CR18 Installation Instructions

Transcription

1 CR8 Installation Instructions Capacity 8,000 lbs. (9,000 lbs. per axle) Four Post Surface Mounted Lift Maximum Wheelbases: 94" & 0" Minimum Wheelbase: 6" August 0 by Vehicle Service Group. IN6008 All rights reserved. CO7980. Rev. - 8//0

2 Installation Instruction 4'-6" Min. To Nearest Obstruction 0 Min. To Nearest Obstruction 6'-6" Min. To Nearest Obstruction APPROACH Left Runway C 6'-6" Min. To Nearest Obstruction Right Runway Fig. REAR LIFT CLEARANCE FRONT Read and understand these instructions completely before proceeding with lift installation.. Lift Location: Use architects plan when available to locate lift. Fig. shows dimensions of a typical bay layout. For power unit at right front, rotate lift 80, leaving ramp/chocks and wheel stops in original position. Lift floor area should be level. WARNING DO NOT install on asphalt or other similar unstable surface. Columns are supported only by anchors in floor. Ceiling or overhead clearance must be 80 plus height of tallest vehicle.. Estimating Column Shim requirements: In the following section, the terms highest and lowest refer to elevation of floor. A. Mark locations where lift columns will be positioned in bay. B. Place target at column positions and record readings, Fig.. C. Find the highest of the four locations. Find the difference between the reading at each of the remaining three columns and the highest reading. D. The difference is the estimated amount of shim thickness needed at each column. transit target Fig. COLUMN SHIM ESTIMATES Dimension at highest position minus other position = shim thickness required

3 Left Rear Cable (#) Right Rear Cable (#4) Right Front Cable (#) Left Front Cable (#) Left Rear Cable (#) Right Rear Cable (#4) FRONT REAR Fig. CABLES IN PROPER SHEAVE GROOVES Front Wheel Chock Runway Bolt Yoke End Cable Right Runway Front Wheel Chock Yoke End Runway Bolt - / " X 5 / 8 " HHCS Cable Runway Sheave Left Runway FEED CABLE ENDS THROUGH YOKE OPENINGS Fig. 4 Note: Maximum shim thickness is /" per column using shims and anchors provided with lift. Shim thickness of " is possible by using optional shim kit #FC59. Contact your authorized parts dstributor for ordering information. 4. Runway and Yoke Tube Assembly: A. Determine direction of approach in bay. B. Position left runway in bay with hydraulic cylinder hose connection to rear of bay. Cables and sheaves are pre-assembled in runway. Runway needs to be up off floor so shipping restraints can be removed from cable ends, air and hydraulic lines, and cylinder rod. Pull cable ends, air, and hydraulic lines out for assembly. Make sure cables are in proper sheave grooves, Fig.. C. Position front and rear yokes at respective ends of runway, Fig.. The opening in the side of the yokes should be lined up with the cable sheaves in the runway ends. Feed cable ends through yoke openings, Fig. 4 and 9. Do not assemble sheaves in yoke ends at this time. IMPORTANT Be sure cables are not crossed inside yoke.

