FOUR POST LIFT STRONGMAN TOOLS. Manual to be used with only Strongman Tools Ltd 4 Post Lift

Transcription

1 FOUR POST LIFT STRONGMAN TOOLS Manual to be used with only Strongman Tools Ltd 4 Post Lift

2 2. SAFETY WARNINGS Thoroughly read this manual before operating the lift and comply with the instructions. Always display the manual in a conspicuous location. 2.1 SAFETY INSTRUCTIONS FOR COMMISSIONING The lift may be installed and commissioned by authorised service personnel only. The standard lift version may not be installed and commissioned in the vicinity of explosives or flammable liquids, outdoors or in moist rooms (e.g. car wash). 2.2 SAFETY INSTRUCTIONS FOR OPERATION Read the operating manual throughly before starting set up of your lift. Lift operation by authorised personnel over 18 years only. Always keep the lift and lift area clean and free of tools, parts, debris etc. After raising the vehicle briefly, stop and check the disk adapters for secure contact. Make sure the vehicle doors are closed during raising and lowering cycles. Closely watch the vehicle and the lift during raising and lowering cycles. Do not allow anyone to stay in lift area during raising and lowering cycles. Do not allow anyone on the lift or inside a raised vehicle. Only use the lift for its intended purpose. Comply with the applicable accident prevention regulations. Do not overload the lift. The rated load capacity is indicated on the lift nameplate. Only use the vehicle manufacturer s recommended lift points. After positioning the vehicle apply the handbrake. Use caution when removing or installing heavy components (center-of-gravity displacement). The main switch serves as emergency switch. In case of emergency turn to position 0. Protect all parts of the electrical equipment from humidity and moisture. Protect the lift against unauthorised usage by padlocking the main switch. 2.3 SAFETY INSTRUCTIONS FOR SERVICING Maintenance or repair work by authorized service personnel only. Turn off and padlock the main switch before doing any maintenance, or repair work. 2

3 Work on pulse generators or proximity switches by authorised service personnel only. Work on the electrical equipment by certified electricians only. Ensure that ecologically harmful substances are disposed of only in accordance with the appropriate regulations. Do not use high pressure / steam jet cleaners or caustic cleaning agents. Risk of damage. Do not replace or override the safety devices. 3

4 4. INSTRUCTIONS 1.Positioning Decide where the Motor Unit will be positioned. It can be attached either front right or rear left as you look at the lift. The platform which houses the pulley on the hydraulic ram must be the same side as the Motor Unit. 2.Jack onto blocks Once lift has been delivered our delivery team will leave your lift in roughly the position you have chosen. They will unload it using dollies, these will be taken away with them so it is essential you provide some wooden blocks, dollies, bricks or similar to leave the platforms on. To make install easier these should be at least 150mm high. 3.Remove Packing Finish unpacking all the posts and other parts of the lift removing all the packing apart from off the platforms themselves to protect from any scratches during set up. 4.Arrange Posts Stand up all 4 posts into their correct corners 4 C O PY R I GH T S TR ON G M AN T OOL S L T D

5 4. INSTRUCTIONS 5. Pull out cables Draw the cables out from the platforms both front and back. 6. Position Crossbeam Position the crossbeam roughly into place to line up with the holes on the platforms. Then proceed to remove the pulley wheel from the crossbeam. 7. Thread Cables Thread the cables from the platform through the crossbeam. The short cable goes to the post next to it; the longer cable runs the length of the crossbeam. 8. Over Locking Bar It is important that the shorter cable runs OVER the locking bar. 5

6 4. INSTRUCTIONS 9. Attach Crossbeam Use blocks or trolley jack to raise the cross beam into position and attach to the platforms. When doing the rear cross beam remember to attach the End Stops before you screw down. 10. Ladder Boards Drop the ladder boards into the crossbeams. 11. Motor Bracket Bolt the Motor Bracket to the Motor Post. Ensure you remove the Motor Pump Unit bolts from the leg and attach to the bracket facing outwards BEFORE bolting the bracket to the post. If you don t do this you will not be able to fit the bolts through. Now ount the motor 12. Attach Control Unit Bolt on the Electric Control Unit above the motor. 6

