located on
either side. However to save operation steps it is recommended that it is
placed on passenger side of Lift.
Installation Requirements
•i
...: •..... .. ....•.: _....
jL-
Adequate! length,for
vehicles
.. ... .... !..,. ..:..7 ... ...:: j... .
----149-918 in. Minimum
4 in. dep
th minimum
6 in. preferred
1. Concrete shall have compression strength of at I st 3,000 PSI nd a
minimum thickness of 4" in order to achieve a mini embedment
of 3 1/4". NOTE: When using the standard supplied 3/4" x 5 1/2 long
anchors; the top of the anchor exceeds 2 1/4" above the floor grade, you
DO NOT have enough embedment.
2. Maintain a 6" minimum distance from any slab edge or seam. Hole to hole
spacing should be a minimum 61/2" in any direction. Hole depth should be a
minimum of 4".
CAUTION!!
3. DO NOT install on asphalt,or other similar unstable surface. Columns are
supported only by anchoring to floor.
4. Using the horseshoe shims provided, shim each column base as required
until each column is plumb. If one column has to -be elevated to match the
plane of the other column, 'full size base shim plates should be used. Torque
Installation Requirements
anchors to 110 ft-lbs. Shim thickness MUST NOT exceed 1/2" when using the
5 1/2 long anchors provided with the lift. Adjust the column extensions
plumb.
5. If anchors do not tighten;to 110 ft-lbs. installation torque, replace the
concrete under each column base with a 4' x 4' x 6" thick 3,000 PSI
minimum concrete pad keyed under and flush with the top of existing floor.
Allow concrete to cure before installing lifts and anchors (typically 2 to °3
weeks).
Tools Required
The installation of this lift is relatively simple and can be accomplished
by two men in a few hours.
The following tools and equipment are needed:
• Hoist or forklift (optional)
• Metric Sockets and Open 'Wrench set
Two 10' to 12' step ladders
• Vise grips
• ISO 32 Light Hydraulic Oil (approx. 12 quarts)
• 8mm Socket Head Wrench
• Tape Measure
• Torque wrench with 1-1/8" socket for anchors
• 4' Level.
• Teflon Tape
• Rotary Hammer Drill with 3/4 in. Drill Bit (Core Drill Rebar Cutter
recommended)
Installation Requirements 9KOH 10
Installation
Procedure
1. After unloading the lift, place it near the intended installation location.
2. Remove the shipping bands and packing material from the lift. The power
Unit and cylinders will be unpacked from the top.
3. Open the wrapping from the upper column and carefully remove the parts
from inside. Unbolt the column from the shipping brackets. Unbolt the up-
rights from the columns and assemble it to the column.
4. Remove the packing brackets and bolts holding the two columns together
(do not discard bolts; they are used in the assembly of the lift).
5. Once the power unit 'coiumn location is decided, insure that the proper
lift placement is observed from walls and obstacles. Also check the ceiling
height for clearance in this location: NOTE: the power unit column can
be located on either side. It is helpful to try and locate the power
side with the passenger side of the vehicle when loaded on the lift to
save steps during operation.
6. Unpack the cylinders and open the oil port on each cylinder by unscrewing
the black plastic cap. Move the carriage up about 20" to 25". Next, carefully
slide the cylinder inside from the bottom of the carriage. The oil port will
face the backside of the column and the notch on -the bottom of the cylinder
will fit into the hole in the center of the base plate.
7. Position the columns facing each other 107-1/4" inside base plates. Square
the columns by measuring Aiagonally from the' corner points on the base
plates (within 1/4").
1341/4-
ao'
r-:
> t
Installation Procedure 9KOH B
• 8. -use the existing holes in column base plate as a guide for drilling the 3/4"
diameter holes into the concrete. Drill the anchor holes only for ONE column,
installing anchors as you go. You will install anchors in second column after
the cables, hoses, and cross beam are installed.
NOTE: Drilling thru concrete slab (recommended) will allow the anchor to be
driven thru the bottom of slab, if the threads are damaged or if the lift will need
to be relocated.
CAUTION!!
• Use a concrete hammer drill with a carbide tip, solid drill .bit the same
diameter as the anchor, 3/4". (.775 to .787 inches diameter). Do not use
excessively worn bits or bits which have been incorrectly sharpened.
