BendPak PCL-16HD portable column lifting system Installation and operation manual

PLEASE READ THE ENTIRE CONTENTS OF THIS MANUAL PRIOR TO
INSTALLATION AND OPERATION. BY PROCEEDING 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.
REV A 09-18-09
INSTALLATION AND OPERATION MANUAL
Model PCL-16HD
Portable Column
Lifting System
Keep this operation manual near the
machine at all times. Make sure that
ALL USERS read this manual.
SHIPPING DAMAGE CLAIMS
When this equipment is shipped, title passes to the
purchaser upon receipt from the carrier.
Consequently, claims for the material damaged in shipment
must be made by the purchaser against the transportation
company at the time shipment is received.
BE SAFE
Your new lift was designed and built with safety in mind.
However, your overall safety can be increased by 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.
1
1645 Lemonwood Dr.
Santa Paula, CA. 93060, USA
Toll Free 1-800-253-2363
Tel: 1-805-933-9970
Fax: 1-805-933-9160
www.bendpak.com
PCL-16HD
Portable Column Lift
This instruction manual has been prepared especially for you.
Your new lift is the product of over 35 years of continuous research, testing and development;
it is the most technically advanced lift on the market today.
READ THIS ENTIRE MANUAL BEFORE INSTALLATION & OPERATION BEGINS.
RECORD HERE THE LIFT AND
POWER UNIT INFORMATION WHICH IS LOCATED
ON THE SERIAL NUMBER
DATA PLATES ON THE LIFT AND
ON THE POWER UNIT
Power Unit Model #
Power Unit Date Of Mfg.
Power Unit Serial #
_____________
_____________
_____________
This information is required when
calling for parts or warranty issues.
PRODUCT WARRANTY
BendPak PCL Lifts are covered under warranty for one year on equipment structure, to be free of defects in material
and workmanship. Power units, hydraulic cylinders, and all other assembly components such as turnplates, slip plates,
cables, chains, valves, switches etc. are covered under warranty for one year against defects in material or workmanship under normal use. BendPak Inc. shall repair or replace at their option for 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, 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
OWNER’S RESPONSIBILITY
IMPORTANT NOTICE
To maintain the lift and user safety, the responsibility of
the owner is to read and follow these instructions:
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 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.
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
Receiving:
The shipment should be thoroughly inspected as soon as it
is received. The signed bill of lading is acknowledgement by
the carrier of receipt in good condition of shipment covered
by your invoice. If any of the goods called for on this bill of
lading are shorted or damaged, do not accept them until the
carrier makes a notation on the freight bill of the shorted or
damaged goods. Do this for your own protection.
DANGER !
Watch for this symbol: 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 !
Watch for this symbol: It Means: Hazards or unsafe
practices which could result in severe personal
injury or death.
IT IS DIFFICULT TO COLLECT FOR LOSS OR DAMAGE
AFTER YOU HAVE GIVEN THE CARRIER A CLEAR
RECEIPT. File your claim with the carrier promptly. Support
your claim with copies of the bill of lading, freight bill,
invoice, and photographs, if available. Our 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.
CAUTION !
Watch for this symbol: It Means: Hazards or unsafe
practices which may result in minor personal injury,
product or property damage.
3
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 entire manual prior to installation.
Do not operate this machine until you read and
understand all the dangers, warnings and cautions
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. / Ranger Products
1645 Lemonwood Dr.
Santa Paula, CA. 93060
I understand that the 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 ALCTV1998, 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).
1-805-933-9970
www.bendpak.com
INSTALLER / OPERATOR
PROTECTIVE EQUIPMENT
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. Tight fitting leather gloves are recommended to protect technician hands
when handling parts. Sturdy leather work shoes with steel
toes and oil resistant soles should be used by all service
personnel to help prevent injury during typical installation
and operation activities.
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.
I will assume full responsibility for the concrete floor
and condition thereof, now or later, where the above
equipment model(s) are 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.
I understand that Bendpak lifts are designed to be
installed in indooor 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.
THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS, WHICH IF NOT FOLLOWED
COULD ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY OF YOURSELF AND OTHERS
AND CAN CAUSE PERSONAL INJURY OR DEATH. READ AND FOLLOW ALL INSTRUCTIONS IN
THIS MANUAL BEFORE ATTEMPTING TO OPERATE THIS MACHINE.
4
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. Wiring should be performed by a
certified electrician only.
IMPORTANT SAFETY INSTRUCTIONS
Read these safety instructions entirely!
