XPR 9 REV A ALEX 1 10 11 9_Manual Manual
User Manual: XPR-9_Manual
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IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS PLEASE READ THE ENTIRE CONTENTS OF THIS MANUAL PRIOR TO INSTALLATION AND OPERATION. BY PROCEEDING WITH LIFT INSTALLATION AND OPERATION YOU AGREE THAT YOU FULLY UNDERSTAND AND COMPREHEND THE FULL CONTENTS OF THIS MANUAL. FORWARD THIS MANUAL TO ALL OPERATORS. FAILURE TO OPERATE THIS EQUIPMENT AS DIRECTED MAY CAUSE INJURY OR DEATH. MAN REV A 1-10-11 P/N 5900048 INSTALLATION AND OPERATION MANUAL 9,000 POUND CAPACITY SURFACE MOUNTED TWO-POST LIFTS MODELS: XPR-9 RECEIVING The shipment should be thoroughly inspected as soon as it is received. The signed Bill of Lading is acknowledgement by the shipping carrier as receipt of this product as listed in your invoice as being in a good condition of shipment. If any of these goods listed on this Bill of Lading are missing or damaged, do not accept goods until the shipping carrier makes a notation on the freight bill of the missing or damaged goods. Do this for your own protection. 1 BE SAFE Your new lift was designed and built with safety in mind. However, your overall safety can be increased with proper training and thoughtful operation on the part of the operator. DO NOT operate or repair this equipment without reading this manual and the important safety instructions shown inside. Keep this operation manual near the lift at all times. Make sure that ALL USERS read and understand this manual. 1645 Lemonwood Dr. Santa Paula, CA. 93060, USA Toll Free 1-800-253-2363 Tel: 1-805-933-9970 Fax: 1-805-933-9160 wwwbendpak.com 9,000 POUND CAPACITY SURFACE MOUNTED TWO-POST LIFTS This instruction manual has been prepared specifically for you. Your new lift is the product of over 40 years of continuing research, testing and development; it is the most technically advanced lift on the market today. READ THIS ENTIRE MANUAL BEFORE INSTALLATION & OPERATION BEGINS. RECORD THE LIFT AND POWER UNIT INFORMATION HERE. YOU MAY FIND THIS INFORMATION LOCATED ON THE SERIAL NUMBER DATA PLATE AND POWER UNIT DATA PLATE This information will be required when calling for parts or warranty issues. Only replace parts with BendPak approved parts. PRODUCT WARRANTY BendPak two-post lifts are covered under warranty for five years on equipment structure, to be free of defects in material and workmanship. Power units, hydraulic cylinders, and all other assembly components (such as cables, chains, valves, switches etc.) are warrantied for one year against defects in material or workmanship under normal use. BendPak Inc. shall repair or replace at its discretion, within the warranty period, those parts returned to the factory freight, prepaid, which prove upon inspection to be defective. BendPak Inc. will pay labor costs for the first 12 months only on parts returned as previously described. The warranty does not extend to... defects caused by ordinary wear, abuse, misuse, negligence, shipping damage, improper installation, voltage or lack of required maintenance; damages resulting from purchaser’s neglect or failure to operate products in accordance with instructions provided in the owner’s manual(s) and/or other accompanying instructions supplied; normal wear items or service normally required to maintain the product in a safe operating condition; any component damaged in shipment; other items not listed but may be considered general wear parts; damage caused by rain, excessive humidity, corrosive environments or other contaminants. THESE WARRANTIES DO NOT EXTEND TO ANY COSMETIC DEFECT NOT INTERFERING WITH EQUIPMENT FUNCTIONALITY OR ANY INCIDENTAL, INDIRECT, OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY RESULT FROM ANY DEFECT, FAILURE, OR MALFUNCTION OF A BENDPAK INC. PRODUCT OR THE BREACH OR DELAY IN PERFORMANCE OF THE WARRANTY. WARRANTY IS NOT VALID UNLESS WARRANTY CARD IS RETURNED. 2 IMPORTANT NOTICE OWNER’S RESPONSIBILITY Do not attempt to install this lift if you have never been trained on basic automotive lift installation procedures. Never attempt to lift components without proper lifting tools such as a forklift or cranes. Stay clear of any moving parts that can fall and cause injury. These instructions must be followed to insure proper installation and operation of your lift. Failure to comply with these instructions can result in serious bodily harm and void product warranty. Manufacturer will assume no liability for loss or damage of any kind, expressed or implied resulting from improper installation or use of this product. To maintain the lift and user safety, the responsibility of the owner is to read and follow these instructions: Follow all installation and operation instructions. Make sure installation conforms to all applicable Local, State, and Federal Codes, Rules, and Regulations; such as State and Federal OSHA Regulations and Electrical Codes. Carefully check the lift for correct initial function. Read and follow the safety instructions. Keep them readily available for machine operators. Make certain all operators are properly trained, know how to safely and correctly operate the unit, and are properly supervised. Allow unit operation only with all parts in place and operating safely. Carefully inspect the unit on a regular basis and perform all maintenance as required. Service and maintain the unit only with authorized or approved replacement parts. Keep all instructions permanently with the unit and all decals on the unit clean and visible. PLEASE READ ENTIRE MANUAL PRIOR TO INSTALLATION. DEFINITIONS OF HAZARD LEVELS Identify the hazard levels used in this manual with the following definitions and signal words: BEFORE YOU BEGIN Watch for this symbol as it means: Immediate hazards which will result in severe personal injury or death. NOTIFY THE CARRIER AT ONCE if any hidden loss or damage is discovered after receipt and request the carrier to make an inspection. If the carrier will not do so, prepare a signed statement to the effect that you have notified the carrier (on a specific date) and that the carrier has failed to comply with your request. WARNING ! IT IS DIFFICULT TO COLLECT FOR LOSS OR DAMAGE AFTER YOU HAVE GIVEN THE CARRIER A CLEAR RECEIPT. Support claim with copies of the Bill of Lading, freight bill, invoice, and photographs, if available. BendPak’s willingness to assist in helping you process your claim does not make BendPak responsible for collection of claims or replacement of lost or damaged materials. DANGER ! Watch for this symbol as it means: Hazards or unsafe practices which could result in severe personal injury or death. CAUTION ! Watch for this symbol as it means: Hazards or unsafe practices which may result in minor personal injury, product or property damage. 3 TABLE OF CONTENTS Contents Page No. Warranty / Serial Number Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Definitions of Hazard Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Owner’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installer/Operator Agreement/ Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Safety / Warning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Step 1 / Selecting Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Step 2 / Floor Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Concrete Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Assembly View / Description of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Step 3 / Post Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11 Step 4 / Site Layout / Floor Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Step 5 / Installing Power Side Post . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-14 Step 6 / Installing Off Side Post . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Step 7 / Mounting The Hydraulic Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15 Step 8 / Installing the Safeties and Safety Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17 Step 9 / Installing Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Step 10 / Routing the Equalizer Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19 Step 11 / Installing Power Unit Hose Assembly and Power Side Safety Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Step 12 / Installing the Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-21 Carriage Stop Bolt Installation Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Leveling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Safety Label Placement Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Step 13 / Power Unit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25 Step 14 / Lift Start Up / Final Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Post Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Step 15 / Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Optional Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-27 Step 16 / Operation / Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-38 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39-41 Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-43 Installation Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Part Number Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-47 4 INSTALLER / OPERATOR PLEASE READ AND FULLY UNDERSTAND. BY PROCEEDING YOU AGREE