4 5. Attaching Runways: With the openings in the front and rear yoke tube sides lined up with the left runway ends, align the two () holes in the top of the front yoke tubes with the slots in the runway end plates and the holes in the front wheel stops. Bolt wheel stops and runway to the yoke using two / x 5/8 hex flange bolts, FRL Adjustment Nut FRL Bracket #0-4NC Nylon Lock Nut Jam Nut Nut Washer Adjustment Nut Jam Nut #0-4NC x /4" SHCS Threaded Cable Latch Bar Jam Nut Power Unit Column Threaded Stud Latch Bar ATTACH FRL Fig. 5b Fig. 5a LATCH BAR IN COLUMN Fig. 4. Repeat for the rear end. Align the slots of the right runway end plates with the holes in the yoke tube. Bolt front wheel stop and runway into place. Rubber Bumper Latch Bar Pull Latch Bar up above sliders. 5/6 8NC BHS x / lg. Threaded Stud Column This side faces out Slider Latch Bar LATCH BAR CROSS SECTION Fig. 6 LATCH BAR OFFSET Yoke ATTACH SLIDERS Fig Column and Yoke Assembly: A. Place the power unit column at the left rear corner of the lift. The hydraulic cylinder connection in the left runway should be visible from this corner. Position remaining three columns. B. Thread the jam nut down the threaded stud as far as possible. Stick rubber bumper to bottom of latch bar, see Fig. 7. Place the latch bar in the back of the column, Fig. 5a. The latch bar is offset from the center line of the threaded stud (inset Fig. 6). The latch bar should be oriented toward the back of the column from center line of the threaded stud. C. Place FRL Bracket on top of power unit column. Guide the threaded stud through the hole in the column top plate and bracket, Fig. 5b. Then thread the adjustment nut down the threaded stud until the nut and top plate are flush, Fig. 5b. Repeat for other columns. 4 D. Start yoke end into the column, allowing slider bolt holes to stay exposed, Fig. 7. Apply thread locking compound to screw threads then bolt sliders onto each side of the yoke end with 5/6"- 8NC screws provided. When both sliders are attached, push column toward yoke end until sliders touch latch bar. E. Raise latch bar above sliders and move column toward yoke until the sliders contact the back of the column. Lower the latch bar into the sliders. Tighten latch bar jam nut against column top plate. Run latch bar adjustment nut down and tighten. The latch bar should engage the sliders for at least " when the lift is completely lowered. Repeat this procedure for each yoke end and column. F. Install yoke end sheaves and plastic spacers, Fig. 8. A plastic spacer is placed on each side of the sheave, inset Fig. 8.

5 Note: Failure to install plastic spacer will result in premature failure and void warranty. G. Retain with sheave pin and 5/6 button head machine screw. Attach each cable to column top plate with nut, jam nut, and washer, Fig. 8. Install rubber sheave guard on each yoke end, Fig. 8. Roping diagram shows a view of completed roping, Fig. 9. IMPORTANT Be sure cable is located in the sheave groove. Jam Nut Washer Nut Latch Bar Adjustment Stud / 4 0 x / lg. Type T Hex. Hd. Tapping Screw Column / 4 Plain Washer 5 / 6 Hex Hd. Bolt Rubber Guard Sheave Pin Plastic Spacers Plastic Spacers Sheave Sheave Yoke Side Plate Yoke End TOP VIEW (top removed) Fig. 8 SHEAVE INSTALLATION Right Front Left Rear Right Rear Left Front CABLE ROPING Do Not Cross Cables at Either End Fig. 9 5

6 7. Concrete and Anchoring Latch Bar Concrete And Anchoring Requirements Floor Requirements: Minimum 000 PSI concrete Recommended Floor Thickness: 5-6" (7mm -5mm) Column A B C Minimum Floor Thickness: 4-/4 (08mm) Drill hole using 5/8 carbide tipped masonry drill bit per ANSI standard B Clean Hole Run the nut down just below the impact section of the bolt. Drive the anchor into the hole until the nuts and washers contact the base. Fig. 0 Slider Yoke COLUMN CROSS SECTION D Maximum anchor exposure floor grade to top of anchor is -/4 (58mm). Exposure greater than -/4 (58mm) NOT ACCEPTABLE. Installation torque value is 50 ft-lbs (04 kpa). E Minimum anchor embedment: -/4 (8mm) F Minimum spacing between anchor bolts 6-/ (65mm) G Minimum distance to: Abandoned anchor hole, expansion joint, crack, or concrete edge, is 4-/ (4mm). Note: Above Information is for Hilti Kwik Bolt III anchors supplied with the lift for standard installation. A B For installations not meeting these requirements or for seismic anchor information contact customer service at: D C A E Fig. F G G G G 6

