INSTALLATION / OWNERS MANUAL
Contents
1. SW 002 30400 17 9053YZ 90 Degree Fitting 1 18 B30 8 Nut M8 10 19 B40 8 Lock Washer 8 24 20 B41 8 Flat Washer 98 60 22 B10 18x100 Hex Head Bolt M18x100 8 23 B41 18 Flat Washer 018 8 24 B40 18 Lock Washer 918 8 25 B30 18 Nut M18 8 26 H4D 7001 07 Bolts M8x50 2 27 B10 12x30 Hex Head Bolt M12x30 16 28 B41 12 Flat Washer 012 32 29 B40 12 Lock Washer 12 16 30 B30 12 Nut M12 18 31 DP8 2013 Flat Washer 920 8 32 B30 20 Nut M20 4 33 PP8S 3100 Runway Weldment Non Power Unit Side 1 34 DP8 3200 Runway Weldment Power Unit Side 1 35 H4D 5001 Car Stop Plates 4 36 NH4D 3303 Nut 4 37 H4D Y003 90 Degree Fitting 1 38 DP8 2012 Cable Pulley 10 39 B33 3 4 16 Nylon Lock Nut 3 4 16 4 41 B33 24x2 Nylon Lock Nut M24x2 1 45 H4D 5003 Cable Lock PlateA 1 46 H4D 5004 Cable Lock PlateB 1 47 DP8 2004 Small Cable Pulley 4 48 PP7 2004 Cable 1 49 PP7 2003 Cable 1 50 PP7 2002 Cable 1 51 PP7 2001 Cable 1 53 B10 8x35 Hex Head Bolt M8x35 36 54 B10 8x20 Hex Head Bolt M8x20 8 55 NH4D 2005 Lock Plate 8 56 DP8 2003 Slider 8 57 DP8 2009 Shaft 4 58 DP3 2001 Pulley Cover 2 59 B22 8x10 Set Screw M8x10 4 60 DP8 2007 Bushings 4 61 DP8 2006 Cable Pulley Pin 4 62 DP8 2014 Flat Washer 24C Level 12 PP8S 32 IN50011 Rev B 03 03 2008 63 NH4D 1011 Spring 8 64 DP8 20112. Go back to the coupler that attaches the T rod to the handle rod and tighten the jam nuts Do not adjust coupler only tighten the jam nuts 27 FINAL ADJUSTMENTS Fill the tank with three gallons of R amp O ISO32 Hydraulic Oil Available at any auto supply store Dexron III Transmission Fluid can also be used 28 Check over cables and make sure they are all in their pulleys Press the up switch on the power unit and the fluid will start to pump into the cylinder The lift will eventually rise after the cylinder fills up Once the lift is raised off of the locks release the up switch and pull the lock lever to disengage the locks and lower the lift with the lowering lever on the power unit Hold lever after lift reaches the very bottom until you hear all of the air escape 29 Raise the lift up to the point where the square block above the lock aligns with the second column lock and stop Look at each column lock to determine the highest point Adjust the cable on the highest point column until three threads pass through the nylock nut Now adjust the other three cables to match this height NOTE There will be some initial stretching of the cables in the beginning It will be necessary to readjust the cables a week after first use then every six months thereafter Run the lift up and down a few times to insure that the locks are engaging uniformly and that the safety release mechanisms are functioning properly Readjust if necessary
3. of the columns then remove the top plates from the top of the columns while columns are standing If you don t have a means for securely lifting them up then you will need to lay the columns down and remove the top plates to allow the cross rails to be slid into the columns 8 Slide each cross rail into the front or rear two columns by holding the lock lever down to allow the rail to slide past the locking positions Leave the cross rail locked in the lowest position on the column Repeat this step for the other cross rail See Fig 1 9 Position the front cross rail columns at 170 5 from the rear cross rail columns by measuring from the outsides of the columns Square the lift by measuring diagonally between the right front column to the same position on the left rear column Compare your measurement between the left front column and the right rear column This should be within to allow some forgiveness to bolt on runways 10 Lift the runways onto the cross rails and bolt them in place using the 34 holes towards the outside ofthe cross rails The four drop in ramp plates will be used with the spacer side facing the lift and through bolted from the outside of the cross rail through the runway using bolts provided with washers lock washers and nuts See Fig 2 ll After runways are bolted on install the column top plates back to their original columns and tighten 12 CABLE INSTALLATION Lay out all cables and measure
4. PP8S 7 IN50011 Rev B 03 03 2008 OPTIONAL CASTER KIT 1 Install caster wheels to caster frames as shown NOTE Hitch Pin and Hairpin Clip will be used to attach casters to lift in following steps DO NOT Install at this time M10 x 1 3 8 Bolt 26 910 Flat Washer 910 Flat Washer 910 Lock Washer M10 Nut Hitch Pin 1 Raise lift 2 3 high 2 Place caster assemblies under crossbeams as shown Secure with Hitchpin and Hairpin Clip 3 Lower lift and the columns will automatically raise off the floor 4 5 Lower Lift and weight of crossbeam Column will automatically raise columns off the ground Crossbeam Hitch Pin amp Hairpin Clip N Caster PP8S 8 IN50011 Rev B 03 03 2008 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 Ya NOTE When using x 5 2 long anchors if the top of the anchor exceeds 2 Ya 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 2 in any direction Hole depth should be a minimum of 4 CAUTION 3 DO NOT instal
