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INSTALLATION / OWNERS MANUAL

1. BOLTMi6M0 GRADERS 6 38 SH4D 4000H LOCKLADDER 4 39 NH4D 3303 JAMNUT 4 40 Bai20 FLATWASHER320 12 12535 BOLTMI2x335 16 13 2 NUTYMD i6 51 0 2001 CROSS RAIL SAFETY LATCII COVER 47 2002 CABLESHEAVE 10 NH4D loI3 BUSHING B 4 CO7338 1 36 IN20525 Rev D 3 30 2009 PARTS LIST 10 8 30 H4D 2004 H4D 1009 H4D 1014 H4D 1002 H4D 1003 H4D 1004 OLT M8x30 UB BLOCK TCH SHAFT SHING C AFETY LATCH A 00 AJ C gt gt gt 1 LATCH SPRING A H4D 1011 SAFETY LATCH SPRING H4D 1005 PLASTIC PULLEY H4D 1006 CABLE SHEAVE B SHAFT H4D 2003 ABLE SHEAVE SHAFT 0 8x20 LT M8x20 4D 3100 RIVER SIDE RUNWAY MAIN SIDE 4D 2002 SHING E SPACER H4D 1012 USHING F SPACER 4D 3001 UNWAY CABLE SHEAVE SHAFT 66 NH4D 2005 OCATING PLATE 67 10 8 16 BOLTM amp X16 8 CABLE A 3 8 x365 8 69 SH4D 80203 CABLEB 3 8x3005 CABLE C 3 8 x185 5 B33 3 4 16 NYLON LOCK NUT 3 4 16 4 HYDRAULIC HOSE WIRE BRAIDED W 002 30400 9053YZ FITTING WITH O RING 4D Y003 90 DEGREE BULKHEAD FITTING H4D 8010 HYDRAULIC HOSE 79 5 P7 9802 2 90 DEGREE FITTING H4D 2021 CABLE LOCK PLATE A BLE LOCK PLATE B LON LOCK NUT M272 OTTER PIN 4x50 YLINDER PIN 57 aio I 2 I O 2 Z O 33 27 2 52 4
2. 45 Figure 1 They will be reinstalled later Arrange the Crossbeams so that the locking linkage is facing outward and the Short Connecting Rod B Item 87 Figure 5 is closest to the power unit column Also remove Crossbeam Covers Items 24 25 amp 26 Figure 7 if not already removed If you have means for securely lifting the Crossbeam lower it into the tops of the columns If you don t then the columns will have to be placed horizontal and the crossbeams installed in the columns Then the entire end structure two columns and crossbeam will need to be stood up as one 4 IN20525 Rev D 3 30 2009 10 11 12 13 14 15 16 CO7338 1 Unpack the Lock Ladders Item 38 Figure 2 from the package and slide them into the precut slot on the Rub Blocks Item 50 Figure 1 inside each column After removing the top nut from the lock ladder you are ready to install the Top Caps A amp B Items 44 amp 94 Figures 2 amp 6 on the columns Be aware of the offset hole in column Top Caps Arrange them so that the cable mounting holes are closest to the runways Use provided bolts nuts washers and lock washers to install Top Caps as shown in Figure 2 Secure Cap and Lock Ladder assemblies together with Washer and Nut Items 40 amp 41 Figure 2 Position the Crossbeams at the second lowest locking position on all columns Stand up and arrange the two end structures Columns amp Cro
3. Single Phase Note 60Hz Single phase motor CAN NOT be run on 50Hz line without a physical change in the motor Up Switch Attach ground wire here Black Black Attach ground wire to screws provided Black 230V 60Hz 2 1 D 2 ai 7 2 White White MOTOR OPERATING DATA TABLE THREE PHASE LINE VOLTAGE RUNNING MOTOR VOLTAGE RANGE 208 240V 50 60Hz 197 253V 400V 50Hz 360 440V 440 480V 50 60Hz 396V 528V 575 60Hz 518 632 5 1 Unit not suitable for use in unusual conditions Contact Rotary for moisture and dust environment duty unit 2 Control Box must be field mounted to power unit 3 Motor rotation is counter clockwise from top of motor FIGURE A CO7338 1 6 IN20525 Rev D 3 30 2009 NOTE Two Different Drum Switches were used please select one of the two options below NOTES 1 Unit not suitable for use in unusual conditions Contact Rotary for moisture and dust environment duty unit 2 Control Box must be field mounted to power unit 3 Motor rotation is counter clockwise from top of motor 3 _2 ______ 9 6 _ PE DRUM FOR 3 POWER UNITS Attach Box using M5 x 10 PHMS Plated Capacitor Box Attachment Option One SWITCH Steel Spacer Re seal Between Gasket Box And Spacer Capacitor With Silicone Drum Switch And Cover 4 M5 x 45 PHMS 4 5 10 5 Ca
4. Lowering Lift e Clear all obstacles from under lift and vehicle and ensure only lift operator is in the lift area e Stay clear of lift and raise the lift off the safety locks e Pull safety latch releases and press the lower lever to begin descent e Ensure lift is fully lowered and having another person guide you carefully unload the lift by driving off of the lift runways CAUTION PAY ATTENTION TO THE LOWERING SPEED OF ALL FOUR CORNERS MAKE SURE THEY ARE MOVING DOWN AT THE SAME SPEED STOP LOWERING THE LIFT BY RELEASING THE LOWERING LEVER ON THE POWER UNIT AND MOVING THE LOCK LEVER TO THE LOCK POSITION IF ANY CORNER STOPS MOVING OR IS SLOWER IN DESCENT ALWAYS LOCK THE LIFT BEFORE GOING UNDER THE VEHICLE NEVER CO7338 1 12 IN20525 Rev D 3 30 2009 ALLOW ANYONE GO UNDER THE WHEN RAISING OR LOWERING NOTE It is normal for an empty lift to lower slowly it may be necessary to add weight Lift to be used Authorized personnel Clear area if vehicle Remain clear of lift by trained operator only in lift area is danger of falling when raising or ONLY lowering vehicle The messages and pictographs shown are generic in nature and are meant to generally represent hazards common to all automotive lifts regardless of specific style Funding for the development and validation af these labels was provided the Automotive Lift Institute PO Box 1519 New York NY 101011519 They are protected by copyright Set
