ECOA ZPL Owner`s Manual - Lift
Contents
1. ms 14 6 GENERAL ASSEMBLY SIDE VIEW aot 15 JE GENERAL ASSEMBLY TOP VIEW mein n dea sco 16 GETTING STARTED PLEASE READ THE INSTALLATION INSTRUCTIONS CAREFULLY BEFORE INSTALLING USING OR SERVICING THE ZPL SERIES INDUSTRIAL LIFT safety of all persons installing using or servicing the ZPL Series Industrial Lift is of utmost importance to ECOA ZPL Series Industrial Lift is capable of supporting heavy loads and is capable of causing SEVERE PERSONAL INJURY if used improperly or certain safety precautions are not taken When properly used and maintained the ZPL Series Industrial Lift will provide many years of safe trouble free service If you have any questions about any of the instructions in this manual or about the use of this product PLEASE contact your DEALER or ECOA Industrial Products Inc ZPL is the model designation for the ZPL Series Industrial Lift Throughout this service manual the ZPL may be referred to as the lift INSPECTION IMMEDIATELY upon receipt of the ZPL Series Industrial Lift remove all packing and strapping material and visually inspect the unit for damage Any damage to the lift MUST BE NOTED on the delivery receipt After the preliminary inspection is conducted the lift should be thoroughly inspected for any concealed damage that was not readily apparent during the preliminary inspection Any concealed damage found that was not noted on th2. e Oil is too thick for proper operation e Refer to Oil Viscosity Recommendations f Lift operates with a shuddering vibration f Cylinder may be binding Check with factory g Pump is inoperative See 1 3 Motor labors or heats excessively a Voltage may be low See l c b Incorrect wiring b Check that one leg of the motor lines is not connected to ground c Oil starvation causes pump to bind High internal heat is developed if this occurs pump may be permanently damaged c See Ic h 1 d Binding cylinders d See 2 f e Oil may be too thick e See Oil Viscosity Recommendations 17 4 Spongy or Jerky Lift operation Do not confuse spongy operation with small surges caused by foreign material on Lift wheel roller plate a Air trapped in cylinders a Bleed cylinders by lowering Lift fully and hold DOWN button for 20 30 seconds more Raise Lift and repeat procedure several times Bleed cylinders also by loosening bleeder screws item 10 until a steady stream of oil comes out b Oil starvation b See 1 b 1 5 Lift lowers too slowly when loaded a Down Valve filter clogged a Remove Solenoid Valve and clean it b Pinched tube or hose b Correct as necessary In case of pipe check for obstruction inline c Oil too thick c See Oil Visc
3. 2 T5 1 1 2 HP 230VAC 1PH 60Hz 77 3450 rpm 1 1 2 HP 460VAC 3PH 60Hz 2 2 3450 rpm 13193108d ATIWWASHL SI SOLOW 3Hl JI 0350 SI QVO 83AD WwWe3Hl JLON 39V11DA 1 T gt AND 3501 OLLVINHHOS IVOLLLOH d AG CSH3H1D 18 qua Sa3HLO 493NNDOSIG ASIAL 03503 HOLIAS LIWII 1140 1411 0 0 15 2 09 09 0 2 802 6112 3119 43 25 1 21412313 LINDYID NI G3SN SI HOLIMS LIWI dN 3I 2 dWnr SION 71051409 3AWA 7705 1915 7031405 ZHO9 HdT AOE2 321 435 HOLIAS LIWIT dn fe 9nd S33H1D 301 493NNDOSIG ASIAL 13573 I AND 3801 quus 48 ONINAVA 43503 ZHO9 Hdl1 ASTT 39IAW3S 831231044 ATWHS3HI Y ZH09 A09v A0E2 A802 ASTT 39IAM3S G3SIVINVIS Sa3HLO 133 02514 03513 2 09 4 09 062 802 1321 435 140 14 LAVA JJS G333AD1 135194 1 9 CIWNOI 1 0 gt HOLIMS LIWII dfi 30073 OL 1340235 LINN 99712 5 9 99014 1402 11 5 303 ONO OT DMY 2 918 3148493 W2I312313 9053 DNDI OT 1 355 9 3SUH x 8 5 18284001 375 7991519373 cw
4. e Raise Lift and remove the safety bar or whatever object is blocking the down travel then press the down button f Binding cylinders f See 2 f 18