7 (000/006/00/06) - -5/6 Ref. (00/007/0/07) /6 Ref. Width and length measurements are made from column sides, NOT column base plate. Diagonals are measured from out side corner of runways. Left Runway APPROACH Diagonals within / 4 " / 6 Ref. Fig. Right Runway CHECK DIAGONALS A. Keep columns square to center line of lift. Check lift location in the bay, Fig.. Check dimensions side-to side, front-to-rear, and diagonally. Diagonals must be equal to within /4", Fig.. B. Move column towards yoke until the sliders contact the back of column, center yoke in column, Fig. 0. C. Place shims (estimated in Step ) under each column. Drill four 5/8 diameter holes through concrete floor using base holes as guide, Fig.. Repeat for other columns. D. Insert base anchors, Fig.'s and. E. Tighten nuts, Fig.. Check columns for plumb and level. Re-shim if necessary. Torque anchor bolts to 5-45 ft. lbs., Fig.. F. If anchor bolts do not hold when torqued to required amount, concrete must be replaced. Saw cut and remove 4 x 4 square area under each column base. Repour with reinforced 000# minimum concrete to depth of 6", keying new concrete under existing floor. Anchor Nut Washer Shim ( / Max.) Fig. INSERT ANCHORS 7

8 8. Runway Leveling: A. Use an engineer s automatic level (transit). Locate the Level at a convenient location in the shop that allows an unobstructed view of all four corners of the lift s runways. Follow the Level manufacturer s instructions for proper setup. Be sure it is adjusted level in all directions. Readjust if tripod or Level is bumped or disturbed. B. Make sure yoke tubes rest on column base plate. C. First place the Level target at the highest corner of the lift. Place it on the runway center line within 6 of yoke tube, whichever one is located over highest point. This will be referred to as target A position. Beginning with target A position, Fig. 4, sight the Level to the target and mark the number or the graduation on the inch scale of the target that aligns to the crosshairs of the Level, Fig. 5. Target Scale TARGET SCALE 4 5 Fig. 5 A D B RUNWAY LEVELING Fig. 4 C Note: Use a pencil, marking pen or attach a paper clip onto the target scale at the crosshair reference. D. Next, move the target and place it on the runway at point B, Fig. 4. Rotate the Level and focus on the target scale. Adjust the column at B using shims under base plate, Fig., until the crosshairs of Level align to reference mark on the target scale. Repeat for points C and D. Runways Should Be Level. Maximum Tolerance Side To SideAnd Front To Rear /8 Cable Slack Cable Arm Roller Sheave 9. Cable Adjustment: Adjust cable with lift fully lowered. Loosen jam nut and tighten nut on cable stud on top of column until yoke end raises /4". Back off nut one turn. Retighten jam nut. Repeat for all four cables. Refer to Fig. 8. Fig. 6 CABLE IN SLACK CABLE ARM 8