• Keep the drill in a perpendicular line while drilling.
• Let the drill do the work. Do not apply excessive pressure. Lift the drill up
and down occasionally to remove residue to reduce binding.
• Drill the hole to depth equal to the length of anchor. Note: Drilling thru
concrete (recommended) will allow the anchor to be driven thru the bottom
of foundation if the threads'are damaged or if -the lift will need to be
relocated.
• For better holding power blow dust from the hole.
Place- a flat washer and hex nut over threaded end of anchor, leaving
approximately 1/2" of thread exposed carefully tap anchor. Do not damage
threads. Tap anchor into the concrete until nut and flat washer are against base
plate. Do not use an impact wrench to tighten! Tighten the nut, two or three
turns on average concrete (28=day cure). If the concrete is very hard only one
or two turns may be required. Check each anchor bolt with torque wrench set to
110 foot pounds.
Installation Procedure 9KOH U
4
2-1/4"
4-1/4" 0 3-1/4"
Drill holes using
Clean hole.
Run nut down
Tighten nut.with
3/4" carbide
just below impact
Torque wrench
tipped masonry
section of bolt.
to 110 ft-ibs.
drill bit per
Drive anchor
ANSI standard
into hole until
B94.12.1.977
nut and washer
contact base.
9. Using a level, check column for side -to -side plumb and front -to -back plumb.
If needed, use horseshoe shims provided by placing shims underneath the
base plate and around the anchor bolt. This will prevent bending the column
bottom plates (Shim thickness should not exceed 1/2"). Tighten 3/4" anchor
bolts to 110 ft-lbs. of torque.
10. Using a tape measure, measure from corner of the base on main side
column to the opposite corner of the offside column to insure legs are
square (within a 1/4"). .
11. Set carriages on the first safety latch engagement. Be sure each carriage is
at the same height by measuring from the top of the base to the bottom of
the carriage (double check the latches, before working under the carriages).
This dimension should be within 1/4".
12. Installing the equalizing cables: for general cable arrangement. Route the
first cable as shown on next page. Tighten nut on one cable stud so that the
end of stud passes the nylon on the nut. Pull the other end of cable and run
nut on it. Repeat above for second cable.
NOTE: DO NOT tighten cables at this time. Just start them on the
threads. Other column will be anchored in later steps. If you tighten
cables at this time you will pull the column and be unable to properly
level/shim it for anchor installation.
Installation P ocedure 9KQH -- 13
13. Install the overhead cross beam. This cross beam has two pieces to be
connected by five (5) bolts in the center of the beam. Be sure to bolt them
together by installing the bolts from inside the cross beam out. This is to
avoid interference with the cable when operating the lift. Next, install the
cross beam between two columns.
14. After fastening the cross beam, check and confirm that the remaining
column is plumb.
15. Secure the remaining coluimn by duplicating STEP 6 and STEP 7.
16. Mount the power unit on the main side leg to the power unit bracket using
the four 5/16" bolts and nuts. Connect the power unit to the fitting installed
on the back of the main leg using a short hose supplied.
Unit
9 Flatwasher
M8 x 1-3/8
17. Connect the equalizing cables. Do not tighten as this stage of assembly.
NOTE: The cable stud that connects to the from right corner of the carriage
should be connected first by pulling the stud through the carriage hole and up
where it is easy to be held by locking pliers. Pull the stud back into place after
threading at least 1/2 of the stud past the locknut. Connect the other ends to
the rear right corners of the carriage with at least 1/2" of thread showing past
the lock nut (cables run on the, inside of the carriage). It may be necessary to
manually raise both carriages above the cylinder to provide enough space to use
the locking pliers. Make sure the carriage is set in the LOCK position.
Installation Procedure 9KOH 14
This is the Power (Motor) Side; carriage. The nuts you see to the right -rear are
where the cables start. Both nuts go above the eyelet, one nut acts as, a locking
nut. The cable will pass down and around the pulley, rear to front, then travel
back up and across to the other side.