IMPORTANT NOTICE!
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 can fall and cause injury.
1. READ AND UNDERSTAND all safety warning procedures before operating lift.
12. GUARD AGAINST ELECTRIC SHOCK. This lift must
be grounded while in use to protect the
operator from electric shock. Never connect the green power cord wire to a live
terminal. This is for ground only.
2. KEEP HANDS AND FEET CLEAR. Remove hands
and feet from any moving parts. Keep feet clear of lift
when
lowering. Avoid pinch points.
3. KEEP WORK AREA CLEAN. Cluttered work areas
invite injuries.
13. DANGER! The power unit used on this lift contains
high voltage. Disconnect power at the
receptacle before performing any electrical repairs. Secure plug so that it cannot
be accidentally plugged in during service.
4. Consider work area environment. Do not expose
equipment to rain. DO NOT use in damp or wet locations.
Keep area well lighted.
5. 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.
14. WARNING! RISK OF EXPLOSION. This
ment 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.
6. USE LIFT CORRECTLY. Use lift in the proper manner. Never use lifting adapters other than what is approved
by the manufacturer.
equip-
15. 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.
7. DO NOT override self-closing lift controls.
8. REMAIN CLEAR of lift when raising or lowering
vehicle.
16. STAY ALERT. Watch what you are doing. Use common sense. Beaware.
9. CLEAR AREA if vehicle is in danger of falling.
0. ALWAYS INSURE that the safeties are engaged
before any attempt is made to work on or near vehicle.
17. 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.
11. DRESS PROPERLY. Non-skid steel-toe footwear is
recommended when operating lift.
5
18. NEVER remove safety related components from the
lift. Do not use lift if safety related components are
damaged or missing.
IMPORTANT INSTRUCTIONS
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.
( Selecting Site )
Before installing your new lift, check the following.
1. LIFT LOCATION: Always use architects plans when
available. Check layout dimension against floor plan
requirements making sure that adequate space if
available.
DO NOT install or use this lift on any asphalt surface
or any surface other than concrete.
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
LIFT MODEL
4.OPERATING TEMPERATURE. Operate lift only
between temperatures of 41° -104° F.
PCL-16HD
CONCRETE REQUIREMENTS
4” Min Thickness
5. Lift is designed for INDOOR INSTALLATION ONLY.
(Floor Requirements)
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.
All models MUST be installed on 3000 PSI concrete only
conformIng to the minimum requirements shown above.
New concrete must be adequately cured by at least
28 days minimum.
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.
6
ϔǃAttention
1. Connect the circuitry according to the electric principle drawings, and be sure all
connections are all right before powering on. There must be a protective breaker against
creepage at the power-input connection, the specifications are required as bellows: if the input
power is 220v/1ph, the rated current is 100A; if the input power is 220v/3ph, the rated current
is 40A; if the input power is 380v/3ph, the rated current is 32A. (Users provide for
themselves.)
2. Use the machine within the rated load range, the maximum rated load of each
column is 7.5 tons, the maximum of upholding point is not more 1.5 times than the
minimum one.
3. You should ensure no parts on the column out of the track surface, keep the track
surface smooth from damaging the surface of the slide blocks.
4. Turn off the power supply immediately, if the “FAULT” light is on. And check if the
safety relay is disengaged, if so, please press the button “RESET”. Get through the power
after 10 seconds, turn the selection knob to “SINGLE”, and adjust each carriage to
make the vehicle horizontal by raising or lowering it, then turning the selection
knob to “PAIR” & “FOUR”, Get through the power after 10 seconds.
5. The load type of the electric motor is S3ˈduty percent is 10%.
6. There should be dual safety with the safety hooks and hydraulic systems when the
technicians are working under the elevated vehicle. It is necessary to inspect all
the connection parts of the lift regularly, and make sure every part is in good
condition.
7. Please select high quality hydraulic oil as diagram 1, fill at least 12 litres of the
hydraulic oil into the oil tank, but don’t fill too much, in case the oil might overflow after
being pressed. (see Fig.1) After the first 100 hours’ work, it is necessary to change the
hydraulic oil and rechange it every 3000 working hours correspondingly.
Item
Name
N32#Lowsolidifying
point hydraulic oil
N46#wearable
hydraulic oil
Diagram 1
Sport
viscosity
(40ć)mm2/s
Solidifying
point
İ
-20̚40ć
30
-35
0̚40ć
40
-25
Acclimation
temperature
-1-
7
Choice
variety
MOBIL
ESSO
SHELL
HME
Fig.1
8. Lubricate the relevant parts every other month. Clear the slide block track and put some
lubricant on; Lubricate safety hooks and their axles.