5. 3 4 3 64 718 to 1 1 8 1 16 1 1 4 0 1 1 2 3 32 Typical Good Cable Cable With Broken Wires gt mem d SSS gt a e 5 x r OA 54 Cable With Severe Corrosion Cable With Necking Daily Inspection amp Maintenance 1 Cleanliness Cables Columns Runways and other lift parts should be kept free of corrosive agents solvents and road salts If such agents are spilled or splashed on any lift component immediately rinse thoroughly with water and wipe down with a clean rag Spray wire rope cables as required with Penetrating Oil and wipe down Failure to keep lift free of corrosive agents and solvents will lead to reduced component service life cable failure etc which could result in property damage and or personal injury 2 Fasteners Check all the attaching bolts and nuts for tightness CO7338 1 21 IN20525 Rev D 3 30 2009 3 Cables Check wire rope cables for wear damage Any cable with broken wires severe corrosion excessive stretch deformed strands variations in diameter necking or any change from its normal appearance must be replaced If any cable is found to be in need of replacement the entire cable set must be replaced immediately Refer to figures below 4 Sheaves Check sheaves pulleys for wear or damage i e wobble tilt cracks loos
6. of labels may be obtained from ALI or its member companies 1992 by ALI Inc ALIANL200c ETY Keep feet a ous bf pinch pointe clonr of lift when lift is moving while lowering Read operating Proper maintenance and safety manuals inspection before using lift is necessary for safe operation SAFETY Do not overide Chock wheel The messages and pictographis shown INSTRUCTIONS inc to prevent are generic in nature and are meant to self closing generally represent hazards common lift controls vehicle movement to all automotive lifts regardless of specific style unding for the development and The messages and pictographs shown are generic in nature and are meant to validation of these labels was provided generally represent hazards common to all automotive lifts regardless of specific hy the Automotive Lift Institute PO style Box 1519 New York NY 10101 1519 Funding for the development and validation of these labels was provided the They are protected by copyright Set Automotive Lifi Institute PO Box 1519 New York NY 10101 1519 af labels may be obtained from ALI Do not operate its member companies They are protected by capyright Set of labels may be obtained from ALI or its Fs maged lift member companies 1992 by ALI Inc 1992 by ALI Inc ALI WL200s y ALI WL200w CO7338 1 13 IN20525 Rev D 3 30 2009 O
7. replace with a dummy device and tag it appropriately as mentioned above 4 Attempt to operate lift to assure 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 Atthis point the authorized person can remove the lock or dummy circuit breaker or fuse amp 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 41 104 5 40 IMPORTANT SAFETY INSTRUCTIONS When using your garage equipment basic safety precautions should always be followed including the following 1 Read all instructions 2 Care must be taken as burns can occur from touching hot parts 3 Do not operate equipment with a damaged cord or if the equipment has been dropped or damaged until it has bee
8. 50 H4D 8030 0 SH4D 5002 SAFETY RELEASE HANDLE B HANDLE ROD 40 5001 86_ SH4D 5003 SH4D 5004 96 97 5 40 8000 COVER co esas am emos aa afar 51 14 CO7338 1 37 IN20525 Rev D 3 30 2009 PARTS LIST _ Description 98 FENDERWASHR 6 20 99 20 6 16 5 6 16 2 100 40 2030 t _101 40 20308 102 SCREWNM4x 1 1 1 1 1 AC 103 30400 1999 WASHER _ 4 104 SH4D 9200G THROTTLE 11 105 H4P R3100 Wheel Chock 108 H4P R3101 ____ jJAngelron 107 4 83102 Rubber Y 8 108 23 5516 Discal Head Screw M5x16 8 5 NutM 18 qM 7366 Switch Box Assembly For 32 _110 40275 5 10 5 Plated _________ 4 Accessories Included in Four Post 9 000 Lift Fig 6 SH4D 7000CK POLYURETHANE CASTERKIT ASSEMBLY 4 SH4D9PNBKD DT DRIPTRAY _______________ 8 6 5 40 8050 JACK TRAY TOOL BOX EH CO7338 1 38 IN20525 Rev D 3 30 2009 NOTES CO7338 1 39 IN20525 Rev D 3 30 2009 NOTES CO7338 1 40 IN20525 Rev D 3 30 2009
9. 525 Rev D 3 30 2009 34 CO7338 1 72 40 71 68 47 CABLE ROUTING amp COMPONENTS FIGURE 8 CO7338 1 35 IN20525 Rev D 3 30 2009 PARTS LIST Item PariNumber Description Cty 5840 1000 COLUMN WELDMENT POWER UNIT 4 8840 3200 RUNWAY PASSENGER 5101 SIDE E mE 5 8840 3000 RUNWAY DRIVER SIDE MAIN SIDE t 6 SHAD 8050 JACK TRAY PARTS BOX O O 1 7 HYDRAULIC POWER UNIT 110VAC EN IIYDRAULIC POWER UNIT 220VAC SINGLE HYDRAULIC POWER UNIT 50 6011 E NE IIYDRAULIC POWER UNIT 220VAC SINGLE 0502 1 8 SH4D 7000 9 SH4D 7100 O o o 4 10 H4D 500663 COTTERPIN 4 40 NUTMIO 16 12 B40 10 LOCKWASHER 910 5 13 40 FLAT WASHER 10 32 14 BI0 l0x35 BOLTMIO3S B80 6x2A POLYURETHANE CASTER WHEEL 6 x2 16 810 8535 M8x35 4 17 41 8 FLAT WASHER 6 8 52 19 B30 8 __ 8 23 SH4D l600 FOOTPLATE t SH4D 2011 25 5 40 2010 ____ 26 27 30 B4L6 FIATWASHFERe6 6 31 BI0 l2x20 BOLTMI220 4 32 840 12 LOCKWASHERe 20 33 B4l I2 FLATWASHERO 2 34 _ B31 16 NUTMIG GRADE amp SS ___ 8 3a B41 16 FLATWASHERS G 36 40 16 TLOCKWASHERAIG
10. 9 000 Ibs Capacity 4 500 Ibs per axle Minimum wheelbase 101 at rated capacity AIMPORTANT Reference ANSI ALI ALIS Safety Requirements for Installation and Service of Automotive Lifts before installing lift INSTALLATION OWNERS MANUAL Read this manual thoroughly before installing operating or maintaining this lift When done with installation be sure to return documents to package and give all materials to lift owner operator When installation is complete be sure to run lift up and down a few cycles with and without typical vehicle loaded on lift CO7338 1 1 IN20525 Rev D 3 30 2009 TABLE OF CONTENTS e IMPORTANT INFORMATION pg 2 e OWNER EMPLOYER RESPONSIBILITY pg 3 e LOCKOUT TAGOUT pg 3 e SAFETY PROCEDURES pg 4 e LIFT SPECIFICATIONS amp FLOOR PLAN pg 6 e TOOLS REQUIRED pg 7 e INSTALLATION INSTRUCTIONS pg 7 e CASTER KIT ASSEMBLY INSTALLATION pg 10 e FOUNDATION 8 ANCHORING REQUIREMENTS 11 e OPERATION INSTRUCTIONS pg 13 e PREVENTIVE MAINTENANCE SCHEDULE pg 15 e TROUBLESHOOTING pg 17 e CABLE INSPECTION GUIDE pg 19 e ILLUSTRATED PARTS LIST pg 26 IMPORTANT INFORMATION Four Post Lifts Always inspect the lift for damage and make note of any damage on the bill of lading In case of freight damage call the truck line immediately and report the damage as a freight claim Make sure you have extra help or heavy duty lifting equipment when unloading and assembling the lift Please read the safety procedures a