This is the Non -Powered side carriage. The arrow is where the cable from the
Power side comes .down. for the Highest setting, use the eyelet at the top, left
hand corner. For the low setting, directly below the top eyelet, there is a second
eyelet inside the carriage. Pass the cable through the top eyelet and bolt into
the inner, hidden eyelet. Just be sure cables do not cross and do not tighten the
cable nuts down until they are !run around the pulleys.
Installation Procedure 9K®H is
18. Adjust the carriage cable'! tension. This -is accomplished by tightening the
carriage adjustment nut on the top of each carriage. The rear carriage
adjustment nut adjusts the opposite post carriage height. The left post
carriage nut adjusts the fight column carriage, and the right column carriage
nut adjusts the left column carriage. Adjust each cable to approximately 1/2"
side -to -side play.
19. Cylinder centering and ct
bottom of the cylinder is
of the cylinder mount in
sides up and over the chi
Incorrect
The Chain Break lock is
activated and the carriage
will' tot lower.
When installing the lift,
the chain must be in front
of the chain- break to operate.
Correct
ain installation: Make sure the "Tip" on the
3roperly Located into the center, hole on top
lase. Pull the pre -attached leaf chain in both
in sheave on top of the cylinders.
20. Connect the Hydraulic Hoses and Fittings.
21. Install remaining anchors at this point using directions from page 8.
22. Install the swing arms on the carriages using the included 1-1/2" diameter
pins. Check for proper engagement of the arm lock - the rack on the lock
should fully engage the gear on the arm. Note you may have to loosen the
arm lock bolts to get proper engagement and to install the arm pins. BE
SURE to retighten the lock, bolts after the arm pins are installed.
Installation Procedure 9KOH
m
3. Adjust the carriage cables tension. Adjust each cable to approximately 1/2"
side -topside play. Check the latch releases to insure the carriage is still
sitting on the appropriate latch.
4. Remove the vent plug from the power unit and fill the reservoir. Use a Ten
Weight (ISO AW32) non -foaming, non -detergent hydraulic fluid (i.e. Texaco
HD32 or equal). The unit will hold approximately twelve quarts of fluid.
5. Install both the "Overhead Shut -Off Bar" and "Limit Switch" on to the
overhead cross beam.
— 9KOH 17
proredure
�Ilation
Wiring The Overhead Shut Off Bar Limit Switch
This'is the way the hydraulic power unit is wired from the factory. Wire colors
may vary. The pre wired -"Pig Tail" is on there _as a reference point so the
electrical contractor knows which terminal to use. DO NOT splice into the "Pig
Tail" with extension wire to the breaker box. Remove and discard the "Pig Tail
"wires. "Pig Tail" wires are in terminals 3L2 and 5L3. DO NOT remove the Push
Button "UP" wire on 3L2 at this time. The power unit is Alternating Current so
crossing the wires from the breaker box to the terminals will not create an issue.
Be sure that the new wires go into 3L2 and 5L3.
1. Disconnect Electrical Power Before Installation
Installation Procedure 9Kf3H 18
2. Disconnect Electrical Power Before Installation
i2011 9: 33
nstallation Procedure 9KOH 19
• Now.you are ready to connect the -Push Button 'SUP" wire to one of the 2 wires
remaining in the overhead shut off wire bundle. Remove Push Button "UP" wire
:From -terminal 3L2. Cut some length off of the wire. Wire nut the Push Button
"UP" wire to one of the 2 remaining over head shut off wires.
3. Disconnect Electrical Power Before Installation
instaIIation Procedure 9KOH 20
4. Now connect the remaining wire .to terminal 3L2. Disconnect Electrical
Power Before Installation
Installation Procedure 9KOH I _ - 21
Lift Lockout/ragout Procedure
Purpose
This procedure establishes they minimum requirements for the lockout of energy
that could cause injury to personnel by the operation of lifts in need of repair or
being serviced. All employees shall comply with this procedure.
Responsibility
The responsibility for. assuring ;that this procedure is followed is binding upon
all employees and service personnel from outside service companies (i.e.,
Authorized Installers, contactors, etc.). All employees shall be instructed in the
safety significance of the lockout procedure by the facility owner/manager. Each
new or transferred employee allong with visiting outside service personnel shall
be instructed by the owner/ma .nager (or assigned designee) in the purpose and
use of the lockout procedure.