9. The elevated vehicle should follow up the bellows:
z No one is allowed to stay in the vehicle during lifting it up and down.
z Please make sure that there is enough air in every tyre, it is forbidden to lift the vehicle
without enough air in its tyre.
z The elevated tyres should be horizontal with the vehicle body.
10. Be sure the minimum space between the vehicle roof and the ceiling is no less than 150mm,
when operating the lift indoors.
11. It is forbidden to operate the lift loaded if there is any fault on it.
12. The operator must be sure the vehicle is fully lowered onto the ground before leaving.
13. During repairing the elevated vehicle, please be sure the horizontal power on it no more than
20% of the vehicle burden.
14. Except the operation of “SINGLE” option, you should operate the lift up&down
uninterruptedly and continuously without any short stroke interruptions.
15. Protect the cable against all kinds of sharp or other items which may damage it.
16.Operate the lift strictly according to the instructions and the below warnings.
(Fig.2)
Fig.2
-2-
8
ѠǃFeature
PCL-16HD
PCL-16HD
ML-4030 Heavy Duty Vehicle Lift is the most up-to-date hydraulic heavy vehicle lift made
by MAXIMA. Driven by hydraulic cylinder in each column, the holding fork arms rise and
lower easily and smoothly. High-accuracy balancing system ensures the cylinders work
synchronously. Unique design aims to fit heavy duty vehicle assembling & repair shop.
The PCL-16HD
ML-4030 lift is available for the vehicles within 30 tons for the purposes of assemble,
repair, maintenance, oil changing, washing and all the possible services.
Unique synchronization system
This ensures a smooth lift up&down cycle, even when the load is unequally distributed.
Human engineering
Each column is equipped with a control box, there are one master control box and three slave
control box. Each column has a hydraulic pump unit.
Safety measures
Double load-safety measures are at your disposal: Both the continuous hydraulic safety device
with sealing valve and the mechanical safety, self-inhibiting with safety hook. Each column is
equipped with up limit switch.
Diagnosing trouble function
PCL-16HD
ML-4030 will stop immediately if there are any problems.
PCL-16HD
ϝǃSpecification
PCL-16HD is designed and manufactured under the items EN1493:1998 European
ML-4030
Standard. The technical parameters are shown in the diagram 2.
Ground requirements: the surface and the foundation should be able to bear the pressure of
at least 15 MPa; The gradient of the floor surface must be not more than 1:200; Within the
area of the columns, the level difference must be not more than 10 mm.
Diagram 2
Specifications/Models
PCL-16HD
ML4030
Lifting Capacity
7.5 tons per column
Max. Lifting Height
1700mm
Time of Full Rise
120 sec.
Voltage (option available)
220v/50Hzǃ1ph
Motor power per column
2.2Kw
Weight per column
550Kg
Lifting forks range
870̚1156mm
Available
options
the hydraulic trolley
One unit per column
Mobile jack stands
One unit per column
-3-
9
220 v/60Hzǃ3ph
380v/50Hzǃ3ph
& One unit for four columns
ಯǃStructure sketch
1
2
3
4
5
6
7
Fig.3
1. safety hook cover
4. hydraulic transport
2. electric control box
3. column
5. pump cover 6.carriage
7. holding fork arm
-4-
10
heavy duty vehicle lift
PCL-16HD
ML4030
Fig.4
Mobile jack stands
(available options)
Equipment sketch
-5-
11
ѨǃThe electronics
There are 6 main parts of the electric control system, they are of a master control
box, three slave control boxes, displacement sensor, electric hydraulic pump, up
limit switches and electromagnets. The master control box includes power switch,
selection switch, power socket, raising button, lowering button, lock button,
emergency switch, relay and transformer etc; and the slave control box includes the
same components except power switch and selection switch (Fig.5,6,7).
“FAULT” light
“POWER” light
Fig.5
“FAULT” light
“POWER” light
Fig.6
-6-
12
Displacement sensor
Safety hook
Up limit switch
Electromagnet
Fig.7
1˅Control switch
1ǃPower switch
When the switch is at “OFF”, the lift is powered off and no operation is available;
when the switch is at “ON”, the lift is powered on and prepared for operation.
2ǃ
ĀPOWERā light
When the power switch is at “ON”, it is shining.
3ǃ
ĀFAULTā light
When the carriages overrun the limit synchronous value of the each column or the
tie-ins of the cables become loose, it shines. And all the other switches do not work.