11. WNER EMPLOYER RESPONSIBILITIES The Owner Employer e Shall ensure that lift operators are qualified and that they are trained in the safe use and operation of the lift using the manufacturer s operating instructions ALI SMO1 1 ALI Lifting it Right safety manual ALI ST 90 Safety Tips card ANSI ALI ALOIM 2000 American National Standard for Automotive Lifts Safety Requirements for Operation Inspection and Maintenance ALI WL Series ALI Uniform Warning Label Decals Placards and in the case of frame engaging lifts ALI LP GUIDE Vehicle Lifting Points Quick Reference Guide for Frame Engaging Lifts Shall establish procedures to periodically inspect the lift in accordance with the lift manufacturer s instructions or ANSI ALI ALOIM 2008 American National Standard for Automotive Lifts Safety Requirements for Operation Inspection and Maintenance and The Employer Shall ensure that lift inspectors are qualified and that they are adequately trained in the inspection of the lift Shall establish procedures to periodically maintain the lift in accordance with the lift manufacturer s instructions or ANSI ALI ALOIM 2008 American National Standard for Automotive Lifts Safety Requirements for Operation Inspection and Maintenance and The Employer Shall ensure that lift maintenance personnel are qualified and that they are adequately trained in the maintenance of the lift Shall maintain the periodic inspection and maintenance records recomme
12. ch agents are spilled or splashed on any lift component immediately rinse thoroughly with water and wipe down with a clean rag Spray wire rope cables as required with Penetrating Oil and wipe down Failure to keep lift free of corrosive agents and solvents will lead to reduced component service life cable failure etc which could result in property damage and or personal injury 2 Fasteners Check all the attaching bolts and nuts for tightness 3 Cables Check wire rope cables for wear or damage Any cable with broken wires severe corrosion excessive stretch deformed strands variations in diameter necking or any change CO7338 1 22 IN20525 Rev D 3 30 2009 from its normal appearance must replaced If any cable is found to be in need of replacement the entire cable set must be replaced immediately Refer to figures below 4 Sheaves Check sheaves pulleys for wear or damage i e wobble tilt cracks loose on pin or excessive noise during operation 5 Sheave Pins Check for loose or missing sheave pulley pins 6 Locking Latches and Slack Cable Devices Watch locking latches and slack cable devices during lift operation to ensure that latches work properly and line up with slots in latch plate located in columns Monthly Inspection amp Maintenance 1 Cables 1 1 Clean wire rope cables with lift in both lowered and raised position by spraying with Penetrating Oil and wiping the cable down 1 2 Adjust cables
13. corrosion on exposed outer wires is normal Penetrating Oil should be applied during monthly periodic inspection c That there are no areas on the cable that have a greatly reduced diameter or necking reference Daily Inspection amp Maintenance When any cable is found with excessive necking all cables must be replaced immediately CO7338 1 23 IN20525 Rev D 3 30 2009 4 That cables do not have excessive stretch It is normal for new cable to require adjustment during break in after which small periodic adjustments may be required However if a cable that has been in service for 6 months should suddenly require frequent adjustments or has used all the cable adjustment available all cables must be replaced immediately e If any cable is found to be in need of replacement the entire cable set must be replaced immediately f Cables are expendable items and should be replaced as a set every 20 000 cycles estimated or every 6 years unless earlier replacement is indicated during inspection 2 Sheaves and Pins Inspect sheaves and pins in yokes and runways Sheaves are expendable items Sheaves and pins should be replaced when worn Use of sheaves and pins with excessive wear will lead to reduced service life of cables 2 1 Inspect sheaves pulleys in yoke ends with lift in lowered position or resting on the locking latches a Hold lowering handle down and pull on cable in column to create slack in cables b Check for
14. d full engagement with rack Check hydraulic connections and hoses for leakage Check cables connections bends cracks and for loose fittings Check for frayed cables in both raised and lowered position Check snap rings at all rollers and sheaves Check bolts nuts and screws and tighten if needed Check wiring amp switches for damage Check floor for stress cracks near columns Check Lubrications on cable sheaves and shafts Weekly Maintenance every 40 Hours e IF LIFT IS ANCHORED TO FLOOR Check anchor bolts torque to 50 ft Ibs for the 3 4 CO7338 1 17 IN20525 Rev D 3 30 2009 anchor bolts Do not use impact wrench to tighten anchor bolts Check floor for stress cracks near columns Check hydraulic oil level Check and tighten bolts nuts and screws Check all cable sheaves assembly for free movement or excessive wear on cable sheave shaft Yearly Maintenance e Lubricate the cable sheave shaft by using grease gun at lease once a year after the lift is in service e Check for excessive wear of cable Replace them if necessary e 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 fol