5. cables must be replaced immediately d 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 Ifany 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 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
6. from end to end to determine correct cable positions See Fig 3 13 Since the nub end ofthe cable is easier to feed through the pulley start with the pulley at the end ofthe cross bar and work your way back to the cylinder See Fig 3 14 Install cable nubs onto appropriate slots in 4 plate and secure with slots on 14 plate Tighten the nubs so the nylock nut is fully threaded onto the head of the cylinder The cable bracket should still be able to move freely on the cylinder head 15 Run the threaded cable ends into the hole in the top caps and secure with washer and nylock nut Hand tighten only final adjustment will be made later Do tighten the nylock nut on the end of the cylinder at this time 16 HYDRAULIC ASSEMBLY Be sure wiring is in compliance with your local electrical codes PP8S 5 IN50011 Rev B 03 03 2008 LA Find the four 5 16 bolts nuts and lock washers and attach the power unit to the mounting bracket on the column 18 Remove dust cover from the port on the side of the power unit and attach the O ring elbow Do not over tighten The backing nut and O ring will complete the seal to the power unit 19 Install the 3 8 hose to the fitting on the side of the runway and connect opposite end to the fitting on the power unit Tighten JIC fittings carefully do not over tighten 20 LOCK LINKAGE ASSEMBLY The single point safety lock is a system of connecting rods and linkage that disengage t
7. 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 Ifthe 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 1 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 1 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 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
8. out Rebuild or replace the cylinder 3 Cylinder Vent the piston seal of the cylinder is out Rebuild or replace the cylinder 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 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 PP8S 19 IN50011 Rev B 03 03 2008 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 to 3 4 3 64 7 8 to 1 1 8 1 16 1 1 4 to 1 1 2 3 32 Typical Good Cable Cable With Broken Wires 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
9. 011 Rev B 03 03 2008 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 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 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
10. B 03 03 2008 A CAUTION Lift to be used by trained operator ONLY A CAUTION Authorized personnel only in lift area 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 of these labels was provided by the Automotive Lift Institute PO Box 1519 New York NY 10101 1519 They are protected by copyright Set of labels may be obtained from ALI or its member companies 1992 by ALI Inc SAFETY INSTRUCTIONS La Read operating and safety manuals before using lift SAFETY INSTRUCTIONS be Do not operate a damaged lift ALI WL200c SAFETY INSTRUCTIONS WE Proper maintenance and inspection is necessary for safe operation 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 of these labels was provided by the Automotive Lift Institute PO Box 1519 New York NY 10101 1519 They are protected by copyright Set of labels may be obtained from ALI or its member companies ALI WL200s 1992 by ALI Inc PP8S Clear area if vehicle is in danger of falling A WARNING IS Keep clear of pinch p
11. DC Work Lock 2 65 NH4D 1004 Spring 2 66 DP8 2008 Spacer 4 67 DP8 2005 Lock Shaft 4 68 DP8 2010DC Safty Lock 2 69 DP8 2002 Pulley Cover 2 70 DP8 2011 Work Lock 2 71 NH4D 1004DC Spring 2 72 DP8 2010 Safty Lock 2 73 H4D 5007 Plastic Plate 2 75 PP7 3001 Cable Pulley Shaft 4 76 PP7 3003 Spacer 2 77 PP7 3002 Spacer 2 78 DP8 4301 Long Rod 2 79 DP8 4401 Short Rod 2 80 DP8 4210 Joy Stick B 1 81 H4D 7000 03 Coupler 1 82 DP8 4110 Joy Stick A 1 83 B72 6 Bearing M6 8 84 B33 6 Nylon Lock Nut M6 8 85 B30 6 Nut M6 8 86 B10 6x30 Hex Head Bolt M6x30 4 87 B41 6 Flat Washer 6 12 88 B84 35 Plastic Knod For Handle 35xM10 1 89 B23 6x10 Discal Head Screw M6x10 4 90 B41 20 Flat Washer 920 8 91 H4D 7000 05 Steel Spacer 2 92 30400 1999 Washer 4 93 B10 8x16 Hex Head Bolt M8x16 8 Optional Accessories for PP8S PP3S 2000CK Caster Kit Assembly 4 PP3S 2000 Caster Kit Frame Weldment 4 B80 6x2 Caster Kit Caster Wheel Assembly 6 x2 4 PP8S 2100 Caster Kit Hitch Pin 4 H4D 5006 03 Caster Kit Hairpin Clip 4 B30 10 Hex Nut M10 16 B40 10 Lock Washer 210 16 B41 10 Flat Washer 910 32 PP8S 33 IN50011 Rev B 03 03 2008 B10 10x35 Hex Bolt M10x35 16 DP7PNBKD DT Drip Tray 3 H4D 6000 Jack Tray Tool Box 1 PP8S 34 IN50011 Rev B 03 03 2008