4ǃSelection knob
Turn the knob to “SINGLE”, you can operate each separate column.
Turn the knob to “PAIR”& “FOUR”, you can just operate the lift by the master
control box.
NOTE:
1. Before turning the knob, please power off the lift first.
2. “PAIR” option is used when there are only two columns connected together;
“FOUR” option is used when there are four columns connected together;
“SINGLE” option can be used at all the options of “SINGLE, PAIR, FOUR”.
5ǃEmergency switch
When you press this switch, and no operation is available right now. There is one
emergency switch on each control box.
It must be released before operating the lift. Then turn on the power switch.
6ǃOperating button
“RAISE” button: Press and hold this button, the carriages rise.
“LOWER” button: Press and hold this button, the carriages go down to the required height
after rise a bit to unlock the hooks.
NOTE˖When the up limit switch works, Press and hold the “LOWER” button, the carriages
-7-
13
go down after the hooks are unlocked.
“LOCK” button: Press and hold this button, the carriages go down to the hooks.
NOTE: In order to avoid the vehicle out of balance, and make sure all the safety hooks are locked
at the horizontal shifts, you must get the initial values of the four carriages at the same height.
z Firstly, turn the knob at “SINGLE” optionˈand hold the “RAISE” button of each
column respectively to get each carriage rise to 5fPPIt means the height from
z
z
z
the rear bottom of the carriage to the floor.). power off the lift, then turn the
knob at “FOUR” option and power on it after ten minutes;
Secondly, hold the “RAISE” button to get the four carriages rise at the same time,
then make sure the lifting height of the master column is 125fPP
Finally, hold the “LOCK” button to get the carriages locked. So that you can be
sure that the four safety hooks are at the first shift horizontally.
Repeatedly, try all the other shifts with the safety hooks by lifting the carriages
every 100mm (viz. 225f3mm, 325f3mm, 425f3mmĂĂf3PPWKHQ
KROGWKHĀ/2&.āEXWWRQDQGJHWWKHVDIHW\KRRNVDWWKHKRUL]RQWDO
VKLIWV
7ǃUp limit switch
If the carriages rise above the switch, the switches works, and the lifts stop rising.
2˅Instruction and FAQ
1) Working voltage: according to the nameplate of the motor. voltage±10%.
2) Working frequency: 50Hz/60Hz±1%.
3) Working temperature: 5̚40ć
4) Working humidity: 50%@40ć-90%@20ć
5) Working altitude: İ1000m
6) The power cable for the lift should be three-core & five-core with jacket on,
and the diameter of each core is required of 6.0mm2.
7) Without permission, any changes and repairs to the control box is forbidden.
14
݁ǃDebugging
1˅Power supply
If you have a 3-phase 380v electric plug, but the power supply is single phase 220V, please do
the connections as follows.
PCL-16HD
If you have a 3-phase 220v electric plug, but the power supply is single phase 220V, please do
the connections as follows.
PCL-16HD
If you have a 3-phase 380v electric plug, and the power supply is 3-phase 380v, please do the
connections as follows.
PCL-16HD
If you have a 3-phase 220v electric plug, and the power supply is 3-phase 220v, please do the
connections as follows.
PCL-16HD
Fig.8
-9-
15
2˅Connecting mode
Note: Before operating, you should ensure the cables have been connected well
according to the Fig.9 & Fig.10. Relevantly, you should ensure the power is cut off
before taking down the cables.
(1) “PAIR” mode (see Fig.9)
Fig.9
(2) “FOUR” mode (see Fig.10)
Slave
column
Slave
column
Fig.10
Single column test
1. 3RZHURQ:First turn the selection knob to “SINGLE” option at the master control
box, then power on the lift, turn the power switch to “ON” to see if the indicator
lights work normally.
2. 5LVH: Unloaded, press and hold the “RAISE” button at the master control box, to
check if the carriage rises normally. Repeat to try the other columns.
$LUUHOHDVH: Raise the carriages about 600mm, and open cylinder drain tap
approximately 2 turns as Fig.11. then tighten the drain tap when the oil streams
out.
- 10 -
16
Drain tap
Cylinder
Fig.11
/RFN: Unloaded, when the carriage is at the very working height, press and hold
the “LOCK” button to lower the carriage to be locked.
Lower: Press and hold the “LOWER” button, the carriages go down to the
requested height after rising a bit to get the hooks unlocked.