15. e Remove passengers before raising vehicle Prohibit unauthorized persons from being in shop area while lift is in use Total lift capacity is 9 000 Ibs Do not exceed this capacity Prior to lifting 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 When approaching the lift with a vehicle make sure to center the vehicle between the columns Slowly drive the vehicle up with some one outside the vehicle guiding the driver 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 Slowly drive the vehicle on and off of the lift Have some one outside the vehicle guide the driver CAUTION NOTE LUBRICATE ALL CABLE SHEAVES BEARINGS AND SHAFTS WITH GREASE PRIOR TO 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 CO7338 1 16 IN20525 Rev D 3 30 2009 Read and heed all WARNING CAUTION and SAFETY INSTRUCTION labels lift PREVENTIVE MAINTENANCE SCHEDULE The periodic Preventive Maintenance Schedule given is the suggested minimum re
16. e on pin or excessive noise during operation 5 Sheave Pins Check for loose or missing sheave pulley pins 6 Locking Latches and Slack Cable Devices Watch locking latches and slack cable devices during lift operation to ensure that latches work properly and line up with slots in latch plate located in columns Monthly Inspection amp Maintenance 1 Cables 1 1 Clean wire rope cables with lift in both lowered and raised position by spraying with Penetrating Oil and wiping the cable down 1 2 Adjust cables using procedures on following pages 2 Slack Cable Device Inspect slack cable devices using procedure on page 5 3 Column Anchor Bolts Check column anchor bolts for tightness Re torque anchors bolts to 65 ft Ibs If anchors do not tighten to the required installation torque replace concrete under each column base per installation instructions Let concrete cure before installing lifts and anchors 4 Columns Look for corrosion giving special attention to the area at the base of the column Check severely corroded areas by pecking with an awl or welder s chipping hammer If column is corroded through at any point it must be replaced immediately not corroded through remove old paint and rust scale then coat with a high quality corrosion resistant paint Daily Inspection amp Maintenance 1 Cleanliness Cables Columns Runways and other lift parts should be kept free of corrosive agents solvents and road salts su
17. excessive side to side wobble Grasp rim of sheave and attempt to wobble tilt side to side If sheaves wobble tilt more than 3 16 4 8 mm side to side or move up and down on shaft more than 1 32 0 8 mm the sheave and pin shaft should be replaced refer figures below c Check sheaves and replace if cracks are found d Check for ease of rotation If sheaves do not turn freely the sheave and sheave pin should be removed inspected lubricated and reinstalled or replaced CO7338 1 24 IN20525 Rev D 3 30 2009 MON _Sheave In Out Runway Sheave Stack Movement 1 16 1 6 mm Maximum _ Allowed 4 Wobble Sheave Pin Mis alignment 1 32 0 8 mm Maximum TOP PIN With Excessive Scoring and Wear BOTTOM PIN With Normal Wear 2 2 Fully raise lift Inspect sheaves pulleys in runway ends with lift in raised position a Visually inspect alignment of sheaves see figure above Misalignment of sheave s indicates excessive wear the sheave s and sheave pin should be removed and inspected Replace as required b Hold lowering handle down to lower lift onto latches Pull on cables under runway to create cable slack Runway sheave Stack Sheave In Out Movement 4 1 16 1 6 mm 727 Maximum Allowed Wobble Sheave Pin _ sheave a Mis alignment 1 32 0 8 Maximum c Check for excessive side to side wobble Grasp rim of s
18. from the edge of the slab or any seam 1 Use a concrete hammer drill with a carbide tip solid drill bit the same diameter as the anchor 34 775 to 787 inches diameter Do not use excessively worn bits bits which have been incorrectly sharpened 2 Keep the drill in a perpendicular line while drilling 3 Let the drill do the work Do not apply excessive pressure Lift the drill up and down occasionally to remove residue to reduce binding 4 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 5 For better holding power blow dust from the hole 6 Place a flat washer and hex nut over threaded end of anchor leaving approximately 1 2 inch 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 85 foot pounds CO7338 1 11 IN20525 Rev D 3 30 2009 OPERATION INSTRUCTIONS NOTE ALWAYS CHOCK WHEELS AND SET PARKING BRAKE BEFORE LIFTING VEHICLE Only authorized personnel are to operate lift Read Operating and safety procedures Manual comp
19. handle down and push the up button at the same time Hold for 10 15 seconds This should flush the system 2 Check the 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 WARNING Failure to properly relieve pressure in the following step can cause injury 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 Oil Blows Breather of Power Unit If oil blows out of the breather of the power unit take the following actions 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 CO7338 1 19 IN20525 Rev D 3 30 2009 Motor Hums and Will Not Run If the motor hums but fails to run take the following actions 1 Lift overloaded Remove excessive weight from lift WARNING The voltages used in the lift can cause death or injury to personnel In the following steps make sure that a