Preparation
Employees authorized to perform lockout shall ensure that the appropriate
energy isolating device (i.e., circuit breaker, fuse, disconnect, etc.) is identified
for the lift being locked out. Other such devices for other equipment may be
located in close proximity of the appropriate energy isolating device. If the
identity of the device is in question, see the shop supervisor for resolution.
Assure „that proper authorization is received prior to performing the lockout
procedure.
Sequence of Lockout Procedure
1. Notify all affected employees that a lockout is being performed and the
reason for it.
2. Unload the subject lift. Shut it down and assure the disconnect switch is
"OFF" if one is provided on the lift.
Lift Lockoutliagout Procedure ! 9i'eoFl 22
1 ' The authorized lockout person operates the main energy isolation device
removing power to the subject lift.
a. If this is a lockable device, the authorized lockout person places the assigned
padlock on the device to prevent its unintentional reactivation. An appropriate
tag is applied stating the person's name, at least 3" x 6" in size, an easily
noticeably color, and states not to operate device or remove tag.
b. If this device is a non -lockable circuit breaker or fuse, replace with a "dummy"
device and tag it appropriately as mentioned above.
4. Attempt to operate lift tolassure the lockout is working. Be sure to return
any switches to the "OFF" position.
5. ' The equipment is now locked out and ready for the required maintenance or
service.
Restoring Equipment to Service
1. Assure the work on the lift is complete and the area is clear of tools,
vehicles, and personnel.
2. At this point, the authorized person can remove the lock (or dummy circuit
breaker or fuse) and tag 'and activate the energy isolating device so that the
lift may again be placed into operation.
Rules for Using Lockout Procedure
Use the Lockout Procedure whenever the lift is being repaired or serviced,
waiting for repair when current operation could cause possible injury to
personnel, or for any other situation when unintentional operation could injure
personnel. No attempt shall be made to operate the lift when the energy
isolating device is locked out.
Operating Conditions
Lift is not intended for outdoor use and has an operating ambient temperature
range of 410-104OF (50-400C).
Lift Lockout/ragout Procedure 9KOH 23
Operating Instructions
Only authorized personnel are to operate lift
Read operating and safety procedures manual
completely before operating lift.
• Properly maintain and inspect lift in accordance to owner's manual.
• Do not operate a lift that is damaged or in need of repair.
• Allow only authorized .personnel in the lift bay.
• Stay clear. of Lift when raising or lowering (NO RIDERS)
• Keep hands and feet away from pinch points at all times.
• Never override the Lifts operating and safety controls.
• If a vehicle is suspected of falling, clear area immediately.
• Do not rock vehicle while 'ipositioned on lift.
• Always use safety jack stands when removing or installing heavy
components.
Vehicle Loading
• Position vehicle for proper weight distribution (center of gravity should be
midway between adapters).
• Swing arms under vehicle, to allow adapters to contact at the
manufacturer's recommended pick up points.
• Use caution before lifting pickup trucks, suv's and other framed vehicles.
The individual axle weight capacity should not exceed 1/2 of lift capacity.
• Make sure vehicle is neither front nor rear heavy.
• Make sure the lifting pads are in a proper and safe position to support the
vehicle. (Ref: Lifting Points Guide and decal on Main side column for typical
arm positioning)
Operating Instructions 9KOH 24
Ralising Lift
• Push Up switch to raise lift (make sure arm restraints engage or stop and
slightly move arm to allow gear to mesh) until tires clear floor.
• Stop and check for secure contact on adapters and vehicle weight
distribution. If secure raise to desired height.
• ALWAYS lower the lift into the nearest lock position by pressing the lower
lever to relieve the hydraulic pressure and let the latch set right in a lock
position.
• Never work under a lift that is not in the locked position.
Lowering Lift
Clear all obstacles from under lift and vehicle and ensure only the lift
operator is in the lift area:.
• Stay clear of lift and raise; the lift off the safety locks.
• Pull safety latch releases and press the lower lever to begin descent.
• Unload lift by first completely lowering lift, then swinging arms to drive-
thru position before moving vehicle.