5. 1 140 NOILVLS 1081 09 1003 1 0405 91 415 5 OT X 3 1 DMY v 9T4 A825 3901 151 1 1509 LV 41003 WNOILdO gt 9053 OT X DS 15 FIGURE 7 GENERAL LAYOUT TOP VIEW SEE CHART PAN LENGTH ZERO PAN LIFT SPECIFICATIONS CAPACITIES 2 000 6 000 LBS MODEL NUMBER CAPACITY PLATF RM OVER ALL DIMENSIONS LOWERED TRAVEL RAISED WEIGHT POUNDS SIZE INCHES HEIGHT INCHES HEIGHT POUNDS CINCHES gt CINCHES gt CINCHES gt SHIP WEIGHTS ARE APPRDXIMATE STANDARD ZPL 02 44048 2 zp oe soo4e 200 ZPL 04 44048 C j 16 TROUBLE SHOOTING Observation Possible Cause Remedy 1 Lift does not raise but pump is running a Motor rotation maybe reversed or humming Change motor rotation per notes in Electrical Section If Lift has been running properly for some time then it is possible that plant wiring has been changed and the motor is now running reversed b Motor may be single phasing humming b Check wiring and overloads fuses etc to ascertain that all 3 phase lines are present at the motor c Voltage at motor terminals may be too low to run pump at existing load c Measure voltage at motor terminals or as near as possible while pump is running under load If voltage is suffi
6. 15 performed in the field NOTE Any modification of the lift in the field without the express written consent of ECOA will void any and all warranties The ZPL is furnished with constant pressure dead man type push button controls Pressing the UP or RAISE button starts the motor see wiring diagram which in turn runs the hydraulic pump The cylinders begin to extend and the platform starts to rise The platform will rise as long as the UP button 1s pressed and the UP LIMIT SWITCH optional is not activated On releasing the button the platform ceases to rise and will remain at that particular elevation When pressing the DOWN button the Down Solenoid Valve is energized The cylinders start retracting as the oil returns to the reservoir and upon releasing the button the platform ceases to lower remaining at that particular elevation In the event that the lift is overloaded the relief valve will open because of excessive pressure build up and oil will bypass into the reservoir When the lift reaches a preset vertical travel the UP LIMIT SWITCH optional will be actuated This shuts off the power to the motor At this point pressing the UP button will have no effect The platform will remain stationary at the desired elevation Always remember that the motor runs only when the UP button is pressed and the Down Solenoid Valve is energized only when the DOWN button is pressed Some Tips to the Operator 1 Always lo
7. 30 30 RELIEF VALVE CHECK VALVE DOWN SOLENOID VALVE WITH FILTER DOWN FLOW CONTROL VALVE ELECTRIC MOTOR 25 MICRON HIGH PRESSURE FILTER OPTIONAL HYDRAULIC CYLINDERS HYDRAULIC SCHEMATIC FOR STANDARD ZPL SERIES LIFT FIGURE 1B HOSE LAYOUT FOR ALL ZPL MODELS PART No DESCRIPTION CSEE ASSY DRAWING s jescoroso 1 TUBE 3 8 00 x 1 4 10 x 4 L ea 5 5 mant 1 7 427 03 90 6 BULKHEAD f 1 Fejesaso sm rume ree 67 05 awemR ra urus _ 11 441 05 9n io came Te z Dsjereei masr 10 FIGURE 2 HYDRAULIC CYLINDER REF CYL A4861 1025 9 16 18 SAE D RING PORT 2 gt PLS 15 75 RETRACTED 10 85 STRDKE 26 EXTENDED FIGURE 3 CROSS SECTIONAL VIEW OF GEAR PUMP USED ON ZPL LIFTS CHECK DUTLET PDRT VALVE 1 E ASSEMBLY OPTIONAL ITEMS URDER AS REQD gt FLOW h CONTROL VALVE RELIEF VALVE INLET PORT ASSEMBLY 3 4 16 SAE PART DESCRIPTION HYDRAULIC GEAR PUMP WITH INTERNAL VALVES HLT 712 2 GPM 3450 RPM INCLUDES ITEMS 2 amp 3C e HLT 751 4VAC SOLENOID COIL W 1 2 LEADS 38 2 755 100 FLOW CONTROL SPOOL 1 GPM x 755 200 FLOW CONTROL SPOOL 2 GPM 3D 755 400 FLOW CONTROL SPOOL 4 GPO 3E H r 755 500 FLOW CONTROL SPOOL