3. Urgency Pause: When emergency occurs, right press the red emergency switch to
stop the machine, and release it after all is in good condition.
Pair & four columns test
1. 3RZHURQ: First turn the selection knob to “PAIR” & “FOUR” option at the
master control box, then turn the power switch to “ON” .
2. 5LVH: Unloaded, press and hold the “RAISE” button at the master control box,
to check if the corresponding two or four carriages rise normally.
3. /RFN: Unloaded, when the carriages are at the very working height, press and
hold the “LOCK” button to lower the carriages to be locked. In order to
avoid the vehicle out of balance, and make sure all the safety hooks are
locked at the horizontal shifts, you must accord to the rule from The
electronics.
4. Lower: Press and hold the “LOWER” button, the carriages go down to the
requested height after rising a bit to get the hooks unlocked.
5. Urgency Pause: When emergency occurs, right press the red emergency
switch button at any column. To check if all carriages can stop immediately.
Then release it after all is in good condition.
- 11 -
17
ϗǃOperation
Raise
1. After testing successfully, move the four holding fork arms to their very positions.
The contacting range must be equal with the width of the tyre. The right position
of each column should be as Fig.12.
Fig.12
2. After connecting the cables well (Fig.13), Turn the select knob to “Pair”&
“FOUR”option, and then turn the power switch to “ON”.
Fig.13
3. Press and hold the “RAISE” button at the master control box, when the vehicle
reaches to the height of 50mm, check and make sure all lifting points is in good
condition. Make the carriage continue rising to the working height,.
LOCK
Press and hold the “LOCK” button to lower the carriages to be locked. In order to
avoid the vehicle out of balance, and make sure all the safety hooks are locked at
the horizontal shifts, you must accord to the rule from The electronics.
Note: When repairing under the vehicle, you must be sure the safety hooks of all
columns locked normally.
LOWER
1. Press and hold the “LOWER” button, the carriages go down to the requested
height after rising a bit to get the hooks unlocked.
2.
After lowering the vehicle to the floor, move the lift away from it, then drive the vehicle
off.
- 12 -
18
ܿǃHydraulic trolley
Installation: Pull the hydraulic trolley to the column rear, put the top of the trolley to
the bushing of the lifting bracket, draw out the two pins on both sides, then turn the
pins anticlockwise at 45ein order to insert the sockets of the trolley. See Fig.14,15.
Lifting bracket
The hydraulic trolley
Fig.14
The top of the trolley
Pin
Fig.15
Lifting: Put down the handlebar, press the handle up and down several times, in order
to lift the column at 30̚60mm height from the floor. Fig.16.
Handlebar
Fig.16
Move the holding fork arm under the tyre of the vehicle by pushing the
Moving:
handlebar.
Falling: Put up the release bar (Fig.17), lower the column to floor.
Release bar
Fig.17
Drawing: It is reverse to the “Installation” process.
- 13 -
19
бǃMaintenance
1ǃIf the carriage does not work when you operate the lift to rise, first check if the up
limit switches or emergency switches work normally.
2ǃ
It may happen that some carriage stops suddenly while the other carriages are still
going up or down, but the fault lights don’t shine. It’s natural, don’t worry about it. Because
the carriages are adjusting the height respectively.
3ǃReplacing fuse: When the fuse of the motor & the electromagnet & the valve is
broken, please replace the fuse from the spare parts.(see Fig.18,19).
Fig.18
Master control box
Eig.19 Slave control box
Diagram 3
Fuse mode
Motor voltage
the electromagnet fuse
the motor fuse
the valve fuse
220vǃ1-phase
5A
25A
2A
220vǃ3-phase
5A
16A
2A
380vǃ3-phase
5A
10A
2A
4ǃIf the fault light is on, please do the followings:
z
Check if the cables are connected well.
z
Check if the emergency button is released, or the up limit switch is touched by other
items.
z
During lifting up & down, if there is any paranormal asynchronization, the possible
faults are as follows:
a) There may be no enough oil in the tank of one of the columns, and the carriage cannot
go up & down. So please fill some more oil into the tank.
b) Maybe, one of the columns is overloaded so that it can not go up. It means the elevated
vehicle is overweight and should not be lifted with this lift.
c) The motor at one of the columns may be over-heated and disengaged, So please open
the control box and check if the overload safety relay is disengaged, if so, press the
“RESET” button, the motor will restart. Turn off the power switch, then turn on the
power switch until the motor cool .
d) The data transfer may be interfered. So turn off the main power supply, and restart after
10 minutes.