TO THE FOLLOWING. Failure to follow Danger, Warning, and Caution instructions may lead to serious personal injury or death to operator or bystander or damage to property. I have visually inspected the site where the lift is to be installed and verified the concrete to be in good condition and free of cracks or other defects. I understand that installing a lift on cracked or defective concrete could cause lift failure resulting in personal injury or death. Please read the entire manual prior to installation. Do not operate this machine until you have read and have understood all of the Danger, Warning and Caution alerts in this manual. For additional copies or further information, contact: I understand that a level floor is required for proper installation and level lifting. I understand that I am responsible if my floor is of questionable slope and that I will be responsible for all charges related to pouring a new level concrete slab if required and any charges. BendPak Inc. 1645 Lemonwood Dr. I understand that BendPak lifts are supplied with concrete fasteners meeting the criteria of the American National Standard “Automotive Lifts - Safety Requirements for Construction, Testing, and Validation” ANSI/ALI ALCTV-2006, and that I will be responsible for all charges related to any special, regional, structural, and/or seismic anchoring requirements specified by any other agencies and/or codes such as the Uniform Building Code (UBC) and/or International Building Code (IBC). INSTALLER / OPERATOR PROTECTIVE EQUIPMENT I will assume full responsibility for the concrete floor and condition thereof, now or later, where the above equipment model is to be installed. Failure to follow Danger, Warning, and Caution instructions may lead to serious personal injury or death to operator or bystander or damage to property. Personal protective equipment helps makes installation and operation safer, however, it does not take the place of safe operating practices. Always wear durable work clothing during any installation and/or service activity. Shop aprons or shop coats may also be worn, however loose-fitting clothing should be avoided. I understand that BendPak lifts are designed to be installed in indoor locations only. Failure to follow installation instructions may lead to serious personal injury or death to operator or bystander or damage to property or lift. Tight-fitting leather gloves are recommended to protect the technician’s hands when handling parts. Sturdy leather steel-toe work shoes and oil resistant soles should be used by all service personnel to help prevent injury during typical installation and operation activities. Santa Paula, CA. 93060 1-805-933-9970 www.bendpak.com Eye protection is essential during installation and operation activities. Safety glasses with side shields, goggles, or face shields are acceptable. Back belts provide support during lifting activities and are also helpful in providing worker protection. Consideration should also be given to the use of hearing protection if service activity is performed in an enclosed area, or if noise levels are high. THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FOLLOWED COULD ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY OR YOURSELF AND OTHERS AND CAN CAUSE PERSONAL INJURY OR DEATH. READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL BEFORE ATTEMPTING TO OPERATE THIS MACHINE. 5 INTRODUCTION 1. Carefully remove the crating and packing materials. CAUTION! Be careful when cutting steel banding material as items may become loose and fall causing personal harm or injury. 2. Check the voltage, phase, and proper amperage requirements for the motor shown on the motor plate. Electrical work should be performed only by a certified electrician. IMPORTANT SAFETY INSTRUCTIONS Read these safety instructions entirely. Do not attempt to install this lift if you have never been trained on basic automotive lift installation procedures. Never attempt to lift components without proper lifting tools such as forklift or cranes. Stay clear of any moving parts that may fall and cause injury. When using your garage equipment, basic safety precautions should always be followed, including the following: 1. Read and understand all instructions and all safety warnings before operating lift. 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 been examined by a qualified service person. 4. Do not let a cord hang over the edge of the table, bench, or counter or come in contact with hot manifolds or moving fan blades. 5. If an extension cord is necessary, a cord with a current rating equal to or more than that of the equipment should be used. Cords rated for less current than the equipment may overheat. Care should be taken to arrange the cord so that it will not be tripped over or pulled. 6. 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. 7. Let equipment cool completely before putting away. Loop cord loosely around equipment when storing. 8. To reduce the risk of fire, do not operate equipment in the vicinity of open containers of flammable liquids (gasoline). 9. Adequate ventilation should be provided when working on operating internal combustion engines. 10. Keep hair, loose clothing, fingers, and all parts of body away from moving parts. Keep feet clear of lift when lowering. Avoid pinch points. 11. DANGER! To reduce the risk of electric shock, do not use on wet surfaces or expose to rain. The power unit used on this lift contains high voltage. Disconnect power at the receptacle or at the circuit breaker switch before performing any electrical repairs. Secure plug so that it cannot be accidentally plugged in during service. or mark circuit breaker switch so that it cannot be accidentally switched on during service. 12. Use only as described in this manual. Use only manufacturer’s recommended attachments. 13. ALWAYS WEAR SAFETY GLASSES. Everyday eyeglasses only have impact resistant lenses, they are not safety glasses. 14. Consider work environment. Keep work area clean. Cluttered work areas invite injuries. Keep areas well lit. 15. Guard against electric shock. This lift must be grounded while in use to protect operator from electric schock. Never connect the green power cord wire to a live terminal. This is for ground only. 16. Only trained operators should operate this lift. All nontrained personnel should be kept away from the work area. Never let non-trained personnel come in contact with, or operate lift. 17. DO NOT override self-closing lift controls. 18. Clear area if vehicle is in danger of falling. 19. ALWAYS make sure the safeties are engaged before attempting to work on or near a vehcile. 21. WARNING! RISK OF EXPLOSION. This equipment has internal arcing or sparking parts which should not be exposed to flammable vapors. This machine should not be located in a recessed area or below floor level. 22. MAINTAIN WITH CARE. Keep lift clean for better and safer performance. Follow manual for proper lubrication and maintenance instructions. Keep control handles and/or buttons dry, clean and free from grease and oil. 23. Check for damaged parts. Check for alignment of moving parts, breakage of parts or any condition that may affect operation of lift. Do not use lift if any component is broken or damaged. 24. NEVER remove safety related components from the lift. Do not use lift if safety related components are missing or damaged. 23. STAY ALERT. Use common sense and watch what you are doing. Remember, SAFETY FIRST. SAVE THESE INSTRUCTIONS 6 TOOLS REQUIRED Rotary Hammer Drill or Similar 3/4” Masonry Bit Hammer 4 Foot Level Open-End Wrench Set: SAE/Metric Socket And Ratchet Set: SAE/Metric Hex-Key / Allen Wrench Set Large Crescent Wrench Large Pipe Wrench Crow Bar Chalk Line Medium Flat Screwdriver Tape Measure: 25 Foot Minimum Needle Nose Pliers IMPORTANT NOTICE THESE INSTRUCTIONS MUST BE FOLLOWED TO INSURE PROPER INSTALLATION AND OPERATION OF YOUR LIFT. FAILURE TO COMPLY WITH THESE INSTRUCTIONS CAN RESULT IN SERIOUS BODILY HARM AND VOID PRODUCT WARRANTY. MANUFACTURER WILL ASSUME NO LIABILITY FOR LOSS OR DAMAGE OF ANY KIND, EXPRESSED OR IMPLIED, RESULTING FROM IMPROPER INSTALLATION OR USE OF THIS PRODUCT. PLEASE READ ENTIRE MANUAL PRIOR TO INSTALLATION STEP 1 (Selecting Site) Before installing your new lift, check the following. DO NOT install or use this lift on any asphalt surface or any surface other than concrete. 1. LIFT LOCATION: Always use architectural plans when available. Check the layout dimension against the floor plan requirements making sure that adequate space is available. DO NOT install or use this lift on expansion seams or on cracked or defective concrete. 2. OVERHEAD OBSTRUCTIONS: The area where the lift will be located should be free of overhead obstructions such as heaters, building supports, electrical lines etc. DO NOT install or use this lift on a second / elevated floor without first consulting building architect. DO NOT install or use this lift outdoors. 