8. NO CIRCUMSTANCES should you attempt any repair or service that is not covered in the service manual or authorized by ECOA Industrial Products Inc 7 ALWAYS ensure all safety warning labels are in place and legible If not remove the industrial lift from service and replace the required labels 8 ALWAYS securely anchor the base frame to the floor to ensure maximum stability and the proper operation of the lift CAUTION l DO NOT continue to operate the hydraulic pump if a squealing noise 1s heard coming from the pump The pressure relief valve is operating Continued operation of the pump with the relief valve operating will cause permanent damage to the pump 2 DO NOT change the relief valve setting The relief valve is installed to protect the operator and the lift RESPONSIBILITIES OF OWNERS USERS It is the responsibility of the Owners Users to 1 Advise the DEALER or ECOA when deflection or creep is critical to the lift application and of any unique application information 2 Ensure the dock lift is properly installed and used in accordance with the guidelines provided in this manual 3 Ensure the dock lift is inspected and maintained in proper working order in accordance with the operation maintenance instructions provided in this manual 4 Ensure any lift not in safe operating condition such as but not limited to excessive hydraulic leakage missing rollers pins or fasteners bent or cracked structural members cut or f
9. components unless you are a QUALIFIED ELECTRICIAN 6 The lift s electrical components can create sparks DO NOT install the lift the power unit or the controls in an area where potentially explosive dusts gases or vapors may be present Failure to comply may result in an explosion and cause SEVERE PERSONAL INJURY or DEATH WARNING 1 The ZPL Series Industrial Lift is designed for use with stable uniformly distributed loads on a solid level floor DO NOT concentrate the load at one point on the pallet or platform ALWAYS uniformly distribute the load over the supporting surface DO NOT use the ZPL Series Industrial Lift for any purpose other than its intended use 2 SHEARING HAZARD ALWAYS keep hands and feet clear of the scissor mechanism and all moving components DO NOT put hands or feet under the lift platform when in use SEVERE PERSONAL INJURY could result 3 CRUSHING HAZARD ALWAYS keep hands and feet clear of all moving components DO NOT put feet in the pit or on the base frame when in use SEVERE PERSONAL INJURY could result 4 PINCH POINT HAZARD ALWAYS keep hands and feet clear of the underside of the lift platform SEVERE PERSONAL INJURY could result 5 NEVER leave the loaded ZPL lift unattended unless the lift platform is in the fully lowered position 6 ALL lift servicing must be performed by qualified personnel Unauthorized modifications to this ZPL lift may compromise the performance and safety of the system UNDER
10. motor which runs the hydraulic pump Oil from the reservoir is sucked in through the suction filter and into the pump The pump delivers the pressurized oil through the internal check valve before entering the cylinders The function of the check valve is to allow the oil to flow in one direction towards the cylinders It also prevents the flow of oil back into the pump circuit when the pump stops running This holds the oil in the cylinders and maintains the desired elevation If the load 15 excessive and the UP button 15 still pressed pressure will build up in the circuit between the pump and the cylinders This forces the ball or poppet in the relief valve to unseat and the pump output returns into the reservoir through the return line When the operator desires to lower the lift he or she presses the DOWN button This energizes the down solenoid valve The poppet in the solenoid valve is unseated and oil now returns from the cylinders through the flow control valve the solenoid valve and into the reservoir The flow control valve controls the down speed of the lift Releasing the DOWN button will de energize the solenoid closing the valve poppet This prevents the oil from returning to the reservoir and the cylinders will stop retracting The lift is now maintained at that particular elevation FIGURE 1A HYDRAULIC SCHEMATIC KEY RESERVOIR SUCTION FILTER HYDRAULIC GEAR PUMP WITH INTERNAL VALVES C INCLUDES ITEMS