- 14 -
20
e) Maybe the hydraulic system (motor valve, oil hose or cylinder) leaks. If the oil hose
leaks, loosen the hose connector, clean it and put some sealed glue on, then fasten it.
If the cylinder leaks, please replace it with a new one. If the motor valve leaks, please
refer to the below paragraph.
5ǃ During operating, if the carriage can be elevated without load, but it can not be elevated with
load, even slide down, there are two possible problems besides the leaking problems:
a) The manual screw may be released (fig.23), the solution is to lock the screw by
switching the button clockwise while pressing; Oppositely, you can release it.
b) Another possible problem is that the pump valve leaks inside. If the carriage can be
elevated without load, and can not with load, but does not slide down, it means there is
some problem with the circuit, which controls the rising of the lift, you can try replacing
the pressure relief valve or three way two position valve; if the carriage can be elevated
without load, but can not with load, even slide down, it means there is some problem
with the circuit, which controls the descending of the lift, you can try replacing the 1#
two way two position valve or 2# two way two position valve or check valve; You can
also replace the pump totally. The pump valves are as the following fig. 20:
1# Two Way Two
Position Valve˄With
bigger Throttle˅
Manual Override Knob
2# Two Way Two
Position Valve˄With
smaller Throttle˅
Check Valve
Pressure Port
Pressure Relief Valve Gear Pump
Startup Snub-Valve
Fig.20
- 15 -
21
Central Valve Block
Three Way Two
Position Valve
6. How to replace the valves:
z
Cut off the main power supply;
z
Unlock the manual screw, or get the carriage come down to be locked or to the ground
automatically, open the cover of the safety hook, and check if the hook is locked solidly. It
will be much safer to put some supporting items under the vehicle, such as Mobile jack
stands.
z
Judging by the above steps, replace the right valve correspondingly.
A. Firstly unscrew the nut outside of the problem valve bar;
B. Get the loop out off the valve bar, and unscrew the valve bar with a wrench;
C. Replace it with a new valve bar;
D. Put the loop on. (Note: Do not upend the position of each connector plug at the loop.)
z
Turn the selection knob to “SINGLE”, power on the lift, and hold the “Raise” button to
balance the vehicle body, and check if the leaking problem is solved. Cut off the lift.
z
Then turn the selection knob to “FOUR”, power on the lift, and hold the “LOWER” button
to get the vehicle down to the ground.
7. How to change the hydraulic cylinder?
1) Lower the carriage down to the ground, take off the cover of safety hook on the column, and
take out the up limit switch.
2˅Take out the displacement sensor and its bracket: Firstly loosen the setscrew of the sensor cable
from the hole at the rear bottom of the column (fig.21), meanwhile hold the cable and draw it
back slowly; Secondly take out the bracket; Then take out the signal cable in the control box.
Finally take off the sensor and position it safely against any possible impact. Please refer to the
connection of the signal cable as Fig. 22,23 to take out the signal cable;
Fig.21
Fig.22
- 16 -
22
shield
blue˄0v˅
black˄A phase˅
brown˄+12v˅
Fig.23
3˅In order to avoid the column moving backwards, move the column to a corner and get the
control box face the wall, and keep space between the corner and the control box surface no
more than 500mm;
4) Raise the carriage to the height of 1775mm from the ground with a forklift.
NOTE: Do not raise the carriage too high to get the sliding block out of the guideway. And put
two mobile jack stands under the carriage.
NOTE: After change the cylinder, it is necessary to fill some more oil and release the air out
of the cylinder.
ǃIt is important to know how to lower the carriages manually, when powered off unexpectedly.
Make sure nothing is under the carriages and all unauthorized personnel must be forbidden to near
the machine.(Fig.24)
A. Place a hydraulic jack to raise the carriage on the master control side 50mm. Then
release the safety hook and get it unlocked.
B. Slowly lower the jack, and repeat the process on the slave control sides.
C. Loose the manual screw on the lowering valve to lower the carriages at the same
time.
NOTE: If some carriage lowers faster than the others, please tighten them immediately, until the
vehicle body is horizontal. Repeat like this to ensure the vehicle lower to the floor smoothly. At
last, tighten up the screw cap.
Lowering valve
Manual screw
Fig.24
- 17 -
23
(Operation)
To Raise Lift;
1. Load vehicle onto the lift using Vehicle Lifting Guide
to determine proper lifting points.
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,
2. Set parking brake or use wheel chock to hold vehicle
in position.