20. he lift to full height LISTEN and WATCH as the first locking latch clicks into place Synchronize the other three columns with this column by adjusting their cables so all four latches click at same time Tighten jam nuts When making changes to adjustment nuts on cable end or latch bar stud always leave at least two threads showing between nut and stud end Latches may not click in at the same time when vehicle is being raised They should be close Be sure all four corners have passed the locking latch bar slot before lowering lift on locking latches CO7338 1 21 IN20525 Rev D 3 30 2009 ILLUSTRATED PARTS LIST CROSSBEAM SAFETY LATCH ASSEMBLY FIGURE 1 CO7338 1 28 IN20525 Rev D 3 30 2009 38 st CN 9 j COLUMN amp LOCK LADDER FIGURE 2 MAIN SIDE RUNWAY amp HYDRAULICS COMPONENTS FIGURE 3 CO7338 1 30 IN20525 Rev D 3 30 2009 MAIN SIDE RUNWAY COMPONENTS FIGURE 4 CO7338 1 3l IN20525 Rev D 3 30 2009 86 87 85 90 88 SAFETY LATCH amp LINKAGE COMPONENTS FIGURE 5 CO7338 1 32 IN20525 Rev D 3 30 2009 44 106 94 FIGURE 6 A GENERAL ILLUSTRATED PARTS LIST IN20525 Rev D 3 30 2009 33 CO7338 1 st 29 30 24 GENERAL ILLUSTRATED PARTS LIST FIGURE 7 IN20
21. he top of each post until lift is level on crossbeams and runways This will ensure the lift travels up and down level NOTE YOU MAY NEED TO USE LOCKING PLIERS TO HOLD THE CABLE FROM TURNING WHEN ADJUSTING THE NYLON NUT MAKE SURE THAT THREADS ENGAGE THROUGH NYLON ON EACH NYLON NUT 22 Reinstall Crossbeam Covers Items 24 25 amp 26 Figure 7 and the bottom Runway Cover Item 97 Figure 4 onto the underside of the Mainside Runway 23 Install front Wheel Stops Item 27 and Foot Plate Item 23 with provided hardware as shown in Figure 7 24 Install the Drive On Ramps Item 20 with Pivot Shafts Item 22 as shown if Figure 6 NOTE BE SURE TO LUBRICATE ALL CABLE SHEAVES BEARINGS AND SHAFTS WITH A GREASE GUN PRIOR TO OPERATING THE LIFT CO7338 1 8 IN20525 Rev D 3 30 2009 CASTER KIT INSTALLATION 1 Raise the Lift two to four feet high 2 Position each of the four Caster assemblies below the Crossbeam rails as shown on page 21 Figure 6 and in below diagram 3 Install the four Pivot pins and Cotter pins to secure assembly to each column as shown below 4 Lower the Lift confirming that the Caster assemblies engage the Crossbeam rails and the four Columns rise to clear the floor CO7338 1 9 IN20525 Rev D 3 30 2009 FOUNDATION REQUIREMENTS Concrete shall have compression strength of at least 3 000 PSI and a minimum thickness of 4 07 1828101111 NOT use on asphalt or similar uns
22. heave and attempt to wobble tilt side to side refer to figures above If sheaves wobble tilt more than 1 16 1 6 side to side or move in and out more than 1 32 0 8 mm the sheave and sheave pin shaft should be replaced refer to figures above 3 Hydraulic Cylinder Inspect the hydraulic cylinder mounting to the runway Inspect cylinder and hydraulic hoses for CO7338 1 25 IN20525 Rev D 3 30 2009 leaks Repair replace as required 1 Check and tighten the hydraulic cylinder rod nuts holding the cable pull bar 4 TRACKS for Rolling Jack and Oil Drain Pan Inspect rolling jack oil drain pan tracks for cleanliness corrosion excessive wear or damage Clean dirty tracks WARNING v or damaged tracks must be repaired immediately Failure to do so will lead to reduced service life which could result in property damage and or personal injury 5 Latch Inspection and Adjustment Check locking latches for proper operation Inspect for worn or missing parts Replace worn or damaged parts and adjust as required 1 Latches Check latch operation on all four corners 2 Latch and Latch Bar Line Up Observe locking latches during lift operation to ensure that all latches line up with slots in latch bar located in all four columns If not relocate and or re shim columns 1 Check slack cable devices for proper operation Inspect for worn or missing parts Replace worn or damaged parts as required 2 Observe both
23. l INSTALLATION INSTRUCTIONS Remove plastic wrap from top runway and remove all hardware This includes the Power Unit Drip Trays Tool Box and or any Jacks Note You should find this manual either in the top of the runway or inside the Power Unit box While the Mainside Runway Item 5 Figures 3 amp 6 15 upside down find the end of the Hydraulic Hose that is already connected to the cylinder Locate the hole in the side of the runway and install the 90 degree Fitting Item 76 securing to runway with Jam Nut Also remove all of the plastic ties securing the cables Extend the cable ends through the runway ends Remove cylinder rod shipping block Tighten hydraulic fittings Extend cylinder piston rod out by pushing or pulling on the Cable Lock Plate A Item 79 Figure 3 on the end of the cylinder Now unbolt the top runway taking the necessary safety precautions Note Using some type of a hoist is recommended this runway will need to be flipped over so it is no longer upside down Place this runway in your bay with the hydraulic fitting facing toward your previously chosen corner for the power unit Next unbolt all four columns from the shipping package and place the column with the power unit mounting bracket in the above chosen corner Arrange the other three columns in the remaining corners Unpack the Crossbeams Ramps Safety Latch Linkage Rods and Lock Ladders from bottom Runway Remove the Safety Latch Covers Items