3. DEFECTIVE FLOOR: Visually inspect the site where the lift is to be installed and check for cracked or defective concrete. CONCRETE SPECIFICATIONS 4. Your new BendPak Two-Post lift is designed for INDOOR INSTALLATION ONLY. LIFT MODEL XPR-9 STEP 2 (Floor Requirements) CONCRETE REQUIREMENTS 4” Min. Thickness / 3,000 PSI This lift must be installed on a solid level concrete floor with no more than 3-degrees of slope. Failure to do so could cause personal injury or death. DANGER! A level floor is suggested for proper use and installation and level lifting. If a floor is of questionable slope, consider a survey of the site and/or the possibility of pouring a new level concrete slab. ALL MODELS MUST BE INSTALLED ON 3000 PSI CONCRETE ONLY CONFORMING TO THE MINIMUM REQUIREMENTS SHOWN ABOVE. NEW CONCRETE MUST BE ADEQUATELY CURED FOR A MINIMUM OF 28 DAYS. IMPORTANT NOTE BendPak lifts are supplied with installation instructions and concrete fasteners meeting the criteria as prescribed by the American National Standard "Automotive Lifts - Safety Requirements for Construction, Testing, and Validation" ANSI/ALI ALCTV-2006. Lift buyers are responsible for any special regional structural and/or seismic anchoring requirements specified by any other agencies and/or codes such as the Uniform Building Code (UBC) and/or International Building Code (IBC). 7 When removing the lift from shipping angles, pay close attention as the posts can slide and can cause injury. Prior to removing the bolts make sure the posts are held securely by a fork lift or some other heavy lifting device. PARTS INVENTORY Be sure to take a complete inventory of parts prior to beginning installation. Description Qty Floorplate 1 Front Arm Assembly Rear Arm Assembly Off Side Post with Carriage Assembly Power Side Post with Carriage Assembly Hydraulic Cylinder Parts Box (Packing List Enclosed) Parts Bag (Packaged in Part Box) Hydraulic Power Unit 2 2 1 1 2 1 1 1 8 1. With the post assemblies laying on the floor, slide the carriage up towards the top of the post. Inspect and ensure all socket head cap screws and hex nuts are tight. (See Fig 3.1 - 3.3) STEP 3 (Post Preparation) COMPLETE THE FOLLOWING PRIOR TO STANDING UP POSTS. NOTE: Fig 3.4 DETERMINE DESIRED LOCATION AND WIDTH LAYOUT BEFORE RAISING COLUMNS. REFER TO LAYOUT CHARTS ON PAGE 12. Tube Fitting DANGER! FAILURE TO TORQUE LIFT CHAIN BOLTS PROPERLY MAY RESULT IN PERSONAL INJURY AND/OR DEATH. ENSURE THE SOCKET HEAD CAP SCREWS ARE TIGHT PRIOR TO LIFT OPERATION. 90° 3/8” to 1/4” JIC Fitting 90° 3/8” to 1/4” Fitting Fig 3.1 2. Install cylinder fittings. First install the 90° 3/8” Fitting into the cylinder port using teflon tape on the pipe threads. Next, assemble the tube fitting and 3/8” to 1/4” Hose Fitting together. Again, use teflon tape on all pipe threads. DO NOT use teflon tape on the JIC hose fittings. (See Fig 3.4) Slide Carriage Upwards Fig 3.5 Fig 3.2 Sheave Sheave Cotter Pin Cotter Pin MUST BE TIGHT Fig 3.3 NOTE: When installing fittings DO NOT use teflon tape on JIC fitting end 3. With the carriage still slid towards the top of the post, remove the sheaves on the post base plate to aid in equalizer cable routing by first removing the two cotter pins securing them, then by sliding the sheaves off of the sheave shaft. (See Fig 3.5) MUST BE TIGHT 9 Fig 3.8 NOTE FOR XPR-9 MODELS: FOR NARROW CONFIGURATION USE THE BUTTON LOCATED AT 12” ABOVE CABLE END. FOR WIDE CONFIGURATION USE THE BUTTON LOCATED ON THE END OF THE CABLE. Towards Top Plate Sheave 4. Identify the correct cable button on the end of each equalizer cable that corresponds to your desired lift configuration. (See Fig 3.6) Secure the correct cable button at the carriage lock plate located inside each carriage. Fig 3.6 For narrow configuration NARROW CONFIGURATION NOTE: Portions of Carriage and Post cut away for clarity To threaded cable end For wide configuration WARNING! FAILURE TO SECURE CABLE BUTTON FOR NARROW LIFT CONFIGURATION MAY RESULT IN LIFTING CHAIN FAILURE OR LIFT MALFUCTION. NOTE: REFER TO STEP 10 FOR CABLE ROUTING DETAILS. ROUTE BUTTON END OF CABLES PRIOR TO RAISING UP THE POSTS. 6. If you have chosen the NARROW lift configuration, secure cable button end by inserting cable into the designated cable clip. (See Fig 3.9) 5. Route the correct button end of the equalizer cable for your chosen lift layout through the cable retainer, located inside the carriage on the front carriage tube wall, up to where the Top Plate sheave would be, and coil the remaining cable up and leave it in the post above the carriage. (See Fig 3.7-3.8) Towards Top Plate Sheave Fig 3.9 Cable Clip Fig 3.7 NOTE: Portions of Carriage and Post cut away for clarity 7. Install the Top Plate Assembly using the M10 hardware as provided in the Parts Bag. (See Fig 3.10) WIDE CONFIGURATION NOTE: Portions of Carriage and Post cut away for clarity 10 Fig 3.13 Fig 3.10 M10 Bolt M10 Spring Lock Washer M10 Nut 8. Slide carriage back towards the base plate. Ensure the lift head chain is properly positioned with the lift head chain sheave and cylinder is properly seated in cylinder ring. (See Fig 3.113.12)Failure to properly align lift head chain and/or cylinder will result in lift malfunction. 9. Uncoil cable and route cable around the Top Plate sheave and coil the remaining cable up and leave it in the post above the carriage. (See Fig 3.13) Fig 3.11 OPTIONAL SHEAVE COVER INSTALLATION INSTRUCTIONS Sheave Cover Fig 3.14 Sheave NOTE: Portions of post cut away for clarity Fig 3.12 Cylinder Ring Cylinder Sheave Shaft NOTE: Post hidden for clarity Cylinder Leveling Plug To install optional sheave covers, first fit sheaves over sheave shafts. Then fit sheave cover over both sheave shaft ends. Ensure the notched face of the sheave cover faces the base plate. Secure sheave cover by inserting cotter pins through the cotter pin holes in the sheave shaft. NOTE: Portions of post, carriage, and cylinder cut away for clarity. NOTE: ENSURE CYLINDER LEVELING PLUG IS ALSO INSTALLED PROPERLY WHEN CHECKING ALIGNMENT OF CYLINDER AND CYLINDER RING 11 SITE LAYOUT / FLOOR PLAN A Model Configuration A Capacity XPR-9 XPR-9 Narrow Wide 3353 mm / 132” 3683 mm / 145” 9,000 LBS 9,000 LBS 2. Now determine where the power unit will be located. The POWER SIDE column has the power unit mounting bracket attached to the side. 4. Once a location is determined, use a carpenters chalk line to layout a grid for the post locations. Keep all dimensions square within 1/8” (3mm) or malfunctioning of the lift can occur. 5. After the post locations are properly marked, use chalk or crayon to make an outline of the posts on the floor at each post location using the post base plates as a template. (See Fig 4.1) 3. Use the chart on this page to determine which lift width layout you would like to use. 6. CHECK ALL DIMENSIONS TWICE and make sure that the layout is perfectly square. STEP 4 (Site Layout) 1. Determine which side of the lift will be the approach side. CHALK LINE Fig 4.1 FOR XPR-9 CONFIGURATIONS USE BASE PLATE EDGES TO ALIGN POSTS 12 CLEARANCES XPR-9 86" 2185 MINIMUM TO NEAREST WALL NOTE: SUBTRACT 6-1/2” FROM MINIMUM NEAREST WALL AND MINIMUM NEAREST BAY DIMENSION FOR NARROW CONFIGURATION. 74" 1881 MINIMUM TO NEAREST BAY OR OBSTRUCTION 156" 3963 MINIMUM TO NEAREST OBSTRUCTION APPROACH 19" 483 132" 3353 MINIMUM TO NEAREST OBSTRUCTION 107" 2717 NOTE: Lift measurements shown in WIDE configuration LIFT HEIGHT CLEARNACE NOTE: There must be a 1” MIN distance from top of lift to nearest obstruction. tap into each hole with a hammer until the washer rests against the base plate. If shimming is required be sure that enough threads are left exposed. (See Fig. 5.2) STEP 5 (Installing the POWER SIDE post) 1. Before proceeding, double the check measurements and make certain that the base plate of each post is aligned with the chalk line. NOTE: BENDPAK LIFTS ARE SUPPLIED WITH INSTALLATION INSTRUCTIONS AND CONCRETE FASTENERS MEETING THE CRITERIA AS PRESCRIBED BY THE AMERICAN NATIONAL STANDARD "AUTOMOTIVE LIFTS - SAFETY REQUIREMENTS FOR CONSTRUCTION, TESTING, AND VALIDATION" ANSI/ALI ALCTV-2006. LIFT BUYERS ARE RESPONSIBLE FOR ANY SPECIAL REGIONAL STRUCTURAL AND/OR SEISMIC ANCHORING REQUIREMENTS SPECIFIED BY ANY OTHER AGENCIES AND/OR CODES SUCH AS THE UNIFORM BUILDING CODE (UBC) AND/OR INTERNATIONAL BUILDING CODE (IBC). Fig 5.1 Fig 5.2 2. Using the base plate on the POWER SIDE post as a guide, drill each anchor hole in the concrete (approximately 4” deep for 9K and 10K models and 6” deep for 12K and 15K; 8” for 18K models) using a rotary hammer drill and 3/4” concrete drill-bit. To ensure full holding power, do not ream the hole or allow the drill to wobble. (See Fig. 5.1) 3. After drilling, remove dust thoroughly from each hole making certain that the posts remain aligned with the chalk line. 4. Assemble the washers and nuts on the anchors then 13 5. If shimming is required, insert the shims as necessary under the base plate so that when the anchor bolts are tightened, the posts will be plumb. (See Fig. 5.3) STEP 7 (Mounting the Hydraulic Power Unit) 1. Attach the power unit to the POWER SIDE post. Install the vibration dampener between the power unit and the power unit mounting plate on the Power Side post, using four M8 hex head bolts and nuts supplied. (See Fig 7.1) Fig 7.1. Vibration Dampener Fig 5.3 6. If installing the optional foot guards, place foot guards on left and right side as shown. (See Fig 5.4) Fig 5.4 M8 x1.25 x 35mm hex head bolts, M8 flat washers and M8 Nylock nuts (Qty 4 ea) 2. Fill the reservoir with 10 WT. HYDRAULIC OIL OR DEXRON TYPE III ATF, approximately four gallons. Make sure the funnel used to fill the Power Unit is clean. Do not connect power unit hydraulic hose assembly at this time. 7. With the foot guards, shims and anchor bolts in place, tighten by securing the nut to the base then turning 3-5 full turns clockwise (90 ft-lbs.). DO NOT use an impact wrench for this procedure. (See Fig. 5.5) DANGER ! ALL WIRING MUST BE PERFORMED BY A LICENSED ELECTRICIAN. DANGER! DO NOT PERFORM ANY MAINTENANCE OR INSTALLATION OF ANY COMPONENTS WITHOUT FIRST ENSURING THAT ELECTRICAL POWER HAS BEEN DISCONNECTED AT THE SOURCE OR PANEL AND CANNOT BE RE-ENERGIZED UNTIL ALL MAINTENANCE AND/OR INSTALLATION PROCEDURES ARE COMPLETED. Fig 5.5 STEP 6 (Installing the OFF SIDE post) 3. The standard power unit for your lift is 220 volt, 60HZ, single phase. All wiring must be performed by a certified electrician only. SEE WIRING INSTRUCTIONS AFFIXED TO MOTOR FOR PROPER WIRING INSTRUCTIONS. 