11. 5 GPM 11 Electrical Section see pages 13 amp 14 The standard power unit is pre wired according to customer request For supplied power other than the original configuration the power unit MUST be re wired according to the Manufacturer s instruction sheet Service and Field wiring is the sole responsibility of the end user ECOA Industrial Products Inc assumes no responsibility for incorrect installation or service wiring Install the power lines to conform to National Electrical Code NEC 480 22 and applicable local codes Given below are the various electrical components used on the Lift A brief description of each is also given Specifications Magnetic Starter 24 VAC Motor 1 5 HP 208 230 460V 3PH 60HZ or 1 5 HP 115 230V 1PH 60HZ Thermally protected automatic reset internal Transformer 75 VA 115 208 240 480 VAC Primary 24 VAC Secondary manual reset w circuit breaker Enclosure NEMA 12 with 5 knockouts Motor Solenoid Power Cord Control Cord amp Limit Switch optional Overall Box Dimensions 8 25 in x 6 25in 4 25in 12 FIGURE 4 MOTOR LEADS CONNECTIONS SINGLE PHASE 5 THREE PHASE P1 LINE 1 T1 gt LINE 1 T7 T8 Pe INSULATE Te gt LINE 2 T3 P8 T4 T3 gt LINE 3 Te LINE P9 TS 1 1 2 HP 1 2 HP 115 VAC 1PH 60Hz 208 230VAC 3PH 60Hz 15 4 3450 rpm 4 5 4 4A 3450 rpm P1 LINE 1 T3 2 NSULATE T4
12. ZPL Series Industrial Lifts Service amp Parts Manual ECOA INDUSTRIAL PRODUCTS INC 7700 NW 74 AVE Medley Fl 33166 7502 USA 305 885 2111 800 433 3833 1 PM ZPL 12 06 Table of Contents GETTING STARTED auctum e UE 3 INSPEC TION one sace 3 kanaa 3 SAFETY INSTRUCTIONS 3 RESPONSIBILITIES OF OWNERS USERS 5 FUNGTIONALADESORTPTION 6 SCISSOR BLOCKING INSTRUGCTIONS 2 dte ol ida 6 OPERATING INSTRUCTIONS icc inte at onte Aute animes daba sale Gentes i dala 7 ROUTINE MAINTENANCE t tpe 8 OIL VISCOSITY RECOMMENDATIONS ttt ttt ttc 8 HYDRAULIC SEC TION a ay e 9 deese ____ 6__ 12 TROUBLE ac aqa hanh 17 18 Figures HYDRAULIC SCHEMATIC FOR STANDARD 2 22 2 2 0 04 0000000 1 10 1B HOSE LAYOUT FOR ALL ZPL MODELS eren 10 2 SECTIONAL VIEW OF TYPICAL HYDRAULIC CYLINDER cere 11 3 SECTIONAL VIEW OF TYPICAL HYDRAULIC PUMP 11 4 MOTOR WIRING DIAGRAMS 13 5 ELECTRICAL SCHEMATIQS
13. ad the lift properly by centering the load on the platform as much as possible 2 Never use the lift if it is need of repairs or in the case of a malfunction 3 Notify your maintenance personnel if you notice anything out of the ordinary such as binding odd pump noises etc 4 Do not continue to press the UP button if the lift is not rising You can permanently damage the motor or pump by doing so ROUTINE MAINTENANCE Raise the lift and engage the maintenance safety bars before beginning any inspection or work on the unit A Monthly Inspections 1 oil level It should be about 1 below top of the tank with the lift in fully lowered position Add oil as required See oil specifications 2 Check for oil leaks See Trouble Shooting Section and correct as necessary 3 Check roller bushings axle pin clevis and pivot points for wear 4 Check for worn or damaged hydraulic hoses or electrical cords Repair as necessary 5 Check rollers for looseness and wear See Trouble Shooting 6 Check retaining rings at all axles pivot points and clevis 7 Never grease rollers or axles 8 Check for unusual noise See Trouble Shooting B Yearly Inspection Oil in reservoir should be changed at least once a year or sooner if the oil darkens or becomes gritty Presence of water 1s indicated if the oil turns milky C Winter Summer Maintenance Change the oil as per Oil Viscosity Recommendations depending on the ambient