24. letely before operating lift e Properly maintain and inspect lift in accordance to owner 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 lift operating and safety controls If a vehicle is suspected of falling clear area immediately Do not rock vehicle while positioned on lift Always use safety jack stands when removing or installing heavy components Vehicle Loading e Position vehicle on lift runways by having another person guide you onto the runways Check for proper weight distribution center of gravity should be evenly distributed between columns e Set vehicle parking brake and chock tires to prevent vehicle movement Use caution before lifting pickup trucks suv s and other vehicles The individual axle weight capacity should not exceed 1 2 of lift capacity e sure vehicle is neither front nor rear heavy Raising Lift e Push up switch to raise lift until platform runways clear floor e Stop and check for vehicle movement and vehicle weight distribution If secure raise to desired height e Always lower the lift to the nearest lock position by pressing the lower lever to relieve the hydraulic pressure and let the latch set tight in a lock position e Never work under a lift that is not in the locked position
25. locking latches and slack cable devices during lift operation to ensure that all latches line up with slots in latch bar located in all four columns Cable Adjustment 1 Initial Adjustment Adjust cable with lift fully lowered Loosen jam nut and tighten nut on cable stud on top of column until yoke end is raised 1 4 6 4 mm and back off nut one turn Retighten jam nut Repeat for all four cables 2 Final Adjustment a Load a typical vehicle on lift b Raise lift as high as it will travel full height You should hear the locking latches click through all latch slots simultaneously c Lower lift onto top latch position d Check clearance e Starting with the right front column use a straight edge to mark the position of the yoke bottom on the column f Raise lift to full height again Mark second position If gap between two marks is less than 2 adjust locking latch bar to reach clearance of 2 Repeat for the other three CO7338 1 26 IN20525 Rev D 3 30 2009 columns g Adjust locking latch bar adjusting nut so that the bottom of the topmost latch bar slot is at least 2 below locking latch After adjustment tighten jam nut underneath column top plate Fig 11 h If entire 2 clearance cannot be attained by adjusting the locking latch bar adjust the cable Turn cable adjusting nut to raise the locking latch 2 above bottom of latch bar slot Tighten cable jam nut i Lower lift and remove vehicle j Raise t
26. lowing items should only be performed by a trained maintenance expert Replacement of hydraulic hoses 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 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 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 CO7338 1 18 IN20525 Rev D 3 30 2009 TROUBLESHOOTING The common problems that may be encountered and their probable causes are covered in the following paragraphs Motor Does Not Operate Failure of the motor to operate is normally caused by one of the following 1 Breaker or fuse blown 2 Faulty wiring connections call electrician 3 Defective up button call electrician for service Motor Functions but Lift Will Not Rise If the motor is functioning but the lift will not rise do the following in the order given 1 A piece of trash is under check valve Push
27. n examined by a qualified service person 4 Donotlet a cord hang over the edge of the table bench or counter or come in contact with hot manifolds or moving fan blades CO7338 1 15 IN20525 Rev D 3 30 2009 10 12 13 lf an extension cord is necessary cord with a current rating equal to or than that of the equipment should be used Cords rated for less current than the equipment may overheat Always unplug equipment from electrical outlet when not in use Never use the cord to pull the plug from the outlet Grasp plug and pull to disconnect Let equipment cool completely before putting away Loop cord loosely around equipment when storing To reduce the risk of fire do not operate equipment in the vicinity of open containers of flammable liquids gasoline Adequate ventilation should be provided when working on operating internal combustion engines Keep hair loose clothing fingers and all parts of body away from moving parts To reduce the risk of electric shock do not use on wet surfaces or expose to rain Use only as described in this manual Use only manufacturer s recommended attachments ALWAYS WEAR SAFETY GLASSES Everyday eyeglasses only have impact resistant lenses they are not safety glasses SAVE THESE INSTRUCTIONS 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 pressur
28. nd operating instructions in this manual before operating lift Keep this manual near lift at all times Make sure all operators read this manual NOTE Are you installing in a level location Lift must be anchored in place if slope is greater than 1 8 per foot Make sure you have enough room to install the lock rods You will need at least 9 of clearance from the opposite end of the power unit end of the lift and 6 at the power unit end See floor plan on page 6 The power unit may be installed on the driver s front or the passenger rear corner Never raise a car until you have double checked all bolts nuts and hose fittings Always lock the lift before going under the vehicle or storing another vehicle underneath lift 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 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 examinati