Lift Points Note:
Refer to the manufacturer's s ecific vehicle p lifting points. Some vehicles display
these points on a label inside the right front door lock face or are identified by
triangle shape marks on the vehicle's undercarriage, reference SAE )2184.
Operating instructions ! 9KOFl 25
Safety Procedures
• Never allow unauthorized! persons to operate lift. Thoroughly train new
employees in the use and care of lift.
• Caution - the power unit operates at high pressure.
• Remove passengers before raising vehicle.
• Prohibit unauthorized persons from being in shop area while lift is in use.
• Total lift capacity is 9,000 lbs. @ 2,250 Ibs per lifting pad. Do not exceed
maximum weight capacity of lift.
• Prior to lifting vehicle, wa'Ik around the lift and check for any objects that
might interfere with the operation of lift and safety latches; tools, air
hoses, shop equipment.
• When approaching the lift with a vehicle, make sure to center the vehicle
between the columns so that the tires will clear the swing arms easily.
Slowly drive the vehicle between the columns. It is recommended to have
someone outside the vehicle guide the driver.
• Always lift vehicle using all four pads.
• Never use lift to raise one end or side of vehicle.
• Always raise vehicle about 3" and check stability by rocking vehicle.
• Prior to lowering vehicle, walk around the lift and check for any objects
that might interfere with the operation of lift and safety latches; tools, air
hoses, shop- equipment.
• Always lower lift to the lock position before going under vehicle. Never
allow anyone to go under the lift when raising or lowering.
Preventive Maintenance Schedule
The periodic Preventive Maintenance Schedule given is the suggested minimum
requirements and minimum intervals; accumulated hours or monthly period,
which ever comes sooner. Periodic maintenance is to be performed on a daily,
weekly, and yearly basis as given in the following paragraphs.
Safety Procedures I9KOH 26
WARNING!!
Occupational Safety and Health Administration (OSHA) and the
American National Standards Institute (ANSI) requires users to inspect
lifting equipment at the start of every.shift. These and other periodic
inspections are the responsibility of the user.
Failure to perform the daily pre -operational check can result in
expensive property damage, lost production time, serious personal
injury, and even death. The safety latch system must be checked and
working properly before the lift is put to use.
Failure to heed this warning can result in death or serious injury, or
damage to equipment. If you hear a noise not associated with normal
lift operation, or, if there is any indications of impending lift failure -
CEASE OPERATION IMMEDIATELY! - Inspect, correct and/or replace
parts as required.
Daily re -Operation Check (8-Hours)
1. Check safety lock audibly and visually while in operation
2. Check safety latches for free movement and full engagement with rack.
3. Check hydraulic connections, and hoses for leakage.
4. Check chain connections - bends, cracks -and loose links.
5. Check cable connections- bends, cracks -and looseness.
6. Check for frayed cables in both raised and lowered position.
7. Check snap rings at all rollers and sheaves.
8. Check bolts, nuts, and screws and tighten if needed.
9. Check wiring & switches for damage.
10. Keep base plate free of dirt, grease or any other corrosive substances.
11. Check floor for stress cracks near anchor bolts.
12. Check swing arm restraints.
Safety Procedures 9KOH 27
Weekly Maintenance (gyeEX 40-Hours)
1. -Check anchor bolts torque to 110 ft-lbs for the 3/a in. anchor bolts. Do not
use an impact wrench to tighten anchor bolts.
2. Check floor for stress cracks near anchor bolts.
3. Check hydraulic oil level.
4. Check and tighten bolts, nuts, and screws.
5. Check cylinder pulley assembly for free movement or excessive wear on
cylinder yoke or pulley pin.
6. Check cable pulley for free movement and excessive wear.
1. Lubricate chains
2. Grease rub blocks and column surface contacting rub blocks
3. Change the hydraulic fluid good maintenance procedure makes it
mandatory to keep hydraulic fluid clean. No hard fast rules can be
established; - operating temperature, type of service, contamination
levels, filtration, and chemical composition of fluid should be considered. If
operating in dusty environment shorter interval may be required.
Special Maintenance Tasks
NOTE: The following items should only be performed by a trained maintenance
expert:
• Replacement of hydraulic hoses.
• Replacement of chains and rollers.