7 4. INSTRUCTIONS 13. Attach Ladder Boards Push the legs into position over the crossbeams and attach the ladder boards to the top using the bolts. The ladder boards go into the rear at the top of the leg. You will need someone to operate the Locking Handle while you adjust the ladder boards. 14. Attach Cables Run the cables up the leg in front the of the ladder board and attached to the top of the leg using the front hole. The cables at this point will be slack, leave around 20mm sticking out the top. 15. Fit Hydraulic Pipe Fit the hydraulic cable from the Motor Unit to the Platform. 16. Fit Hose Bracket Fit the Hose bracket to the platform, then fit the hose to the bracket. 7

8 4. INSTRUCTIONS 17.Install Limit Switch Install the limit switch and run the cable down the inside of the leg, and out inline with the Motor Unit. Adjust the limit arm using an allen key. 18. Thread Cables Thread the Limit Switch cable and the Motor Cable through the rear grommet at the bottom of the Electric Control Box connecting all 5 wires to the block. 19. Fill with 7L of Oil Fill with the oil tank with approximately 7L of ISO 32 Hydraulic Oil. We advice using a flexible funnel with a filter. 20. Connect Mains Connect the 16amp electric plug to your mains. Ensure you have a C or D Motor Rated circuit breaker installed as well. 8 C O PY R I GH T S TR ON G M AN T OOL S L T D

9 4. INSTRUCTIONS 21. First Lift Start to raise the lift a short distance till you hear the first locks engage. Don t keep starting and stopping the motor in short bursts or this will shorten the life of your motor and capacitors. You can now remove the blocks holding the platforms. 22. Ensure Levels Lower the lift again to the floor, then raise to about 1m high again. Ensure all the platforms, cross beams and posts are now level using a Spirit Level. If legs are not level use shims till they are perfectly level. 23. Bolt Down Once you are satisfied everything is completely level lower the lift to the floor and start to bolt. Always start with the Motor Post and work your way round. Raise the lift in between each set of bolts to ensure it is still level. 24. Test Limit Switch Once all bolted in raise the lift to the top to test the limit switch. 9 C O PY R I GH T S TR ON G M AN T OOL S L T D

10 4. INSTRUCTIONS 25. Cable Adjustments With the lift raised approximately half way adjust the levels using the cable bolts at the top of the posts. 26. Checks Check every single locking point at all 4 corners. Check the ladder boards are even as well 27. Attach Up Ramps Attach the up ramps. Lower the lift to the floor and position them in place and slide the bar through. You may need one person to stand at the end of the ramps shifting them slightly till the pole slides all the way through. 28. Weight Test Use a vehicle to weight test the lift raising it up and checking regularly that it is still being locked in and everything is still level. 10

11 5. MAINTENANCE 5.1 MAINTENANCE DETAILS Keep all the moveable parts clean, regularly grease them. All the oil cups should be refilled once every week. Replace the hydraulic oil once every year. Clean the oil tank and oil filter. The oil level should keep upper limit. The compressed air for the pneumatic safety lock should be filtered to ensure the reliability of the safety lock. Ordinary Maintenance The lift has to be properly cleaned at least once a month using self-cleaning clothes, Lubricate all pivot pins at least once a week. 5.2 MAINTENANCE CHECK TIMETABLE Every 3 Months Every 6 Months Every 12 Months Hydraulic Circuit Foundation Bolts Hydraulic Pump Safety System Oil General Check Electrical System Oil Check oil tank level; refill with oil, if needed. Check the circuit for oil leaks. Check seals for proper conditions and replace them, if necessary. Check bolts for proper tightening Verify that no noise changes take place in teh pump when running and check fixing bolts for proper tightening. Check safety devices for proper operation. Check oil for contamination or ageing. Contaminated oil is the main reason for failure of valves and shorter life of the pump s gears. Verify that all components and mechanisms are not damaged A check of the electrical system to verify that motor, limit switch and control panel operate properly must be carried out by skilled electricians. Empty the oil tank and change the hydraulic oil. 11