12. PP8S Four Post Lift 8 000 Ibs Capacity 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 IN50011 Rev B 03 03 2008 PP8S 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 11 e FOUNDATION amp ANCHORING REQUIREMENTS pg 13 e OPERATION INSTRUCTIONS pg 15 e PREVENTIVE MAINTENANCE SCHEDULE pg 17 e TROUBLESHOOTING pg 19 e CABLE INSPECTION GUIDE pg 21 e ILLUSTRATED PARTS LIST pg 27 e WARRANTY POLICY pg 35 IMPORTANT INFORMATION Four Post Lifts 1 Always inspect the lift for damage and make note of any damage on the bill of lading 2 In case of freight damage call the truck line immediately and report the damage as a freight claim 3 Make sure you have extra help or heavy duty lifting eguipment when unloading and assembling the lift 4 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 rea
13. d this manual 5 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 6 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 7 Never raise a car until you have double checked all bolts nuts and hose fittings 8 Always lower the lift to locks 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 examination The user assum
14. done by pulling or pushing on the 4 plate on the end of the cylinder Make sure that the 2 plate is threaded tight against the cylinder rod Also be sure the 4 plate is on the rod and hand tighten the lock nut on the end of the cylinder 4 Unbolt the top runway from the shipping plates at each end of the package Be sure to secure runway with a hoist to prevent runway from falling Runway will need to be tumed over so it is no longer upside down Place this runway in your bay with the hydraulic fitting facing toward the outside see Page 1 5 Next unbolt the four columns from the package and place the column with the power unit mounting bracket at the end of the previously unpacked runway nearest to the hydraulic fitting Stand these columns on their base plates with the locking ladders facing to the outside front or rear and the pulleys toward the inside see Fig 1 6 Unpack the bottom runway Lay the approach ramps near the approach end of the lift and set out the remaining parts away from the lift Place the two cross rails at each end of the lift with the locks toward the outside front or rear of the lift see Fig 1 Remove the shipping brackets from the bottom runway and turn over placing the runway in the bay next to the other runway with the L shaped side facing the L shaped side of the PP8S 4 IN50011 Rev B 03 03 2008 7 If you have a means for securely lifting cross rails high enough to lower them into the top
15. es full responsibility for any equipment damage personal injury or alteration of the equipment described in this manual or any subsequent damages PP8S 2 IN50011 Rev B 03 03 2008 LIFT SPECIFICATIONS amp FLOOR PLAN 81 1 2 158 169 1 2 175 1 2 151 1 2 YOU WILL NEED A MIN OF 6 YOU WILL NEED A MIN OF CLEARANCE IN FRONTTO 9 CLEARANCE IN REAR INSTALL HANDLE ROD TO INSTALL T ROD 103 1 2 100 3 4 Technical Data Lifting Height 72 112 Overall Length with Ramps 207 1 2 Overall Length without Ramps 175 1 2 Overall Width 103 1 2 Height Of Columns 81 1 2 Runway Width 18 1 2 Runway Height 4 1 2 Clearance Between Runways 38 Capacity 8000 Ibs PP8S 3 IN50011 Rev B 03 03 2008 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 Oil INSTALLATION INSTRUCTIONS l Remove plastic wrap from top runway and remove all hardware safety lock rods hoses and cables You should also find this manual in the top runway 2 Find the end of the hose that is already mounted to the cylinder and tighten the elbow that attaches the hosc to the side of the runway using the jam nut Also check the fitting at the cylinder end and make sure it is tight 3 Extend cylinder rod out of the cylinder to about 18 from end of runway This can be
16. ety 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 Z244 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 PP8S 11 IN50011 Rev B 03 03 2008 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 Rotary 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 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 Employees authorized to perform lockout shall ensure that the appropriate energy
17. fety 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 2000 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 2000 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 recommended by the manufacturer or ANSI ALI ALOIM 2000 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 ALI Lifting it Right safety manual ALI ST 90 ALI Safety Tips card ANSI ALI ALOIM 2000 American National Standard for Automotive Lifts Saf