1. Position the OFF SIDE post at the designated chalk locations and secure post to floor following the same procedures as outlined in STEP 5; Paragraphs 1-6. 14 WARNING! DO NOT RUN POWER UNIT WITHOUT OIL. DAMAGE TO POWER UNIT PUMP CAN OCCUR. THE POWER UNIT MUST BE KEPT DRY. DAMAGE TO POWER UNIT CAUSED BY WATER OR OTHER LIQUIDS SUCH AS DETERGENTS, ACID ETC., IS NOT COVERED UNDER WARRANTY. OPERATE LIFT ONLY BETWEEN TEMPERATURES OF 41 °- 104° F. IMPROPER ELECTRICAL HOOK-UP CAN DAMAGE MOTOR AND WILL NOT BE COVERED UNDER WARRANTY. MOTOR CAN NOT RUN ON 50HZ WITHOUT A PHYSICAL CHANGE IN THE MOTOR. USE A SEPARATE CIRCUIT BREAKER FOR EACH POWER UNIT. PROTECT EACH CIRCUIT WITH TIME DELAY FUSE OR CIRCUIT BREAKER. FOR 208-230 VOLT, SINGLE PHASE, USE A 25 AMP FUSE. FOR 208-230 VOLT, THREE PHASE, USE A 20 AMP FUSE. FOR 380-440 VOLT, THREE PHASE, USE A 15 AMP FUSE. STEP 8 (Installing the Safeties and Safety Cable) Fig 8.3 Safety Bar Safety Clevis Pin 1. Install safety weldments on to each respective post. (See Fig 8.1 - 8.3) Fig 8.1 Safety Clevis Pin Hairpin Cotter Top Safety Weldment Off Side Safety Weldment Torsion Spring Off Side Bottom Safety Safety Bar Hairpin Cotter 2. From the Off Side post insert the non-looped end of the safety cable through the hole located to the right of the Off Side safety weldment. (See Fig 8.4) Off Side and Power Side Top Safety Fig 8.4 Fig 8.2 Safety Clevis Pin Torsion Spring Insert nonlooped end of safety cable through hole in post Safety Bar Hairpin Cotter Power Side Safety Weldment Slip looped end over bottom pin Power Side Bottom Safety 15 3. Route the cable over the sheave and route it towards the baseplate safety sheave. (See Fig 8.5) Fig 8.7 Safety Cable DANGER ! ENSURE THAT BOTH THE POWER SIDE & OFF SIDE SAFETIES ENGAGE PROPERLY PRIOR TO LIFT OPERATION. Fig 8.5 From Off Side Post Route safety cable over Off Side safety sheave and down towards base plate Fig 8.6 NOTE: Post and carriage cut away for clarity 7. Pull the slack out the safety cable and keep tension on the cable as nuts are being tightened. Tighten jam nuts on either side of the cable keeping the cable centered to the hole to secure it into place. (See Fig 8.8) NOTE: MAKE SURE TO KEEP THE SAFETY CABLE CENTERED WHEN TIGHTENING JAM NUTS ON SAFETY. Route safety cable the hole in the threaded pin NOTE: Post cut away for clarity Route safety cable over the top pin of the Power Side Safety Weldment 4. Route the cable through the baseplate’s safety sheave(s) and across the floor towards the Power Side post. (See Fig 8.6 - 8.7) Fig 8.6 Safety Cable Tighten jam nuts ensuring safety cable is centered in hole To Power Side Post Fig 8.5 Fig 8.8 NOTE: Post and carriage cut away for clarity 5. Route the cable the same way as on the Off Side going up the post and over the safety cable sheave. 8. Operate the Power Side safety handle, check for proper operation of both safety assemblies and adjust cable tension as required. 6. Route the cable over the top pin on the safety handle. Insert the cable end through the hole on the threaded pin. (See Fig 8.7) 9. Raise and lock each carriage approximately 28” above the ground. (See Fig. 8.9) 16 DANGER ! WARNING ! ENSURE THAT BOTH THE POWER SIDE & OFF SIDE SAFETIES ENGAGE PROPERLY PRIOR TO LIFT OPERATION. WHEN ROUTING HYDRAULIC HOSES THROUGH THE POSTS, ROUTE HOSES THROUGH THE HOSE CLIPS WELDED ON EACH POST. MAKE SURE THAT THE HOSE IS CLEAR OF ANY MOVING PARTS. IT MAY BE NECESSARY TO TIE THE HOSES CLEAR BY USING NYLON TIE STRAPS OR WIRE. FAILURE TO KEEP THE HYDRAULIC HOSES CLEAR MAY RESULT IN THE HYDRAULIC HOSES TO FAIL, WHICH MAY RESULT IN DAMAGE OR PERSONAL HARM. Fig 8.9 Fig 9.2 STEP 9 (Installing Hydraulic Lines) NOTE: FOR THE WIDE CONFIGURATION, A 13” EXTENSION MUST BE INSTALLED TO THE CROSSOVER HOSE. A JIC TO JIC STRAIGHT FITTING HAS BEEN PROVIDED TO CONNECT THE CROSSOVER HOSE TO THE EXTENSION HOSE IN THE PARTS BOX. NOTE: Post and carriage cut away for clarity Fig 9.3 1. Connect the two cyliinder hydraulic hoses in line to the tee fitting. Connect the 90° fitting to the tee fitting. Connect the power unit hose to the 90° fitting. (See Fig 9.1) Tee Fitting Cylinder Hose JIC Elbow Fitting Power Unit Hose Power Unit Hose Clip 90° Fitting Power Unit Hose Off Side Hose Safety Cable Cylinder Hose Power Side Hose NOTE: Post and carriage cut away for clarity NOTE: Fig 9.1 POWER PORT LOCATION IN HYDRAULIC POWER UNIT MAY VARY. CONFIRM THE LOCATION OF THE POWER PORT ENCLOSED IN THE POWER UNIT DOCUMENTATION. 2. Connect the cylinder hoses to the JIC elbow fittings on the cylinders. DO NOT use teflon tape on the JIC fitting end. (See Fig 9.2) 3. Route the power unit hose under the cylinder seat and the equalizer sheave pin. Route the hose through the hose clip. Failure to do so may cause damage or injury. (See Fig 9.3) Fig 9.4 90° Power Unit Fitting 4. Remove the plastic plug from the power unit power port. Install the 90° power unit fitting with O-ring using teflon tape. (Connect the power unit hose assembly to the 90° hydraulic fitting on the power unit. DO NOT use teflon tape on the JIC hose fittings. (See Fig 9.4) Power Unit Hose 17 STEP 10 (Routing the Equalizer Cables) Refer to illustrations on Page 10. WARNING! 1. Raise and lock each carriage approximately 28” above the ground. (See Fig. 10.1) WHEN THE CABLE ADJUSTING NUTS BOTTOM OUT ON THE THREADED END OF THE CABLE CONNECTOR AND THERE IS STILL SLACK IN THE CABLES, THE CABLES HAVE STRETCHED BEYOND THE SAFE USEFUL LENGTH AND NEED TO BE REPLACED WITH FACTORY APPROVED CABLE ASSEMBLIES. DO NOT PLACE WASHERS, SPACERS OR OTHER DEVICES TO “SHORTEN” THE EFFECTIVE CABLE LENGTH AS DAMAGE TO THE LIFT OR INJURY TO PERSONS MAY OCCUR. Fig 10.1 WARNING ! DANGER ! THE EQUALIZER CABLE SHEAVES WILL NEED TO BE REMOVED TO EASE THE ROUTING OF THE EQUALIZER CABLES. BE SURE TO REINSTALL ALL PINS, COVERS AND CLIPS OR SERIOUS DAMAGE OR INJURY MAY OCCUR. MAKE SURE THAT THE SAFETY LOCKS ON EACH POST ARE FULLY ENGAGED BEFORE ATTEMPTING TO ROUTE EQUALIZER CABLES AND/OR HOSES. CARRIAGES MUST BE EQUAL HEIGHT FROM THE FLOOR BEFORE PROCEEDING. XPR-9 Equalizer Cable Routing NOTE: WIDE configuration shown 18 2. With the carriages locked at 28” off the floor, uncoil the equalizer cables and route the threaded end of the equalizer cables towards the Base Plate sheave. Wrap the cable around the base plate sheave and reinstall sheave. (See Fig. 10.2) STEP 11 (Installing power unit hose assembly and Power Side safety cover) 1. After safeties have been adjusted and checked for proper operation, install and tighten Power Side safety cover and Off Side safety cover mounting screws. (See Fig. 11.1) Fig 10.2 To Top Plate sheave To cable holder To opposite Base Plate sheave Screw From opposite Base Plate sheave Fig. 11.1 NOTE: Post and carriage cut away for clarity 2. Install the floor plate between the columns as shown. For Wide configuration use the floor plate extension. (See Fig. 11.2) 3. Route the threaded cable end to the opposite post’s base plate sheave. Wrap the cable around the opposite post’s Base Plate sheave and reinstall sheave. (See Fig. 10.2) Fig. 11.2 4. Route threaded end upwards from Base Plate sheave and insert the threaded end of the cable through the cable holder on top of the carriage. Place M18 washer and M18 Nylock nut on threaded cable end. Tighten cable nuts until cable is taut. Check that both cables have equal tension. (See Fig 10.4) Floorplate Extension Fig. 10.4 Threaded Cable End Threaded cable end comes up from Bottom Plate sheave and into cable retainer on top of the carriage. Floorplate Nylock Nut STEP 12 (Installing the Lift Arms) Washer 1. Place the appropriate lift arm assembly in the lift heads. (See Fig. 12.3) NOTE: 2. Install the lift head pins into the lift head and through the holes in the arm assembly. (See Fig. 12.1) THERE WILL BE INITIAL STRETCHING OF THE CABLES AND/OR WITH INCREASED LOADS. ADJUST THE CABLES AS OUTLINED ABOVE A WEEK AFTER FIRST USE, THEN EVERY THREE TO SIX MONTHS THEREAFTER DEPENDING ON USAGE AND/OR TO COMPENSATE FOR STRETCH. 3. Install the snap ring into the groove in the lift head pin on under side of the lift head. (See Fig. 12.2) 19 Lift Head Pin Lift Head Pin Lift Head Pin Lift Head Pin Lift Head Snap Ring Snap Ring Fig. 12.1 Snap Ring Snap Ring Fig. 12.2 Fig. 12.3 Low Profile Triple Telescoping Arm Assembly Low Profile Medium Arm Assembly DANGER! THE ARM RESTRAINT GEARS MUST BE POSITIONED AND ADJUSTED PROPERLY. CONFIRMATION OF PROPER GEAR ENGAGEMENT MUST BE MADE PRIOR TO THE OPERATION OF THE LIFT. PERIODIC INSPECTION AND ADJUSTMENT IS REQUIRED. FAILURE TO INSPECT AND ADJUST THE ARM RESTRAINT GEARS ON ALL FOUR ARMS PROPERLY CAN RESULT IN DAMAGE TO THE VEHICLE OR INJURY AND/OR DEATH. 