3. Before raising vehicle, be sure all personnel are clear
of the lift and surrounding area. Pay careful attention to
overhead clearances.
WEEKLY MAINTENANCE
1. Lubricate all rollers with general purpose oil or
WE-40.
4. Raise the lift to the desired height by pressing the
push button on the power unit.
2. Check all cable connections, bolts and pins to insure
proper mounting.
3. Lubricate safety lock pivot points with general
purpose oil or WE-40.
VISUALLY CONFIRM THAT ALL PRIMARY
SAFETY LOCKS ARE ENGAGED BEFORE
ENTERING WORK AREA.
Suspension components us 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.
MONTHLY MAINTENANCE
1. Check safety locks to insure they are in good
operating condition.
2. Check all cables for excessive signs of wear.
3. Make a visual inspection of ALL MOVING PARTS
and check for excessive signs of wear.
4. Replace ALL FAULTY PARTS before lift is put back
into operation.
5. After vehicle is raised to the desired height, lower the
lift onto the nearest safety lock. Do not allow cables to
become slack. ALWAYS INSURE ALL SAFETY LOCKS
ARE ENGAGED before entering work area.
NEVER EXCEED THE RATED CAPACITY of lift.
To Lower Lift;
1. Before lowering vehicle, be sure all personnel are
clear of the lift and surrounding area. Pay careful attention
to overhead clearances. Insure all tools and equipment
have been cleared from under the lift.
DO NOT USE LIFT if any component is found to be
defective or worn.
2. Raise the lift off of the safety locks by pressing the
push button on the power unit. Make sure you raise the
lift by at least two inches to allow adequate clearance for
the locks to clear.
ALWAYS STAND CLEAR of lift when lowering or
raising.
NEVER OPERATE LIFT with any person or
equipment below.
ALWAYS INSURE SAFETY LOCKS ARE
ENGAGED before entering work area.
3. Press the push button air safety valve and HOLD.
NEVER LEAVE LIFT IN ELEVATED CONDITION
unless all safety locks are engaged.
4. Push the LOWERING HANDLE on the power unit
until the lift has descended completely.
24
25
26
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 runway. (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.
27
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 INSURE that the safeties are engaged and lowered on to the safety ladders 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.
28
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
it possible contamination 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 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Consult Lift Manufacturer.
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.
29
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
nametag. 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . .Consult Lift Manufacturer.
2.
Replace with new part . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replace with new part.
3.
4.
Return for repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return for repair.
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.
30
WILL NOT RAISE LOADED LIFT
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)
6. Motor runs backwards, (10,12,9)
7. Pump damaged, (5,9)
8. Pump won’t prime, (1,2,3,4,5,11,9)
9. Relief valve leaks, (8,5,9)
10. 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Consult Lift Manufacturer.
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.
31
LIFT WILL NOT STAY UP
POSSIBLE CAUSE
1. Air in oil, (1,2,3)
2. Check valve leaks, (6)
3. Cylinders leak internally, (7)
4. Lowering valve leaks, (4,5,1,7,6)
5. Leaking fittings, (8)
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Consult Lift Manufacturer.
8. Check complete hydraulic system for leaks. . . . . . . . . . . . . . . Tighten all hydraulics fittings and inspects all hoses.
32
Fault Codes
Refer to the Chart below for an explanation of the Fault
lights displays.
1. The Master Column Electronic Control Board has a
set of three Blue LED lights. The set of three LEDs will
display a Fault Code when a faulty Condition is detected.
(See Fig. A )
Fig. A
FAULT
1
2
3
4
5
6
LED 2
z
z
|
|
z
z= ON
|=OFF
LED 3
|
z
|
z
z
Ò
LED 4
|
|
z
z
z
Ò
Ò
Ò= BLINKING
3. Once you determined which Fault Code is being
displayed. Refer to the trouble shooting flowcharts on the
following pages to determine the course of the Fault and
the possible remedies.
2. The three Fault Pilot lights, LED2, LED3, LED4 will
be illuminated in different configurations to display one or
more of six different Fault Codes.
FAULT No. 1
FAULT No. 6
Turn Main
Power Switch
OFF.
Check microswitch
and electromagnet.
Select the correct
MODE,
Wait 20 Seconds.
FINISH
Turn Main
Power Switch
ON.
33
34
Finish
Complete
Trouble shooting.
Reset the Over-heated protective
Relay Motor Starter on faulty
MASTER Column.
YES
Is the Fault light on?
Reset the Over-heated protective
Relay Motor Starter on faulty
SLAVE Column.