14. cient check for inadequate or incorrect wiring as this can starve the motor Correct as necessary d Hose or hydraulic line is leaking d Correct as necessary e Oil level in reservoir is low e Add oil f Load exceeds capacity requirements Relief Valve is bypassing the oil back into tank f Do not change Relief Valve setting Instead reduce the load to rated capacity g Suction filter is clogged starving pump g Remove and clean h Suction line may be leaking air due to loose fittings h Check fittings i Filler Breather capon tank may be clogged i Remove and clean j Down Valve may be energized by faulty wiring or stuck open 1 Remove Solenoid Valve check and clean See Hydraulic Section k Hydraulic pump may be inoperative k Disconnect hydraulic line at power unit Put hose end in a large container and run pump again It no output check motor rotation as per 1 a above If pump is worn replace with a new pump 2 Lift rises too slowly a Foreign material stuck in Down Solenoid causing some oil to bypass back into tank a Lower the Lift Remove the Solenoid Valve and clean it See Hydraulic Section b Foreign material clogging suction filter breather cap pressure line filter pinched hose b Correct as necessary See also 1 g c Low Motor voltage See l c d Lift overloaded d See 1 f
15. e delivery receipt should be IMMEDIATELY reported in writing TO THE DELIVERING CARRIER SAFETY DEFINITIONS ECOA uses the following system to identify the degree of risk associated with hazards and unsafe practices DANGER Immediate hazard which will result in SEVERE PERSONAL INJURY or DEATH WARNING Hazard or unsafe practice which could result in SEVERE PERSONAL INJURY or DEATH and PROPERTY DAMAGE Hazard or unsafe practice which could result in MINOR PERSONAL INJURY and PROPERTY DAMAGE SAFETY INSTRUCTIONS DANGER 1 READ THIS MANUAL COMPLETELY BEFORE USING AND THOROUGHLY UNDERSTAND AND FOLLOW ALL SAFETY INSTRUCTIONS 2 A falling industrial lift can cause SEVERE PERSONAL INJURY or DEATH NEVER go under the lift platform until the load is removed and the scissor mechanism is blocked with the maintenance bars 3 The maintenance bars have been designed for use only when the lift is UNLOADED NEVER place any load on the lift platform with the maintenance bars engaged SEVERE PERSONAL INJURY or DEATH and PROPERTY DAMAGE could result 4 DO NOT attempt to remove or loosen the platform or base frame hinge pins Loosening or removing these pins could cause the lift to suddenly collapse EVEN IF THE MAINTENANCE BARS ARE ENGAGED SEVERE PERSONAL INJURY or DEATH and PROPERTY DAMAGE could result 5 The lifts electrical circuits use voltages which can cause SEVERE PERSONAL INJURY or DEATH DO NOT work with the electrical
16. ing the DN button the Down Solenoid Valve is energized The cylinders start retracting as the oil returns to the reservoir and upon releasing the button the platform ceases to lower remaining at that particular elevation SCISSOR BLOCKING INSTRUCTIONS To Engage the Maintenance Bars 1 REMOVE ALL LOADS from the platform and depress the up button to raise the ZPL to its fully raised position 2 Rotate each maintenance bar until it contacts the base Ensure both maintenance bars properly positioned against the 2 end bars 3 Lower the lift by pressing the DOWN button until the rollers stop against the maintenance bars and the lift ceases to come down any further To Disengage the Maintenance Bars 1 Raise the ZPL by pressing the button until the rollers are well clear of the maintenance bars 2 Rotate each maintenance bar back to its original position WARNING MAINTENANCE BARS ARE TO BE USED ONLY WHEN THE LIFT IS UNLOADED USE OF THE MAINTENANCE BARS TO SUPPORT A FULLY LOADED LIFT COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH OPERATING INSTRUCTIONS The load capacity rating as stamped on the nameplate of your ZPL designates the maximum lifting capacity with a uniformly distributed load This capacity must never be exceeded as permanent damage may result Lowering loads that exceed the rated capacity will result in excessive wear or damage to the lift Consult the factory before any modification