4. Each arm restraint gear can be oriented in a Left or Right configuration on the arms. Each arm and arm restraint gear must be positioned in the proper location in the lift head. (See Fig. 12.4 & 12.5) Fig. 12.4 NOTE: Arm gears rings have Left and Right orientations Fig. 12.5 NOTE: LEFT AND RIGHT ARE DETERMINED WHEN FACING THE INSIDE. OPEN SIDE OF THE LIFT POST. 5. Loosen the arm restraint gear bolts and adjust the arm restraint gears so that the teeth on the gear ring mesh smoothly with the teeth on the gears of the arm restraint pin. (See Fig. 12.6) LEFT 20 RIGHT CARRIAGE STOP BOLT INSTALLATION WARNING Arm Restraint Pin Assembly Arm Restraint Gear Ring WARNING! YOU MUST RE-INSTALL TOP CARRIAGE-STOP BOLT (SHOWN BELOW). TIGHTEN CARRIAGE-STOP BOLT TO 2-3 FT.-LBS. OF TORQUE UPON FINAL INSTALLATION INSPECTION. THESE INSTRUCTIONS MUST BE FOLLOWED TO ENSURE PROPER INSTALLATION AND OPERATION OF YOUR LIFT. FAILURE TO COMPLY WITH THESE INSTRUCTIONS CAN RESULT IN SERIOUS BODILY INJURY AND/ OR DEATH AND/OR VOID PRODUCT WARRANTY. MANUFACTURER WILL ASSUME NO LIABILITY FOR LOSS OR DAMAGE OF ANY KIND, EXPRESSED OR IMPLIED RESULTING FROM IMPROPER INSTALLATION OR USE OF THIS PRODUCT. Fig. 12.6 6. Tighten the gear ring bolts. 7. Verify the operation of the arm restraints by pulling up on the key ring of the arm restraint pin. Pivot the arms back and forth and test the operation of the arm restraint pin in various positions. (See Fig. 12.7) Fig. 12.7 8. Ensure that the arms do not move when a force of approximately 100 pounds or less is applied laterally to the fully extended arms. 9. Adjust the gear ring on the arm as necessary to ensure smooth operation and solid engagement of all four arm restraint pin assemblies with the arm restraint gear ring. DANGER! EACH ARM RESTRAINT ASSEMBLY MUST BE INSPECTED AND ADJUSTED AS NEEDED BEFORE EACH AND EVERY TIME THE LIFT IS OPERATED. DO NOT OPERATE THE LIFT IF ANY OF THE FOUR ARM RESTRAINT SYSTEMS ARE NOT FUNCTIONING PROPERLY. REPLACE ANY BROKEN COMPONENTS OR COMPONENTS WITH BROKEN TEETH ONLY WITH AUTHORIZED OR APPROVED REPLACEMENT PARTS. 21 22 TWO-POST LIFT POWER SIDE POST SAFETY LABEL PLACEMENT GUIDELINES WARNING! THESE ANSI/ALI ALCTV-2006 MANDATED SAFETY LABELS ARE PROVIDED FOR THIS PRODUCT FOR THE PROTECTION OF THE OPERATOR AND ANY PERSON(S) WORKING NEAR THE LIFT. THE SAFETY STICKERS MUST BE INSTALLED AS PER THE INSTRUCTIONS BELOW, PRIOR TO THE COMPLETION OF INSTALLATION. FAILURE TO PROPERLY INSTALL WARNING LABELS COULD FAIL TO WARN AND LEAD TO SERIOUS PERSONAL INJURY OR DEATH TO OPERATOR OR BYSTANDER OR DAMAGE TO PROPERTY. BE SURE EVERYONE WHO OPERATES THIS EQUIPMENT UNDERSTANDS ALL THE INFORMATION, CAUTION, WARNING, AND DANGER LABELS. KEEP ALL LABELS CLEAN SO THEY ARE LEGIBLE. THIS APPLIES TO ALL CAUTION, WARNING, AND DANGER LABELS. IT IS THE OWNER’S RESPONSIBILITY TO PROVIDE INFORMATION TO ALL OPERATORS FOR SAFE OPERATION OF THIS LIFT. REPLACE ANY DAMAGED OR WORN LABELS. ONCE ANY PART OF A LABEL BECOMES ILLEGIBLE, IT SHOULD BE REPLACED. THE PART NUMBERS FOR THE LABELS ARE LOCATED IN THE LOWER RIGHT CORNER OF THE LABEL. REPLACEMENT LABELS MAY BE ORDERED THROUGH YOUR DEALER OR THE ADDRESS BELOW. WHEN INSTALLING AND/OR REPLACING LABELS, BE SURE THE SURFACE IS CLEAN AND DRY, PEEL THE BACKING OFF THE LABEL, AND APPLY TO THE POST AS SHOWN BELOW. BE SURE TO WIPE WITH A CLEAN CLOTH TO RUB OUT ALL AIR BUBBLES. Maximum Lifting Capacity Label Blue Safety Label Yellow Safety Label Orange Safety Label Serial Number Plate Gold Safety Label Product Data Label Power Unit Mounting Bracket 23 Safe Operation and Maintenence Label DANGER! DO NOT PERFORM ANY MAINTENANCE OR INSTALLATION OF ANY COMPONENTS WITH OUT FIRST ENSURING THAT ELECTRICAL POWER HAS BEEN DISCONNECTED AT THE SOURCE OR PANEL AND CANNOT BE RE-ENERGIZED UNTIL ALL MAINTENANCE AND/OR INSTALLATION PROCEDURES ARE COMPLETED. IMPORTANT POWER-UNIT INSTALLATION NOTES DO NOT run power unit without oil. Damage to pump can occur. The power unit must be kept dry. Damage to power unit caused by water or other liquids such as detergents, acid etc., is not covered under warranty. Improper electrical connection can damage motor and will not be covered under warranty. Motor can not run on 50HZ without a physical change in the motor. Use a separate breaker for each power unit. Protect each circuit with time delay fuse or circuit breaker. For 208-230 volt, single phase, use a 25 amp fuse. For 208-230 volt, three phase, use a 20 amp fuse. For 380-440 volt, three phase, use a 15 amp fuse. Installation and adjustment. DO NOT attempt to raise vehicle until a thorough operation check has been completed. All wiring must be performed by a certified electrician only. SEE WIRING INSTRUCTIONS AFFIXED TO MOTOR FOR PROPER WIRING INSTRUCTIONS. 24 STEP 13 (Power Unit Connection) CAUTION! 1. Have a certified electrician run the power supply to motor. Refer to the data plate found on the motor for proper power supply and wire size. DURING THE START-UP PROCEDURE, OBSERVE ALL OPERATING COMPONENTS AND CHECK FOR PROPER INSTALLATION AND ADJUSTMENT. DO NOT ATTEMPT TO RAISE VEHICLE UNTIL A THOROUGH OPERATIONAL CHECK HAS BEEN COMPLETED. RISK OF EXPLOSION! STEP 14 (Lift Start Up / Final Adjustments) This equipment has internal arcing or parts that may spark and should not be exposed to flammable vapors. Motor should not be located in a recessed area or below floor level. NEVER expose motor to rain or other damp environments. DAMAGE TO MOTOR CAUSED BY WATER IS NOT COVERED UNDER WARRANTY. 1. Make sure the power unit reservoir is full with four (4) gallons of 10-WT hydraulic oil or Dexron-III automatic transmission fluid. 2. Apply light axle grease to the inside of the posts where the slide blocks glide, NOTE: CAUTION NEVER OPERATE THE MOTOR ON LINE VOLTAGE LESS THAN 208V. MOTOR DAMAGE MAY OCCUR WHICH IS NOT COVERED UNDER WARRANTY. HAVE A CERTIFIED ELECTRICIAN RUN APPROPRIATE POWER SUPPLY TO MOTOR. SIZE WIRE FOR 25 AMP CIRCUIT. SEE MOTOR OPERATING DATA TABLE. USE SEPARATE CIRCUIT FOR EACH POWER UNIT. PROTECT EACH CIRCUIT WITH TIME DELAY FUSE OR CIRCUIT BREAKER. FOR SINGLE PHASE 208-230V, USE 25 AMP FUSE. THREE PHASE 208-240V, USE 25 AMP FUSE. FOR THREE PHASE 400V AND ABOVE, USE 15 AMP FUSE. ALL WIRING MUST COMPLY WITH NECK AND ALL LOCAL ELECTRICAL CODES. 3. Test the power unit by pressing the push-button switch. If the motor sounds like it is operating properly, raise the lift and check all hose connections for leaks. If the motor gets hot or sounds peculiar, stop and check all electrical connections. 4. Before proceeding, double-check to make sure all cables are properly positioned within the grooves of ALL sheaves. Make sure all cable sheave retaining pins and/or clips are secure. 5. Check to make sure that all safety locks are cleared and free. Fig 13.1 6. Continue to press the button to raise lift until the cables get taut and the lift starts to move. 7. KEEP HANDS AND FEET CLEAR. Remove hands and feet from any moving parts. Keep feet clear of lift when lowering. Avoid pinch points. 8. Check all MAIN SAFETY LOCKS to make sure they move freely and spring back to the lock position when released. Lubricate all SAFETY PIVOT points with light spray-oil. 9. Cycle the lift up and down a few times to ensure that the safety locks are engaging uniformly and that the safety release mechanisms are functioning. Re-adjust if necessary. 25 POST-INSTALLATION CHECK-OFF OPTIONAL FOOT GUARD INSTALLATION Posts properly shimmed and stable Anchor bolts tightened Pivot / sheave pins properly attached Carriage stop bolts torqued to 2-3 ft-lb Electric power supply confirmed Cables adjusted properly Safety locks functioning properly Check for hydraulic leaks Oil level Lubrication of critical components Check for overhead obstructions Lift arms level All screws, bolts, and pins secured Surrounding area clean Operation, maintenance and safety manuals on site. 1. Install the Foot Guards to the outside of the 4 Lift Arm Assemblies. Tighten the Hex Head Bolts. (See Figures Below) Hex Head Bolt Footguards Footguards STEP 15 (Lubrication) 1. After installation and start-up has been completed, lubricate lift components as described below. (See Fig. 15.1) Footguards OPTIONAL CRADLE AND SCREW PAD ADAPTERS SCREW PAD ADAPTER FRAME CRADLE PAD ADAPTER Optional Equipment available through your Authorized BendPak Dealer. Fig. 15.1 26 OPTIONAL EQUIPMENT INSTALLATION 27 • 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-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. STEP 16 (Operation Instructions) OWNER/EMPLOYER RESPONSIBILITIES The Owner/Employer: • 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-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 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. • Shall not modify the lift in any manner without the prior written consent of the manufacturer. • 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. LIFT OPERATION SAFETY • DAILY inspect your lift. Never operate if it malfunctions or if it has broken or damaged parts. Use only qualified lift service personnel and genuine BendPak parts to make repairs. • ALWAYS keep area around lift free of tools, debris, grease and oil. • NEVER overload lift. Capacity of lift is shown on nameplate affixed to the lift. • THOROUGHLY train all employees in use and care of lift, using manufacturer’s instructions and “Lifting It Right” and “Safety Tips” supplied with the lift. • DO NOT stand in front of the vehicle while it is being positioned in lift bay. • NEVER allow unauthorized or untrained persons to position vehicle or operate lift. • DO NOT hit or run over lift arms or adapters. This could damage lift or vehicle. Before driving vehicle into lift bay, position arms and adapters to provide unobstructed entrance onto lift. • PROHIBIT unauthorized persons from being in shop area while lift is in use. • DO NOT permit anyone on lift or inside vehicle when it is either being raised or lowered. 