• Replacement of cables and, sheaves.
• Replacement or rebuilding air and hydraulic cylinders as required.
• Replacement or rebuilding pumps / motors as required.
• Checking of hydraulic cylinder rod and rod end (threads) for deformation or
damage.
Safety Procedures ` 9KOH 28
CAUTION!!
Relocating or changing ,components may cause .problems. Each
component in the system must be compatible; an undersized or
restricted line will cause a, drop in pressure. All valve, pump, and hose
connections should be sealed and/or capped until just prior to use. Air
hoses can be used to clean fittings and other components. However,
the air supply must be filtered and dry to prevent contamination. Most
important is cleanliness; Contamination is the most frequent cause of
malfunction or failure of hydraulic equipment.
Safety Procedures 9KOH 29
Troubleshooting
The common problems that may be encountered and their probable causes are
covered in the following paragraphs:
PROBLEM 1 SOLUTION
Motor Does Failure of the motor to operate is normally caused by
Not Operate one of the following:
1. Breaker or fuse blown.
2. Faulty wiring connections; call electrician.
3. Defective up button; call electrician for service.
Motor If the motor pis functioning, but the lift will not rise do
Functions but the following in the order given:
Lift Will Not I. A piece of trash is under check valve. Push handle down
Rise and push the up button at the same time. Hold for 10-15
seconds. This should flush the system.
2. Check they clearance between the plunger valve of the
lowering handle. There should be 1/16" clearance.
3. Remove the check valve cover and clean ball and seat.
i
WARNING!!
Failure to properly relieve pressure in the following step
can cause injdry to personnel. This lift uses ISO Grade 32
or other good grade non -detergent hydraulic oil at a high
hydraulic pressure. Be familiar with its toxicological properties,
precautionary! measures to take, and first aid measures
as stated in the Safety Summary before performing any
maintenance with the hydraulic system.
4. Oil level too low. Oil level should be just under the vent cap
port when the lift is down. Relieve all hydraulic pressure
and add oil as required.
Troubleshooting 9KOH 30
Oil Blows out If oil blows; out of the breather of the power unit, take
Breather of the following actions:
Power Unit
1. Oil reservoir overfilled. Relieve all pressure and siphon out
hydraulic fluid until at a proper, level
2. Lift lowered too quickly while under a heavy load. Lower
the lift slowly under heavy loads..
Motor Hums If the motor hums but fails to run, take the following
and Will Not actions:
Run
1. Lift overloaded. Remove excessive weight from lift
WARNING!!
The voltages fused in the Lift can cause death or injury to
personnel. In the following steps, make sure that a qualified
electrician is used to perform maintenance
2. Faulty wiring
Call electrician
3. Bad capacitor
Call electrician
4. Low voltage
Call electrician
Lift Jerks 1. If the lift Jerks while going up and down., it is usually a
Going Up and sign of air in the hydraulic system. Raise lift all the way to
Down top and return to.floor. Repeat 4-6 times. Do not let this
overheat power unit.
Oil Leaks Oil leak causes at the power unit and cylinders are
normally caused by the following: ,
1. Power unit: if the power unit leaks hydraulic oil around the
tank -mounting flange check the oil level in the tank_ The
level should be two inches below the flange of the tank. A
screwdriver can be used as a "dipstick".
2. Cylinder - Piston Rod: the rod seal of the cylinder is out.
Rebuild or' replace the cylinder.
3. Cylinder - Vent: the piston seal of the cylinder is out.
Rebuild or�replace the cylinder.
Troubleshooting 9KOH 31
i
Lift makes Excessive noise from the lift is normally caused by the
excessive following;
noise / 1, Cross beam ends are rubbing the columns. Readjustment
vibrates 9 J
needed..
2. Cylinder !too tight, load lift half capacity and cycle up and
down a few times to break in. Lift cylinder should quiet
down with use. If not contact your Direct Lift Distributor to
purchase an Oil Additive.
3. May have excessive wear on cable sheaves or shafts.
Replace them.
Troubleshooting SKOH 32
.:..'......'Illustrated Parts Breakdown
66
53 \ \40 10;
48 4T46 4!