17. osity Recommendations d Foreign material in Flow Limiter d Remove and clean e Binding cylinders e See 2 f 6 Lift lowers too quickly a Leaking hoses Cracked fittings Correct as necessary Check underground conduit for evidence of fluid b Check valve stuck open The combination of a stuck Check Valve and open Solenoid Valve will cause excessive speeds b Remove Check Valve and clean it See Hydraulic Section 7 Lift rises then lowers slowly a Down Solenoid Valve may be incorrectly wired or is stuck open due to dirt a See 2 b Check Valve may be stuck open b Remove and clean See Hydraulic Section c Check for leaking hoses fittings pipes C Correct as necessary d Cylinder seals may be worn or damaged d Replace seals See Cylinder Repair procedure 8 Lift has risen but does not lower a Blown electrical fuse Check and replace b Incorrect Down Solenoid Valve wiring b Correct as necessary See Wiring Diagram c Down Solenoid Valve is stuck c Lightly tap down the Solenoid Coil body to seat it properly Do not hit hard as it will permanently damage the internal stem Do not remove the Solenoid Valve from the Block as the unit will come down at a dangerous speed d Faulty Down Solenoid Coil d Remove and replace e Maintenance safety bar or some other object blocking down travel
18. rayed hydraulic lines damaged or malfunctioning controls or safety devices etc shall be removed from service until it is repaired to ECOA s standards 5 Ensure all repairs are made by qualified personnel in conformance with the instructions provided by ECOA Industrial Products Inc 6 Ensure only trained and authorized personnel are permitted to operate the lift and that all operators understand the operating instructions safety rules and hazards associated with this lift 7 Ensure modifications or alterations of any lift are made only with the written permission of ECOA Industrial Products Inc 8 Ensure that the power unit is wired correctly for the available power supply according to the enclosed Manufacturer s instruction sheet FUNCTIONAL DESCRIPTION The ZPL Series of lifts have been primarily designed for industrial ergonomic assistance applications The most important advantage of the ZPL Series is that it is finitely adjustable in height The installation of this lift provides full flexibility allowing lifting and accurate positioning of the load anywhere within the lift s travel range Pressing the UP button starts the motor see wiring diagram which in turn runs the hydraulic pump The cylinders begin to extend and the platform starts to rise The platform will rise as long as the button is pressed On releasing the button the platform ceases to rise and will remain at that particular elevation When press
19. temperatures prevailing your area Oil Viscosity Recommendations Best performance can be obtained by utilizing ISO Vg grade 32 46 oil with a viscosity range between 150 250 SUS at 100 F 32 54 cSt at 40 C Minimum viscosity at operating temperature is 60 SUS 10 cSt Maximum start up viscosity at minimum ambient temperature 1s 4000 SUS 880 cSt Maximum recommended operating temperature of hydraulic oil is 150 F 650C Oil should be non corrosive have maximum anti wear properties rust and oxidation treatment and be non foaming Recommended list of oils for an ambient temperature range of 10 F to 100 F 23 C to 38 are as follows 1 Amoco Oil Co Rycon Oil No 32 46 Amoco AW 32 46 2 Cities Service Oil Co Citgo AW Hyd Oil 32 46 Citgo All Temp Hyd Oil 3 Chevron USA Chevron EP Hyd Oil 32 46 4 Fina Oil Co Fina AW 32 46 Fina Automatic Transmission Fluid Dextron II 5 Gulf Oil Corporation Gulf Harmony 32 AW 46 AW 6 Mobil Oil Corporation DTE 15 24 25 Mobil Fluid 300 Transmission Fluid 7 Sentinel Lubricants Corp Sentinel SH 10 Hydraulic Oil 8 Shell Oil Co Tellus Hyd Oil 32 46 Tellus 1 Hyd Oil 32 46 9 Texaco Inc Rando Oil Hd 32 46 10 Union 76 XCelI AW 46 200 Note 1 Do Not use brake fluid 2 Lifts requiring oil by ECOA will be supplied with AW 46 200 Hydraulic oil HYDRAULIC SECTION When the operator wants to raise the platform he or she presses the UP button This starts the electric
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