28 LIFT OPERATION SAFETY • ALWAYS load vehicle on lift carefully. Position the lift adapters to contact at the vehicle manufacturer’s recommended lift points. Raise lift until adapters contact vehicle. Check adapters for secure contact with vehicle. Raise lift to desired working height. (See Fig.19.1) WARNING! WHEN LOWERING THE LIFT PAY CAREFUL ATTENTION THAT ALL PERSONNEL AND OBJECTS ARE KEPT CLEAR. ALWAYS KEEP A VISUAL LINE OF SITE ON THE LIFT AT ALL TIMES. ALWAYS MAKE SURE THAT ALL LOCKS ARE DISENGAGED. IF ONE OF THE LOCKS INADVERTENTLY LOCKS ON DESCENT THE LIFT AND/OR VEHICLE MAY DISRUPT CAUSING PERSONAL INJURY OR DEATH. Never exceed 9” of lift adapter height by any combination of adapters. 9" MAXIMUM Failure to comply can result in serious damage, personal injury, or death. • ALWAYS REMOVE tool trays, stands, etc. before lowering lift. • ALWAYS RELEASE safety locks before attempting to lower lift. Fig. 17.1 • DO NOT block open or override self-closing lift controls; they are designed to return to the “Off” or Neutral position when released. • ALWAYS POSITION the lift arms and adapters to provide an unobstructed exit before removing vehicle from lift area. • DO NOT remove or disable arm restraints. TO RAISE THE LIFT • ALWAYS remain clear of lift when raising or lowering vehicles. • ALWAYS use safety stands when removing or installing heavy components. WARNING! TO AVOID PERSONAL INJURY AND/OR PROPERTY DAMAGE, PERMIT ONLY TRAINED PERSONNEL TO OPERATE LIFT. AFTER REVIEWING THESE INSTRUCTIONS, PRACTICE USING LIFT CONTROLS BY RUNNING THE LIFT THROUGH A FEW UNLOADED CYCLES BEFORE LOADING VEHICLE ON LIFT. ALWAYS LIFT THE VEHICLE USING ALL FOUR ADAPTERS. NEVER RAISE JUST ONE END, ONE CORNER, OR ONE SIDE OF VEHICLE. • DO NOT go under raised vehicle if safety locks are not engaged. DANGER! VISUALLY CONFIRM THAT ALL PRIMARY SAFETY LOCKS ARE ENGAGED BEFORE ENTERING WORK AREA.SUSPENSION COMPONENTS USED ON THIS LIFT ARE INTENDED TO RAISE AND LOWER LIFT ONLY AND ARE NOT MEANT TO BE LOAD HOLDING DEVICES. REMAIN CLEAR OF ELEVATED LIFT UNLESS VISUAL CONFIRMATION IS MADE THAT ALL PRIMARY SAFETY LOCKS ARE FULLY ENGAGED AND THE LIFT IS LOWERED ONTO THE SAFETY LOCKS, REFER TO INSTALLATION/ OPERATION MANUAL FOR PROPER SAFETY LOCK PROCEDURES AND/OR FURTHER INSTRUCTION. 1. Before Loading: Lift must be fully lowered and service bay clear of all personnel before the vehicle is brought on lift with the swing arms set to the full drive-thru position. 2. Loading: Swing arms under vehicle and position adapters at vehicle manufacturer’s recommended lift points. Use height extenders or optional frame-cradle adapters when necessary to ensure good contact. (See Fig 17.2-17.3) 3. Some vehicles may have the manufacturer's Service Garage Lift Point locations identified by triangle shape marks on the undercarriage (reference ANSI/SAE J21841992). Also, there may be a label located on the right front door jamb area showing specific vehicle lift points. • NEVER LEAVE LIFT IN ELEVATED CONDITION unless all Safety Locks are engaged. • AVOID excessive rocking of vehicle while on lift. • ALWAYS CLEAR AREA if vehicle is in danger of falling. 29 LIFT OPERATION SAFETY (CONT’D) TYPICAL LIFTING POINTS Fig. 17.2 9" MAXIMUM Never exceed 9” of lift adapter height by any combination of adapters. Failure to comply can result in serious damage, personal injury, or death. Fig. 17.3 WARNING! MANY SPECIALTY OR MODIFIED VEHICLES CANNOT BE RAISED ON A TWO-POST FRAME ENGAGING LIFT. CONTACT VEHICLE MANUFACTURER FOR RAISING OR JACKING DETAILS. 4. Position vehicle for proper weight distribution arms under vehicle to allow adapters to contact at the manufacturer’s recommended pick up points. NOTE: 5. If the specific vehicle lift points are not identified, or if the vehicle has additional or uniquely positioned payload, have a qualified person calculate the vehicle center of gravity or have the vehicle center of gravity determined at a vehicle scale. Load the vehicle with the enter of gravity midway between adapters. ALLOW (2) SECONDS BETWEEN MOTOR STARTS. FAILURE TO COMPLY MAY CAUSE MOTOR BURNOUT. 6. Push the RAISE button or rotate the control switch on the power unit. 7. Stop before making contact with vehicle. Check arm restraint pins for engagement. If required, slightly move arm to allow restraint gear and pawl to mesh. DO NOT hammer arm restraint pin down as this will damage the restraint gear teeth. 8. Raise vehicle until tires clear the floor. 9. Stop and check adapters for secure contact at vehicle manufacturer’s recommended lift points. 30 LIFT OPERATION SAFETY (CONT’D) TO LOWER THE LIFT 10. Continue to raise to desired height only if vehicle is secure on lift. 11. DO NOT go near or under a raised vehicle if all four adapters are not in secure contact with vehicle at vehicle manufacturer’s recommended lift points. WARNING! WHEN LOWERING THE LIFT PAY CAREFUL ATTENTION THAT ALL PERSONNEL AND OBJECTS ARE KEPT CLEAR. ALWAYS KEEP A VISUAL LINE OF SITE ON THE LIFT AT ALL TIMES. ALWAYS MAKE SURE THAT ALL LOCKS ARE DISENGAGED. IF ONE OF THE LOCKS INADVERTENTLY LOCKS ON DESCENT THE LIFT AND/OR VEHICLE MAY DISRUPT CAUSING PERSONAL INJURY OR DEATH. 12. Repeat entire loading and raising procedures if required. 13. Lower lift onto safety locks. 1. Remove all tools or other objects from the lift area. DANGER! 2. Raise lift off safety locks. Make sure you raise the lift by at least two inches to allow adequate clearance for the locks to clear. VISUALLY CONFIRM THAT ALL PRIMARY SAFETY LOCKS ARE ENGAGED BEFORE ENTERING WORK AREA.SUSPENSION COMPONENTS USED ON THIS LIFT ARE INTENDED TO RAISE AND LOWER LIFT ONLY AND ARE NOT MEANT TO BE LOAD HOLDING DEVICES. REMAIN CLEAR OF ELEVATED LIFT UNLESS VISUAL CONFIRMATION IS MADE THAT ALL PRIMARY SAFETY LOCKS ARE FULLY ENGAGED AND THE LIFT IS LOWERED ONTO THE SAFETY LOCKS, REFER TO INSTALLATION /OPERATION MANUAL FOR PROPER SAFETY 3. Push safety lock release handle fully and hold. 4. Push LOWERING valve handle to lower. Note: Both SAFETY LOCK release and LOWERING valve handles must be held down simultaneously to lower lift. Do not override self-closing lift controls. 5. Remain clear of lift when lowering vehicle. Observe pinch point warning decals. • DO NOT enter work area or go under vehicle if safety locks are not engaged. • 6. Remove adapters from under vehicle and swing arms to full drive-thru position before moving vehicle. CLEAR AREA if vehicle is in danger of falling. 7. If lift is not operating properly, DO NOT use until adjustment or repairs are made by qualified lift service personnel. • DO NOT position yourself between a wall and the lift. If the vehicle falls in that direction, you may be severely injured or killed. • Before attempting to lift pickup trucks or other truck frame vehicles, be sure that: MAINTENANCE INSTRUCTIONS Vehicle frame is strong enough to support its weight and has not been weakened by modification or corrosion. Vehicle individual axle weight does not exceed one-half lift capacity. Adapters are in secure contact with frame at vehicle manufacturers recommended lift points. Vehicle is stable on lift and the center of gravity is NOT off balance. The overhead switch bar will contact the highest point on the vehicle. CAUTION! IF YOU ARE NOT COMPLETELY FAMILIAR WITH AUTOMOTIVE LIFT MAINTENANCE PROCEDURES; STOP AND CONTACT THE MANUFACTURER FOR INSTRUCTIONS. TO AVOID PERSONAL INJURY, PERMIT ONLY QUALIFIED PERSONNEL TO PERFORM MAINTENANCE ON THIS EQUIPMENT. WHILE USING LIFT • Always keep bolts tight. Check periodically. • Avoid excessive rocking of vehicle while on lift. • Always keep lift components clean. • Always use safety stands as needed or when removing or installing heavy components. • Always if oil leakage is observed, call local service representative. 