76----
75
76
77
,71
4.0
21,22-23 11
Illustrated Parts Breakdown 9KOH
33
;I Ilustrated Parts Breakdown
Illustrated Parts Breakdown 9K®H 33
Parts List
ITEM
DRAWING
DESCRIPTION µ `
QTY
1
QL4W-2R1-00
RIGHT COLUMN WELDED GROUP
1
2
QL4W-2L1-00 J
LEFT COLUMN WELDED GROUP
1
3
QL4W-`100-00
LONG COLUMN GROUP
1
4
GB5782-86
HEXAGONAL HEAD BOLT M12X40
24
5
GB93-87
LOCK WASHER 12
24
6
GB97.1-85
FLAT WASHER 12
34
7
GB6170-86
HEXAGON NUTS M12
29.
8
QL4L-400-04
SHORT SLEEVE
4
9
QL40-700-02
THICK CABLE WHEEL BUSHING
4
10
QL4L-400-02
4" THICK CABLE WHEEL
4
11
GB894.1-86
AXIAL ELASTIC RINGS 25
10
12
QL4L-400-01
PULLEY SHAFT
2
13
QL4L-400-03
LONG BUSHING
2
14
QL4L 4R0-00
RIGHT BEAM WELDING GROUP
1
15
GB5782-86
HEXAGONAL HEAD BOLT M12X25
5
16
QL4L-4L0-00
LEFT BEAM WELDING GROUP
1
17
GB91-86
SPLIT PIN 2X20
8
18
QL40-000-12
CH,AIN PIN
4
19
QL4W-000-03
SWELLING BOLT GROUP
10
20
QL4L-600-00
WIRE ROPE PARTS
2
21
QL40-200-03
CABLE WHEEL
2
22
QL40-200-04
CABLE WHEEL WASHER
2
23
QL40-200-05
SLEEVE BUSHING
2
24
QL40-000-09
INTERNAL AND EXTERNAL CONNECTIONS
2
25
QL40-000-B10
ANTI -RIOT BARREL CONNECTOR
2
26
QL40-100-00
CYLINDER PARTS
2
Farts List 9KQH 34
,ITEM
DRAWING
DESCRIPTION
QTy
27
QL4W-000-02
OIL PIPE (JOINT -TANK)
1
28
QL40-200-01
WINDOW PANEL
2
29
GB818-85
CROSS RECESSED PAN HEAD SCREW M6X8
20
30
QL40-000-08
OILS PIPE (VALVE TANK) a
1
31
QL4L-000-18
FRID
2
32
QL40-000-04
SHORT JOINTS
4
33
QL40-000-05
LONG JOINT
4
34
QL4L-000-21
HYDRAULIC POWER UNITS
1
35
QL4W-000-01
TEEI CONNECTOR
1
36
GB5782-86
HEXAGONAL.HEAD BOLT M8X25
4
37
GB97.1-85
FLAT WASHER 8
8
38
GB93-87
LOCK WASHER 8
4
39
GB6170-86
HEXAGON NUTS M8
4
40
GB97.1-85
FLAT WASHER 20
41
GB6170-86
HEXAGON NUTS M20
8
42
QL4W-500-RO
RIGHT BEND ARM OF WELDING GROUP
1
43
QL40-500-02
EXTENSION SPRING
2
44
QL40-521-00
INSURANCE BOLCK WELDING GROUP
-2
45
GB5783-86
HEXAGONAL HEAD BOLT M20X50
2
46
QL40-500-03
SLEEVE BUSHING
2
47
GB93-87
LOCK WASHER 20
2
48
GB6170-86
HEXAGON NUTS M20
2
49
GB818-85
CROSS RECESSED PAN HEAD SCREW M6X35
2
50
GB97.1-85
FLAT WASHER 6
2
51
QL40-520-01
COM PRESSION SPRING
2
52
QL4W-400-00
STRAIGHT ARM OF WELDING GROUP
2
53
GB879-86
ELASTIC CYLINDRICAL PIN
4
54
QL40-53'0-02
COM;PRESSION SPRING
4
55
QL4W-500-LO
LEFT BEND ARM OF WELDING GROUP
1
56
QL40-800-00
BOLT WELDING GROUP
4
Farts List 9KOH 35
ITEM
DRAINING
DESCRIPTION
QTY
57
QL4W-310-00
SLIPWAY WELDING GROUP
2
58
QL40-000-15
HANDLE THE BALL M10
4
59
QL40-530-01
DRAFT BAR
4
60
GB6170-86
HEXAGON NUTS M10 =rY
4
61
G693-87
LOCK WASHER 10
4
62
GB97.1-85
FLAT WASHER 10Am`,.