NO
NO
Finish
Check Fault 5
instructions
Are the Three blue LEDs on?
Is the Fault light on?
Turn Main
Power Switch
ON.
Make sure four
columns are
connected together
Wait for 20
seconds
Turn Main
Power Switch
OFF.
Connect the four columns together.
Switch to
“SINGLE”
Mode
FAULT No. 2
FAULT No. 3
Check other
displayed Fault
instructions.
YES
35
RESTART
Add more
Hydraulic oil
YES
Clean the Hose connections,
reapply Teflon tape,
re-connect Hoses.
Change the
Check Valve.
YES
NO
YES
Is the valve of
Hydraulic unit
leaking?
Is the Carriage
sliding down in nonoperation mode?
RESTART
Problem
Gone?
Problem
Gone?
Change the UP Valve on
3-way 2-position Valve.
Change the EM Lowering
Valve on 2-way 2 position
Valve ( non-manual)
NO
Lower the fork on to a
Safety or on to the ground.
UP Valve is
Faulty.
NO
NO
Lower the fork on to a
Safety or on to the ground.
Lowering Valve
is Faulty.
Are the Hose/Fitting
connections leaking?
Turn the “Reset”
switch on Motor
Starter to cool down.
Is the hydraulic
system leaking.
YES
YES
NO
YES
Is the Motor on the
Slower Column overheating?
NO
Lower the fork on to a
Safety or on to the ground.
Does the slower column
have enough hydraulic
oil?
FAULT No. 4
Change the
Pressure Relief
Valve.
Overloaded
condition is not
allowed.
Stop.
Remove load
from Columns.
The slower
column is
overloaded.
NO
Is the Cylinder
leaking?
Repair or
Replace
cylinder.
YES
36
From Fig. 5.1
Press Down.
YES
Does Carriage
Rise?
Press “UP”
Select “Single”
Mode.
Connect the Main
Column Only.
FAULT 5
NO
YES
Is Carraige at
Max Height?
Step 3.1
From Page 5.3
NO
Change the Fuse.
Check the
Connection of the
Motor.
Check the
Motor/fuse
starter.
Replace the Limit
Switch.
NO
NO
Is the AC
Contactor
closed?
YES
OK
BAD
Check Limit
Switch?
OK
Repair the line
connection.
NO
Check all of the
connectors.
OK
Change the Main
Board.
FAULT 5
Page 1
37
To Fig. 5.3
YES
Will Lift go
down?
YES
Is the
electromagnet
open?
Press Down.
From Fig. 5.1
NO
NO
Open the Pump
Cover.
Repair the valve
wire/solenoid
NO
Change the
Control Board
YES
Is the connection
of the valve
solenoid good?
Are the Lights
on even if you
do not press
the button?
Repair the wire
controller
electromagnet
contactor.
NO
Check if
electromagnet
wire is ok?
YES
YES
NO
NO
Are the lights
on the front two
down solenoids
bright?
Chagne the
Electromagnet
fuse.
Check the
Micorswitch and
Elctromagnet
AC Contactor
(controlling
electromagnet)
closed?
YES
Yes
NO
Is the micro
switch closed?
NO
YES
Check the
hydraulic system
and valve.
Change the AC
Contactor.
NO
Electromagnet
AC contactor
good?
Change Control
Board.
FAULT 5
Page 2
38
Refer to other
Fault code
procedures.
NO
Repair the cables
between Man and
Slave Column
NO
Is communication
between Main &
Slave good?
YES
Are all three
LEDs on?
YES
Check Fault
Information.
YES
Is the Fault
Light on?
Switch on.
Select ”PAIR”
MODE
Connect main
Column and one
Slave Column
From Fig. 5.2
YES
NO
Change the
Control Board on
Slave
GO to Page 5.1
Step 3.1
Is it working?
YES
NO
Change Control
Board on Main
Column.
YES
Are all three
LEDs on?
Connect other
Slave Column with
Main Column.
NO
Are the three slave
columns tested
completely?
YES
Chips must be A,
B, C, and D
YES
Are all three
LEDs on?
Connect all four
Columns together
FINISH
NO
FAULT 5
Page 3
NO POWER - TROUBLE SHOOTING
START
Connect the
four Columns.
Check all of the
Emergency Buttons.
Switch on the electricity.
Are the Power
Lights on?
NO
Check whether the AC
Contactor on Main
Column is on or not.
YES
NO
YES
Check the
Fuse.
Check the
Connection.
RESTART
39
MAINTENANCE RECORDS
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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
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