18. for ease of rotation If sheaves do not turn freely the sheave and sheave pin should be removed inspected lubricated and reinstalled or replaced PP8S 22 IN50011 Rev B 03 03 2008 Runway Sheave Stack Sheave In Out Movement 1 16 1 6 mm Maximum Allowed Wobble Sheave Pin us 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 WA Movement a 4 4 16 1 6 mm Maximum Allowed 7 Wobble BEER alignment 1 32 0 8 mm Maximum c Check for excessive side to side wobble Grasp rim of sheave and attempt to wobble tilt side to side refer to figures above If sheaves wobble tilt more than 1 16 1 6 mm 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 leaks Repair or replace as reguired PP8S 23 IN50
19. he four lock latches that secure the lift to each column Locate the six rods a 2 longrods b 2 short rods c 1 handle rod d 1 Trod Also locate hardwarc a 1 rodcouplmg with 2 jam nuts b 8 heim ends with connecting nuts and bolts c 2 spacers 21 Slip spacer over threaded end of handle rod and insert rod into hole on cross bar near power column 22 Slip spacer over threaded end of T rod and insert end into hole located on opposite cross rail taking care to run rod through rod guide located under ramp 23 Thread jam nuts onto ends of handle rod and T rod Attach the handle rod to the T rod using the rod coupling Adjust coupling to take the slack out of the rods The rods should remain free enough to move with no slack Do not tighten coupler or lock nuts at this time 24 Locate the two long rods and remove one end from each rod and slide off the eye bolt Attach eye bolts to center of cross rails by threading of the way in and tighten jam nut PP8S 6 IN50011 Rev B 03 03 2008 25 Attach short rod on the T side lock and to the bottom of the T and hand tighten Slide long rod through the eye bolt and attach one end to the top side of T Attach the other end of the long rod to the lock on the other side Repeat this process for the other end of the lift The locking rods should be in perfect alignment since the lift is still sitting in the locked position Tighten all jam nuts making sure the linkage does not bind 26
20. icle 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 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 completely before operating lift 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 Set vehicle parking brake and chock tires to prevent vehicle movement Use caution before lifting pickup trucks suv s and other vehicles The individual a
21. l on asphalt or other similar unstable surface Columns are supported only by anchoring to floor 4 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 Ibs Shim thickness MUST NOT exceed 12 when using the 5 2 long anchors with the lift Adjust the column extensions plumb 5 If anchors do not tighten to 85 ft Ibs 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 PP8S 9 IN50011 Rev B 03 03 2008 ANCHORING TIP INSTRUCTIONS PP8S CAUTION Anchors must be at least 6 from the edge of the slab or any seam Use aconcrete hammer drill with a carbide tip solid drill bit the same diameter as the anchor 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
22. 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 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 F 5 40 C PP8S 12 IN50011 Rev B 03 03 2008 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 8 000 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 veh
23. movement or excessive wear on cable sheave shaft PP8S 16 IN50011 Rev B 03 03 2008 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 following 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 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 Contamina
24. nd add oil as required Oil Blows out 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 PP8S 18 IN50011 Rev B 03 03 2008 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 qualified electrician is used to perform maintenance 2 Faulty wiring Call electrician 3 Bad capacitor Call electrician 4 Low voltage Call electrician 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
25. oints when lift is moving A WARNING Do not overide self closing lift controls Remain clear of lift when raising or lowering vehicle WARNING Keep feet clear of lift while lowering WARNING d ew A Chock wheel to prevent vehicle movement 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 of these labels was provided by the Automotive Lift Institute PO Box 1519 New York NY 10101 1519 They are protected by copyright Set of labels may be obtained from ALI or its member companies 1992 by ALI Inc ALI WL200w 15 Read and heed all WARNING CAUTION and SAFETY INSTRUCTION labels on lift IN50011 Rev B 03 03 2008 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 vearly basis as given in the following paragraphs ARNING Occupational Safety and Health Administration OSHA and the American National Standards Institute ANSI reguires users to inspect lifting eguipment at the start of every shift These and other periodic inspections are the responsibility of the user Fail