29. nded by the manufacturer or ANSI ALI ALOIM 2008 American National Standard for Automotive Lifts Safety Requirements for Operation Inspection and Maintenance Shall display the lift manufacturer s operating instructions ALI SM 93 1 AL Lifting it Right safety manual ALI ST 90 AL Safety Tips card ANSI ALI ALOIM 2008 American National Standard for Automotive Lifts Safety Requirements for Operation Inspection and Maintenance and in the case of frame engaging lifts ALI LP GUIDE Vehicle Lifting Points Quick Reference Guide for Frame Engaging Lifts in a conspicuous location in the lift area convenient to the operator Shall not modify the lift in any manner without the prior written consent of the manufacturer Shall provide necessary lockout tagout means for energy sources per ANSI 2244 1 1982 R1993 Safety Requirements for the Lockout Tagout of Energy Sources before beginning any lift repairs Lift Lockout Tagout Procedure Purpose This procedure establishes the 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
30. on The user assumes full responsibility for any equipment damage personal injury or alteration of the equipment described in this manual or any subsequent damages CO7338 1 2 IN20525 Rev D 3 30 2009 LIFT SPECIFICATIONS FLOOR PLAN Capacity 9 000 Ibs Lifting Height 84 707 Ceiling Height to be height of highest vehicle to be raised plus 84 7 0 Overall Length w Ramps 223 1 2 18 7 1 2 Overall Length w Ramps 192 1 2 16 1 2 Overall Width 121 10717 Approach Ramp Length 31 277 Runway Width 21 1 2 1 9 1 2 Runway Length 188 15 8 Runway Height 4 3 4 Height of Columns 97 8 1 Clearance between Columns 109 5 9 1 1 2 Clearance between Runways 39 Outside Runway to Outside Runway 79 7 Clearance Under Runway 81 6 9 Motor specs 110VAC 1HP Shipping Weight 2 350 LBS Swank NOTE NOTE mor WILL NEED AT WILL NEED AT LEAST 9 LEAST 6 21 1 2 CLEARANCE CLEARANCE T INSTALL INSTALL ROD HANDLE ROD j tss sisest 192 12 Pe Top View 109 1 2 424 Front View CO7338 1 3 IN20525 Rev D 3 30 2009 CO7338 1 TOOLS REQUIRED Set of metric wrenches and or sockets Adjustable wrench Locking pliers 25 Tape measure Step Ladder 3 Gallons of Hydraulic Oil Recommended Oil ISO 32 Light Hydraulic Oi
31. pacitor Box Power Unit 1 Capacitor Box Attachment 3 Phase 6 e 1 Option Two MOTOR DRUM SWITCH Three Phase Power Unit L3 MOTOR OPERATING DATA TABLE THREE PHASE LINE VOLTAGE RUNNING MOTOR VOLTAGE RANGE 208 240V 50 60Hz 197 253V e 360 440V 396V528V 518V632V 400V 50Hz 440 480V 50 60Hz 575V 60Hz L1 440 480V 50 60 Hz 30 575V 60 Hz 38 380 400V 50 Hz 39 208 240V 50 60 2 30 FIGURE CO7338 1 7 IN20525 Rev D 3 30 2009 17 Install the braded Hydraulic Hose Item 74 to the Fitting on the side of the Mainside Runway and attach the other end to the 90 degree Fitting on the Power Unit as shown in Figure 3 18 Now raise the complete unit Lift and set at one of the bottom lock positions Place level on crossbeam 19 Tighten Lock Ladder Rod Nut located on the top of each posts Item 41 This will raise the corner of the lift to adjust leveling Each post has this adjustment Adjust the proper columns to level the lift Place level on each runway and crossbeam and check for proper levelness NOTE YOU MAY HAVE TO LOOSEN THE NUT UNDER TOP PLATE TO MAKE ADJUSTMENTS 20 After leveling is complete tighten the Nut on the Lock Rod underneath the Top Cap on each post This will lock the Lock Ladder in position 21 Raise lift off all locks until cables are supporting the lift Adjust the Cable Nylon Lock Nut Item 72 located on t
32. procedure by the facility owner manager Each new or transferred employee along with visiting outside service personnel shall be instructed by the owner manager or assigned designee in the purpose and use of the lockout procedure Preparation CO7338 1 14 IN20525 Rev D 3 30 2009 Employees authorized to perform lockout shall ensure that 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 3 The authorized lockout person operates the main energy isolation device removing power to the subject lift 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 If this device is a non lockable circuit breaker or fuse
33. qualified electrician is used to perform maintenance 2 Faulty wiring Call electrician 3 capacitor Call electrician 4 Low voltage Call electrician o Lift Jerks Going Up and Down 1 If the lift jerks while going up and down it is usually a sign of air in the hydraulic system Raise lift all the way to 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 e Lift makes excessive noise vibrates Excessive noise from the lift is normally caused by the following 1 Cross beam ends are rubbing the columns Readjustment needed 2 Cylinder too tight load lift half capacity and cycle up and down a few times to break in 3 May have excessive wear on cable sheaves or shafts Replace them CO7338 1 20 IN20525 Rev D 3 30 2009 Cable Inspection Guide Maximum Allowable Cable Necking Nom Cable Diameters Max Reduction in Diameter Up to 5 16 1 64 3 8 to 1 2 1 32 9 16 0