8
63
QL40-530-04
RACK
4
64
QL40-530-03
GEAR GASKET
4
65
QL40-200-02
DRAY CHAIN
2
66
QL40-500-01
SLIDE BLOCK
16
67
QL40-100-03
ROLLED AXLE
2
68
QL40-100-02
CONTACT ROLLER
2
69
QL40-100-04
BEARING HPB
2
70
QL40-500-04
WIREROPE
2
71
GB70-85
HEXALOBULAR SOCKET CHEESE HEAD
SCREWS M6X20
4
72
QL40-000-03
PALLET PAD
4
73
QL40-000-02
PALLET
4
74
O-RING
1
75
GB819-85
CROSS RECESSED COUNTERSUNK HEAD
SCREW M6X12
4
76
GB97.1-85
FLAT WASHER 6
4
77
QL4L-X20-01
BRACKET PAD
2
78
QL4L-X21-00
BRACKET WELDED GROUP
4
79
QL4W-000-04
DOOR SHIELD
2
80
GB818-85
CROSS RECESSED COUNTERSUNK HEAD
SCREW M6X20
4
80
QL4L-000-05
STAPLE BOLT
6
101
QL4L-320-00
RACK - ROD COMPONENTS
4
102
QL40-520-00
INSURANCE STOPPER BLOCKS
2
"103
QL4L-X20-00
BRACKET PARTS
2
Parts List 9KOH 36
Warranty
This item is warranted for two (2) years on structural
components and one (1) year on.,air or electric hydraulic
power units ;..
pneumatic power un�s, cylinders and
major components from date of'invoice. Wear items are
covered by a 90 day warranty.
This LIMITED warranty policy does
NOTE! ALL WARRANTY CLAIMS
MANUFACTURER TO BE VALID.
not include a labor warranty.
MUST BE PRE -APPROVED BY THE
The Manufacturer shall repair or replace at their option for this period those parts
returned to the factory freight prepaid, which prove after inspection to be defective.
This warranty will not apply unless the product is installed, used and maintained
in accordance with the Manufacturers installation, operation and maintenance
instructions.
This warranty applies to the ORIGINAL purchaser only, and is non -transferable. The
warranty covers the products to be free of defects in material and workmanship but,
does not cover normal maintenance or adjustments, damage or malfunction caused by:
improper handling, installation, abuse, misuse, negligence, carelessness of operation
or normal wear and tear. In addition, this warranty does not cover equipment when
repairs or alterations have been made or attempted to the Manufacturer's products.
THIS WARRANTY IS EXCLUSIVE AND IS LIEU OF ALL OTHER WARRANTIES EXPRESSED
OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OR MERCHANTABILITY OR ANY
IMPLIED WARRANTY OF FITNESS FROM A PARTICULAR PURPOSE, AND ALL SUCH
IMPLIED WARRANTIES ARE EXPRESSLY EXCLUDED.
THE REMEDIES DESCRIBED ARE EXCLUSIVE AND IN NO EVENT SHALL THE
MANUFACTURER, NOR ANY SALES AGENT OR OTHER. COMPANY AFFILIATED WITH IT
OR THEM, BE LIABLE FOR SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGES FOR
THE BREACH OF OR DELAY IN PERFORMANCE OF THIS WARRANTY. THIS INCLUDES,
BUT IS NOT LIMITED TO, LOSS OF' PROFIT, RENTAL OR SUBSTITUTE EQUIPMENT OR
OTHER COMMERCIAL LOSS.
PRICES: Prices and specifications are subject to change without notice. All orders will
be invoiced at prices prevailing at time of shipment. Prices do not include any local,
state or federal taxes.
RETURNS: Products may not be returned without prior written a
Manufacturer.
P approval from the
Warranty 9KOH 37