26. ould be close Be sure all four corners have passed the locking latch bar slot before lowering lift on locking latches PP8S 25 IN50011 Rev B 03 03 2008 FOUR POST 8K ILLUSTRATED PARTS LIST IN50011 Rev B 03 03 2008 26 GENERAL ILLUSTRATED PARTS LIST FIGURE 1 PP8S FIGURE 2 CROSSBEAM ASSEMBLY IN50011 Rev B 03 03 2008 27 PP8S LV QV gt 05 ae Wa si z Ca CABLE COMPONENTS 8 ROUTING FIGURE 3 PP8S 28 IN50011 Rev B 03 03 2008 33 RUNWAY AND SHEAVE COMPONENTS FIGURE 4 PP8S 29 IN50011 Rev B 03 03 2008 SAFETY LATCH amp LINKAGE COMPONENTS FIGURE 5 PP8S 30 IN50011 Rev B 03 03 2008 37 SL gt ow HYDRAULIC amp CYLINDER COMPONENTS FIGURE 6 PP8S PARTS LIST Items Drawing Description QTY 1 PP8S 1000 Column Weldment A 1 2 PP8S 1100 Column Weldment B 3 3 DP8 1200 Column Top Caps 2 4 DP8 1200DC Column Top Caps 2 5 PP8S 1210 Latchbar Weldment 4 6 DP8 2100 Crossbeam Weldment 2 7 P3543 Power Unit 1 8 DP8 5000 Ramp Weldment 2 9 YG02 9100G Hydraulic Cylinder 1 10 PP7 9802 2 Pipe Fitting 1 11 PP7 9200 Throttle 1 12 1WB 04 Hydraulic Hose 1 13 H4D 5005 Hydraulic Cylinder Pin 1 14 B52 5x60 Cotter Pin 5x60 2 15 H4D 5000 Link Frame 4 16 1WB 05 Hydraulic Hose 1 PP8S 31 IN50011 Rev B 03 03 2008
27. result in property damage and or personal injury 2 Fasteners Check all the attaching bolts and nuts for tightness PP8S 20 IN50011 Rev B 03 03 2008 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 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 loose on pin or excessive noise during operation 9 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 8 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 torgue anchors bolts to 65 ft lbs If anchors do not tighten to the required installation torque replace concrete under each column base per installation instruc
28. 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 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 10 IN50011 Rev B 03 03 2008 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 OWNER 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 SM01 1 ALI Lifting it Right safety manual ALI ST 90 ALI Safety Tips card ANSI ALI ALOIM 2000 American National Standard for Automotive Lifts Sa
29. tion is the most frequent cause of malfunction or failure of hydraulic equipment PP8S 17 IN50011 Rev B 03 03 2008 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 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 a
30. tions 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 If not corroded through remove old paint and rust scale then coat with a high quality corrosion resistant paint NOTE f 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 PP8S 21 IN50011 Rev B 03 03 2008 b That cables are free of severe corrosion and pitting reference Daily Inspection amp Maintenance A light surface 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
31. 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 columns g Adjust locking latch bar adjusting nut so that the bottom of the topmost latch bar slot is PP8S 24 IN50011 Rev B 03 03 2008 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 the 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 sh
32. ure 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 eguipment 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 Pre Operation Check 8 Hours Check safety lock audibly and visually while in operation Check safety latches for free movement and 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 8 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 lbs for the 3 4 in anchor bolts Do not use an 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
33. xle weight capacity should not exceed 1 2 of lift capacity Make sure vehicle is neither front nor rear heavy Raising Lift PP8S Push up switch to raise lift until platform runways clear floor Stop and check for vehicle movement and vehicle weight distribution If secure raise to desired height 13 IN50011 Rev B 03 03 2008 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 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 ALLOW ANYONE TO GO UNDER THE LIFT WHEN RAISING OR LOWERING NOTE lt is normal for an empty lift to lower slowly it may be necessary to add weight PP8S 14 IN50011 Rev
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