34. quirements 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 In the event you need replacement parts use only lift manufacturer replacement parts available from your local distributor Do not modify the lift in any manner without the prior written consent of the WARNING manufacturer 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 Use only lift manufacturer replacement parts available from your local distributor Daily Pre Operation Check 8 Hours Check safety lock audibly and visually while in operation Check safety latches for free movement an
35. rovided Hardware Items 29 amp 30 Figure 7 Mount the Power Unit Item 7 to the Mainside Column with the attached mounting bracket using the Hardware Items 16 17 amp 103 provided as shown in Figure 6 Once mounted fill the Power Unit reservoir tank with hydraulic fluid Now install the 90 degree Hydraulic Fitting Item 75 Figure 3 to the high pressure port on the Power Unit Connect the electrical power to the Power Unit Have a certified electrician run appropriate power supply to motor Fig A amp Fig B Size wire for 20 amp circuit See Motor Operating Data Table 5 IN20525 Rev D 3 30 2009 07 18 Never operate the motor on line voltage less than 208 Motor damage may occur 1111 401 4 Use separate circuit for each power unit Protect each circuit with time delay fuse or circuit breaker For single phase 208 230V use 20 amp fuse Three phase 208 240V use 15 amp fuse For three phase 400V and above use 10 amp fuse For 38 wiring see Fig All wiring must comply with NEC and all local electrical codes Note 60Hz single phase motor CAN NOT be run on 50Hz line without a physical change in the motor Attach black wire Single Phase Power Unit Attach white to one motor wire wire to one MOTOR OPERATING DATA TABLE SINGLE PHASE Black White motor wire LINE VOLTAGE RUNNING MOTOR VOLTAGE RANGE E 208 230V 50Hz 197 253V 208 230V 60Hz 197 253V 208 230V 60Hz
36. ssbeams so that the outside of the Crossbeam rail to the outside of the other Crossbeam rail measure s 184 5 Compare the measurements from the left and the right until they are diagonally within 1 2 The 72 variance will help in mounting the runways later Lift and position each Runway into place and secure with the provided Hex Bolts Lock Washer Flat Washer and Nut Items 34 35 36 amp 37 as shown in Figure 7 The lift will square itself as you further assemble it Note Install the Offside Runway Item 4 opposite from the Mainside Runway Item 5 and Power unit Column as shown in Figure 7 Begin cable routing installation by removing the Cable Sheaves Shafts and opacers from all four corners of the Mainside Runway as shown in Figure 4 Route and mount the appropriate Cable s Items 48 49 50 amp 51 to each Column Top Cap while ensuring that the Plastic Cable Pulley Item 58 is between the Cable and the Lock Ladder as shown in Figures 1 amp 8 This will allow the secondary slack cable lock to function properly See Figure 8 for Cable routing installation Reinstall the Cable Sheaves Shafts Spacers and hardware as shown in Figures 4 Note Make sure all Cables are properly routed around Cable Sheaves Install all Lock Rods amp Linkage components per the drawing on Page 20 Figure 5 Also install the Crossbeam Bracket Item 28 to middle outside of each Crossbeam Secure with the p
37. table surfaces SPECIAL NOTE This Lift does not require bolting to the floor BUT If you choose the option to anchor the Lift to the floor please follow the detailed instructions and criteria below FOUNDATION and ANCHORING REQUIREMENTS 1 Concrete shall have compression strength of at least 3 000 PSI and a minimum thickness of 4 in order to achieve a minimum anchor embedment of 3 14 NOTE When using 34 x 5 12 long anchors if the top of the anchor exceeds 2 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 6 in any direction Hole depth should be a minimum of 4 3 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 anchors to 85 ft lbs Shim thickness MUST NOT exceed 72 when using the 5 long anchors with the lift Adjust the column extensions plumb 4 If anchors do not tighten to 85 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 CO7338 1 10 IN20525 Rev D 3 30 2009 ANCHORING TIP INSTRUCTIONS CAUTION Anchors must be at least 6
38. using procedures on following pages 2 Slack Cable Device Inspect slack cable devices using procedure on page 5 3 Column Anchor Bolts Check column anchor bolts for tightness Re torque anchors bolts to 65 ft Ibs If anchors do not tighten to the required installation torque replace concrete under each column base per installation instructions Let concrete cure before installing lifts and anchors 4 Columns Look for corrosion giving special attention to the area at the base of the column Check severely corroded areas by pecking with an awl or welder s chipping hammer If column is corroded through at any point it must be replaced immediately not corroded through remove old paint and rust scale then coat with a high quality corrosion resistant paint NOTE thorough inspection of the lifting system must be performed quarterly by qualified lift service personnel more frequently monthly under extreme service conditions such as outside installations or high usage 10 or more cycles per day etc Quarterly Inspection amp Maintenance 1 Cables 1 1 Inspect cables in both lowered and raised position The cables may also be viewed through various inspection holes and openings in yokes and runways Check all the following a That cables have no broken wires visible reference Daily Inspection amp Maintenance b That cables are free of severe corrosion and pitting reference Daily Inspection amp Maintenance A light surface

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