31 LIFT OPERATION SAFETY (CONT’D) • Always call local service representative if electrical problems develop. • Weekly: Check all cable connections, bolts and pins to insure proper mounting. Always replace ALL FAULTY PARTS before lift is put back into operation. • Monthly: Check equalizer cable tension. Adjust per lift installation instructions. Daily: Make a visual inspection of ALL MOVING PARTS and check for excessive signs of wear. • Monthly: Lubricate locking latch shafts. Push latch handle several times for oil to penetrate pivot points. Daily: Check safety locks to ensure they are in good operating condition. • Every 3 Months: Check anchor bolt torque. Anchors should be torqued to 90 ft/lbs. • Daily: Check cables and sheaves for wear. Replace worn parts as required with genuine BendPak parts. • • Daily: Inspect adapters for damage or excessive wear. Replace as required with genuine BendPak parts. Semi-Annually: Check fluid level of lift power unit and refill if required per lift installation instructions. Replace all caution, warning or safety related decals on the lift if unable to read or missing. Reorder labels from BendPak. • Weekly: Lubricate all sheaves and rollers with general purpose oil. • • • • • Refer to ANSI/ALI ALOIM booklet for periodic inspection checklist and maintenance log sheet. Make sure vehicle is neither front nor rear heavy and select the proper configuration for the vehicle to be lifted (symmetric/asymmetric) as shown below. Center of balance should be midway between adapters. 32 TO RAISE LIFT Read operating and safety manuals before using lift. Always lift a vehicle according to the manufacturers recommended lifting points. Position vehicle between posts. Adjust swing arms so that the vehicle is positioned with the center of gravity midway between pads. Use truck adapters as needed. Never exceed 9” of pad height. NEVER use lift pad assemblies without rubber slip over pads in place. Raise the vehicle by depressing button until the vehicle just lifts off the ground. Re-check to make sure the vehicle is secure and all locking pins are lock in place. Raise vehicle to desired height. Lower vehicle onto nearest safety, Always ensure safeties are engaged before any attempt is made to work on or near vehicle. First raise the lift to disengage the safeties. Release safeties by pushing on the safety handle. Be sure tool trays, stands or personnel are cleared from under the vehicle. Lower vehicle by activating lowering handle on power unit. Before removing vehicle from lift; position lift arms and supports to provide an unobstructed exit. NEVER, drive over lift arms. Check all arm adjusting locks for proper operation. Check all cables connections, bolts and pins to insure proper mounting and torque. Visually inspect safeties for proper operation. Lubricate posts with grease. Inspect all anchors bolts and retighten if necessary. Check all posts for squareness and plumb. Inspect all pivot arms pins making sure they are properly secure. Check equalizer cable tension, and adjust if necessary. If lift is equipped with over head microswitch, check for proper operation. TO LOWER THE LIFT REQUIRED MONTHLY MAINTENANCE 1. 2. 3. 4. 5. 6. WARNING!: If cement anchor bolts are loose or any component of the lift is found to be defective, DO NOT USE THE LIFT!! Never operate the lift with any person or equipment below the vehicle. Never exceed the rated lift capacity. Always ensure the safeties are engaged before any attempt is made to work on or near the vehicle. Never leave lift in elevated position unless the safeties are engaged. Do not permit electric motor to get wet! Motor damage caused by dampness is not covered under warranty. NEVER LIFT ANY VEHICLE IN ANY MANNER WITH LESS THAN ALL FOUR (4) ARMS. RATED CAPACITY OF EACH LIFT ARM IS NO GREATER THAN ONE FOURTH (1/4) OF THE OVERALL LIFT CAPACITY. 33 WIRE ROPE INSPECTION AND MAINTENANCE Lifting cables should be replaced every three - five years or when visible signs of damage are apparent. DO NOT USE LIFT WITH DEFECTIVE / WORN CABLES. Lifting cables should be maintained in a well-lubricated condition at all times. Wire rope is only fully protected when each wire strand is lubricated both internal and external. Excessive wear will shorten the life of the wire rope. The factory suggested wire rope lubricant that penetrates to the core of the rope and provides long-term lubrication between each individual strand is 90-WT gear oil or ALMASOL® Wire Rope Lubricant. In order to make sure that the inner layers of the rope remain well lubricated, lubrication should be carried out at intervals not exceeding three months during operation. All sheaves and guide rollers in contact with the moving rope should be given regular visual checks for surface wear and lubricated to make sure that they run freely. This operation should be carried out at appropriate intervals generally not exceeding three months during operation. For all sheave axles, the factory recommends standard wheel bearing grease. For all sheaves and/or guide rollers, the factory recommends 90-WT gear oil or similar heavy lubricant applied by any method including pump / spray dispensing, brush, hand and/or swabbing. . HOW OFTEN TO INSPECT Lifting cables should be visually inspected at least once each day when in use, as suggested by American Petroleum Institute (API) RP54 guidelines. Any lifting cables that have met the criteria for removal must be immediately replaced. WHEN TO REPLACE LIFTING CABLES DUE TO BROKEN WIRES Lifting cables should be removed from service when you see six randomly distributed broken wires within any one lay length, or three broken wires in one strand within one lay length. OTHER REASONS TO REPLACE LIFTING CABLES Corrosion that pits the wires and/or connectors. Evidence of kinking, crushing, cutting, bird-caging or a popped core. Wear that exceeds 10% of a wire’s original diameter. Evidence of heat damage. HOW TO FIND BROKEN WIRES The first step is to relax your rope to a stationary position and move the pick-up points off the sheaves. Clean the surface of the rope with a cloth — a wire brush, if necessary — so you can see any breaks. Flex the rope to expose any broken wires hidden in the valleys between the strands. Visually check for any broken wires. One way to check for crown breaks is to run a cloth along the rope to check for possible snags. With an awl, probe between wires and strands and lift any wires that appear loose. Evidence of internal broken wires may require a more extensive rope examination. 34 35 36 Safe Lift Operation Automotive and truck lifts are critical to the operation and profitability of your business. The safe use of this and other lifts in your shop is critical in preventing employee injuries and damage to customer’s vehicles. By operating lifts safely you can insure that your shop is profitable, productive and safe. Safe operation of automotive lifts requires that only trained employees should be allowed to use the lift. TRAINING SHOULD INCLUDE, BUT NOT LIMITED TO: Proper positioning of the vehicle on the lift arms. (See manufacturers minimize wheel base loading requirements.) Use of the operating controls. Understanding the lift capacity. Proper use of jack stands or other load supporting devices. Proper use, understanding and visual identification of safety lock devices and their operation. Reviewing the safety rules. Proper housekeeping procedures (lift area should be free of grease, oil, tools, equipment, trash, and other debris). A daily inspection of the lift should be completed prior to its use. Safety devices, operating controls, lift arms and other critical parts should be inspected prior to using the lift. All maintenance and repairs of the lift should be completed by following the manufacturer’s requirements. Lift repair parts should meet or exceed OEM specifications. Repairs should only be completed by a qualified lift technician. The vehicle manufacturer’s recommendations should be used for spotting and lifting the vehicle. LIFT OPERATION / SAFETY It is important that you know the load limit. Be careful that you do not overload the lift . If you are unsure what the load limit is, check the data plate found on one of the lift columns or contact the manufacturer. The center of gravity should be followed closely to what the manufacturer recommends. Always make sure you have proper overhead clearance. Additionally, check that attachments, ( vehicle signs, campers, antennas, etc.) are not in the way. Be sure that prior to the vehicle being raised, the doors, trunk, and hood are closed securely. Prior to being raised, make sure there is no one standing closer than six feet from the lift. After positioning the vehicle on the lift runways, set the emergency brake, make sure the ignition is off, the doors are closed, overhead obstructions are cleared, and the transmission is in neutral. Double check that the automatic chock devices are in position and then when the lift is raised, observe the chocks. Put pads or adapters in the right position under the contact points that have been recommended. The lift should be raised just until the vehicle’s wheels are about one foot off the ground. If contact with the vehicle is uneven or it appears that the vehicle is not sitting secure, carefully lower the lift and readjust. Always consider potential problems that might cause a vehicle to slip, i.e., heavy cargo, undercoating, etc. Pay attention when walking under a vehicle that is up on the hydraulic lift. 37 DO NOT leave the controls while the lift is still in motion. DO NOT stand directly in front of the vehicle or in the bay when vehicle is being loaded or driven into position. DO NOT go near vehicle or attempt to work on the vehicle when being raised or lowered. REMAIN CLEAR of lift when raising or lowering vehicle. DO NOT rock the vehicle while on the lift or remove any heavy component from vehicle that may cause excessive weight shift. DO