12 TROUBLE SHOOTING LIFT STUCK IN THE AIR Just stuck in one corner Ratchet not coming out Pull handle down further (unlocking) Underneath crossbeam ratchet joined to the linkage adjust the nut to pull out ratchet more Raise lift slightly more to ensure lift is OFF the locking points Nylon Guide Block Jammed Ensure guide blocks can be moved and cables are evenly taute. Slacken off the cable that is too tight, power motor to even cables The whole lift is stuck in the air Check locks are UNENGAGED Lift moved a little bit, then stopped Pull handle to full unlock position Parachute Valve has been activated. To deactivate, turn IN the throttle valve adjustment fully. This will either be an Allen key or Flat Head screwdriver Grub screw depending on your lift. This is positioned on the side of the pump. Then send a small bit of oil back into the system to re-pressurise and open the spring loaded parachute valve. As soon as the lift starts to raise a bit stop. If you are up against the limit switch so you can t rise any higher, you will need to unscrew the limit switch to allow it to rise. Ensure to put the limit switch back in the same point, MAKE SURE NOT TO RAISE THE LIFT TOO HIGH ABOVE LIMIT SWITCH. With locks disengaged, keep your hand on the lowering handle on the pump; whilst this is depressed you need to adjust the throttle valve ¼ of a turn ANTICLOCKWISE until lift is lowering at desired speed. Lift stops close to ground but not at the bottom Check cable tensions as CABLE LOCK might have activated and stopping one corner from lowering. Tighten the cable by adjusting the nuts at the top of the post. Once done raise the lift a bit, then re-lower. 12

13 TROUBLE SHOOTING LIFT WON T RAISE Electrical Check power INTO the controller Ensure lift is plugged in Lights turning on; check breaker / consumer unit Check fuses in the actual power pack Check limit switch is not activated and its wiring is all okay Motor starts to turns but makes whirring noise often trips fuse. Sometimes gives off an acrid smell Replace capacitors; call our team for the part. Remove the faulty capacitor and crimp the wires for the new capacitors in Steel Cables Ensure they are located corrected in the terminating clamp Ensure they are located corrected around all the pulleys Ensure that no cables are twisted Ensure they corrected terminated and fixed to the top of the post Ratchets Ensure they are free, to test manually move the locking handle Grease the ratchet mechanism to make sure moves freely 13

14 TROUBLE SHOOTING Hydraulic Pump Check for hydraulic leaks Ensure the unloading valve handle is NOT depressed Lift works okay without load, but won t raise with load Perform all Steel Cable checks first (as above) Adjust capacity valve by ¼ each time until it takes load Other problems Lift is leaking oil Lift moved a little bit, then stopped Tighten all unions, if still leaking remove and add new PTFE tape Parachute Valve has been activated. To deactivate, turn IN the throttle valve adjustment fully. This will either be an Allen key or Flat Head screwdriver Grub screw depending on your lift. This is positioned on the side of the pump. Then send a small bit of oil back into the system to re-pressurise and open the spring loaded parachute valve. As soon as the lift starts to raise a bit stop. If you are up against the limit switch so you can t rise any higher, you will need to unscrew the limit switch to allow it to rise. Ensure to put the limit switch back in the same point, MAKE SURE NOT TO RAISE THE LIFT TOO HIGH ABOVE LIMIT SWITCH. With locks disengaged, keep your hand on the lowering handle on the pump; whilst this is depressed you need to adjust the throttle valve ¼ of a turn ANTICLOCKWISE until lift is lowering at desired speed. Lift stops close to ground but not at the bottom Check cable tensions as CABLE LOCK might have activated and stopping one corner from lowering. Tighten the cable by adjusting the nuts at the top of the post. Once done raise the lift a bit, then re-lower. 14

15 Plan of the layout for lifting cables. Strongman Tools Ltd. Unit 1 Coventry Bridge Yard, Napton, Warwickshire, CV47 8HX Tel: sales@sm-eng.co.uk