NOT lower the vehicle until people, materials, and tools are clear ALWAYS ENSURE that the safeties are engaged and lowered on to the safeties before any attempt is made to work on or near vehicle. Some vehicle maintenance and repair activities may cause the vehicle to shift. Follow the manufacturer’s guidelines when performing these operations. The use of jack stands or alternate lift points may be required when completing some repairs. READ AND UNDERSTAND all safety warning procedures before operating lift. KEEP HANDS AND FEET CLEAR. Remove hands and feet from any moving parts. Keep feet clear of lift when lowering. Avoid pinch points. ONLY TRAINED OPERATORS should operate this lift. All non-trained personnel should be kept away from work area. Never let non-trained personnel come in contact with, or operate lift. USE LIFT CORRECTLY. Use lift in the proper manner. Never use lifting adapters other than what is approved by the manufacturer. DO NOT override self-closing lift controls. CLEAR AREA if vehicle is on danger of falling. STAY ALERT. Watch what you are doing. Use common sense. Be aware. CHECK FOR DAMAGED PARTS. Check for alignment of moving parts, breakage of parts or any condition that may affect its operation. Do not use lift if any component is broken or damaged. NEVER remove safety related components from the lift. Do not use lift if safety related components are damaged or missing. When the lift is being lowered, make sure everyone is standing at least six feet away. Be sure there are no jacks, tools, equipment, left under the lift before lowering. Always lower the vehicle down slowly and smoothly. 38 LIFT WILL NOT RAISE POSSIBLE CAUSE 1. Air in oil, (1,2,8,13) 2. Cylinder binding, (9) 3. Cylinder leaks internally, (9) 4. Motor run backward under pressure, (11) 5. Lowering valve leaks, (3,4,6,10,11) 6. Motor runs backwards, (7,14,11) 7. Pump damaged, (10,11) 8. Pump won’t prime, (1,8,13,14,3,12,10,11) 9. Relief valve leaks, (10,11) 10. Voltage to motor incorrect, (7,14,11) REMEDY INSTRUCTION 1. Check for proper oil level. . . . . . . . . . . . . . . . . . . . . . . . . . The oil level should be up to the bleed screw in the reservoir with the lift all the way down. 2. Bleed cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Installation Manual 3. Flush release valve to get rid of. . . . . . . . . . . . . . . . . . . . . Hold release handle down and start unit allowing possible contamination it to run for 15 seconds. 4. Dirty oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . Replace oil with clean Dexron ATF. 5. Tighten all fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten fasteners to recommended torques. 6. Check for free movement of release. . . . . . . . . . . . . . . . . . . If handle does not move freely, replace bracket or handle assembly. 7. Check if motor is wired correctly. . . . . . . . . . . . . . . . . . . . . . .Compare wiring of motor to electrical diagram on drawing. 8. Oil seal damaged or cocked . . . . . . . . . . . . . . . . . . . . . . . . Replace oil seal around pump shaft. 9. See Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact BendPak Customer Support. 10. Replace with new part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace with new part. 11. Return unit for repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return unit for repair. 12. Check pump-mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . Bolts should be 15 to 18 ft. lbs. 13. Inlet screen clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean inlet screen or replace. 14. Check wall outlet voltages and wiring . . . . . . . . . . . . . . . . . Make sure unit and wall outlet are wired properly. 39 MOTOR WILL NOT RUN POSSIBLE CAUSE 1. Fuse blown, (5,2,1,3,4) 2. Limit switch burned out, (1,2,3,4) 3. Microswitch burned out, (1,2,3,4) 4. Motor burned out, (1,2,3,4,6) 5. Voltage to motor incorrect, (2,1,8) REMEDY INSTRUCTION 1. Check for correct voltage . . . . . . . . . . . . . . . . . . . . . . . . . . .Compare supply voltage with voltage on motor name tag. Check that the wire is sized correctly. N.E.C. table 310-12 requires AWG 10 for 25 Amps. 2. Check motor is wired correctly . . . . . . . . . . . . . . . . . . . . . . .Compare wiring of motor to electrical diagram on drawing. 3. Don’t use extension cords . . . . . . . . . . . . . . . . . . . . . . . . . . According to N.E.C. : “ The size of the conductors… should be such that the voltage drop would not exceed 3% to the farthest outlet for power…” Do not run motor at 115 VAC – damage to the motor will occur. 4. Replace with new part . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace with new part. 5. Reset circuit breaker/fuse . . . . . . . . . . . . . . . . . . . . . . . . . .Reset circuit breaker/fuse. 6. Return unit for repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return unit for repair. 7. See Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Installation Manual. 8. Check wall outlet voltage and wiring . . . . . . . . . . . . . . . . . . Make sure unit and wall outlet is wired properly. Motor must run at 208/230 VAC. LIFT LOWERS SLOWLY OR NOT AT ALL POSSIBLE CAUSE 1. Cylinders binding, (1) 2. Release valve clogged, (5,4,2,3) 3. Pressure fitting too long, (6) REMEDY INSTRUCTION 1. See Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact BendPak Customer Support. 2. Replace with new part . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace with new part. 3. Return for repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return for repair. 4. Check oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use clean 10-WT hydraulic oil or Dexron-III automatic transmission fluid only. If ATF is contaminated, replace with clean ATF and clean entire system. 5. Clean release valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wash release valve in solvent and blow out with air. 6. Replace fitting with short thread lead . . . . . . . . . . . . . . . . . . . Replace fitting with short thread lead. 40 WILL NOT RAISE LOADED LIFT 6. 7. 8. 9. 10. POSSIBLE CAUSE 1. Air in oil, (1,2,3,4) 2. Cylinder binding, (5) 3. Cylinder leaks internally, (5) 4. Lift overloaded, (6,5) 5. Lowering valve leaks, (7,8,1,5,9) Motor runs backwards, (10,12,9) Pump damaged, (5,9) Pump won’t prime, (1,2,3,4,5,11,9) Relief valve leaks, (8,5,9) Voltage to motor incorrect, (10,12,5) REMEDY INSTRUCTION 1. Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The oil level should be up to the bleed screw in the reservoir with the lift all the way down. 2. Check/Tighten inlet tubes . . . . . . . . . . . . . . . . . . . . . . . . . . Replace inlet hose assembly. 3. Oil seal damaged or cocked . . . . . . . . . . . . . . . . . . . . . . . . Replace oil seal and install. 4. Bleed cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Installation Manual. 5. See Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact BendPak Customer Support. 6. Check vehicle weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compare weight of vehicle to weight limit of the lift. 7. Flush release valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hold release handle down and start unit allowing it to run for 15 seconds. 8. Replace with new part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace with new part. 9. Return unit for repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return unit for repair. 10. Check motor is wired correctly . . . . . . . . . . . . . . . . . . . . . . . Compare wiring of motor to electrical diagram on power unit drawing. 11. Inlet screen clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean inlet screen or replace. 12. Check wall outlet voltage and wiring . . . . . . . . . . . . . . . . . . Make sure unit and wall outlet is wired properly. LIFT WILL NOT STAY UP 3. Cylinders leak internally, (7) 4. Lowering valve leaks, (4,5,1,7,6) 5. Leaking fittings, (8) POSSIBLE CAUSE 1. Air in oil, (1,2,3) 2. Check valve leaks, (6) REMEDY INSTRUCTION 1. Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The oil level should be up to the bleed screw in the reservoir with the lift all the way down. 2. Oil seal damaged and cocked . . . . . . . . . . . . . . . . . . . . . . . . Replace oil seal around pump shaft. 3. Bleed cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to Installation Manual. 4. Flush release valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hold release handle down and start unit allowing it to run for 15 seconds. 5. Replace with new valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace with new valve. 6. Return unit for repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return unit for repair. 7. See Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact BendPak Customer Support. 8. Check complete hydraulic system for leaks. . . . . . . . . . . . . . Tighten all hydraulics fittings and inspects all hoses. 41 MAINTENANCE RECORDS ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 42 MAINTENANCE RECORDS ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ 43 44 45 46 47 For Parts Or Service Contact: BendPak Inc. / Ranger Products 1645 Lemonwood Dr. Santa Paula, CA. 93060 Tel: 1-805-933-9970 Toll Free: 1-800-253-2363 Fax: 1-805-933-9160 www.bendpak.com www.rangerproducts.com p/n 5900048 48
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