9 IMPORTANT Cables must fit in slack cable arm rollers, Fig Power Unit: A. Align Latch Release Air Valve Bracket with holes in right side of Column Bracket. Put four 5/6" x /" hex bolts through holes in Air Valve Bracket and Column Bracket, using push nuts to hold in place, Fig. 7. B. Mount power unit, with motor up, to column bracket and install lock washers and nuts. Run hydraulic hose from runway through grommet in side of runway to power unit output port, Fig. 9. DO NOT use Teflon tape on hydraulic hose connections. Install and hand tighten elbow to pump until O-ring is seated and elbow should be oriented downward. Tighten locknut to 5-40 ft. lbs. Install enclosed Capacity label on power unit.. Electrical: Have a certified electrician run appropriate power supply to motor, Fig. &. Size wire for 0 amp circuit. See Motor Operating Data Table. CAUTION Never operate the motor on line voltage less than 08V. Motor damage may occur. IMPORTANT: Use separate circuit for each power unit. Protect each circuit with time delay fuse or circuit breaker. For single phase 08-0V, use 0 amp fuse. Three phase 08-40V, use 5 amp fuse. For three phase 400V and above, use 0 amp fuse. For wiring see Fig. 0, & Fig.. All wiring must comply with NEC and all local electrical codes. Note: 60Hz. single phase motor CAN NOT be run on 50Hz. line without a physical change in the motor. WARNING Risk of explosion. This equipment has internal arcing or sparking parts which should not be exposed to flammable vapors. It should not be located in a recessed area or below floor level.. Hydraulic Fluid Filling: System capacity is thirteen () quarts. Use Dexron III ATF. Remove fill/breather, Fig. 9. Pour in hydraulic fluid until it reaches the Fill Line. Replace fill/breather. Start motor and raise lift to full rise. Lower onto latches. Note: If fill/breather, Fig. 9, is lost or broken, order replacement. FRONT VIEW AIR BRACKET Push nuts hold bolts to brackets Air Valve Bracket Raise Switch PUSH TO RELEASE LATCHES NP80 Elbow Use (4)5/6"-8NC x -/" lg. HHCS CAPACITY 8,000 LBS. Lowering Valve Crimped Hose Sleeve (Typical) Use (4)5/6"-8NC Nuts and 5/6" Star Washers Fill Breather Cap Fig. 7 MOUNTING AIR VALVE BRACKET Fig. 8 9

10 Column Cable Ties Fill/Breather Cap Fill Line Fig. 9 Air Line Power Unit Hydraulic Hose Black Attach black wire to one motor wire. White Green Attach white wire to one motor wire. Single Phase Power Unit MOTOR OPERATING DATA TABLE - SINGLE PHASE LINE VOLTAGE RUNNING MOTOR VOLTAGE RANGE 08-0V 50Hz. 97-5V 08-0V 60Hz. 97-5V 08-0V 60Hz Single Phase Note: 60Hz. Single phase motor CAN NOT be run on 50Hz. line without a physical change in the motor. Attach ground wire here. Black Black Up Switch Black Attach ground wire to screws provided. 0V 60Hz Single Ph Green White White M Fig. 0 0

11 NOTE: Two Different Drum Switches were used please select one of the two options below. NOTES:. Unit not suitable for use in unusual conditions. Contact Rotary for moisture and dust environment duty unit.. Control Box must be field mounted to power unit.. Motor rotation is counter clockwise from top of motor. Phase Supply L L L PE DRUM SWITCH MOTOR FOR Ø POWER UNITS: Attach Box using M5 x 0 PHMS, Plated Capacitor Box Attachment Option One (4) M5 x 45 PHMS, Plated Gasket Drum Switch And Cover Re-seal Between Box And Spacer With Silicone Sealer Capacitor Box Fig. (4) M5 x 0 PHMS, Plated Capacitor Box To Power Unit Phase Supply L L L PE MOTOR Capacitor Box Attachment Option Two DRUM SWITCH Three Phase Power Unit MOTOR OPERATING DATA TABLE - THREE PHASE LINE VOLTAGE RUNNING MOTOR VOLTAGE RANGE 08-40V 50/60Hz. 97-5V 400V 50Hz V V 50/60Hz. 96V-58V 575V 60Hz. 58V-6V L L L T T T T9 T8 T V 50/60Hz. Ø T6 T5 T4 L L L T T T T9 T8 T7 T6 T5 T V 50/60 Hz. Ø V 50 Hz. Ø V W U V W U 575V 60 Hz. Ø T T T

12 . Air Line Connections: Note: Locking latches require 90 psi. min. to 0 psi. max. air pressure. IMPORTANT A filter/regulator/lubricator must be installed on air supply at lift. Failure to do so will void the warranty. A. Lift should be at full height and lowered on latches. B. Connect air valve to Reducing Tee, Fig.. Cut provided /4 air line tubing with sharp blade to length as required. Tubing must be cut square with no burrs. Note: To assemble air line tubing into fitting, use firm, manual pressure to push tubing into fitting until it bottoms, Fig.. If removal of the air line tubing from the fitting is ever required, hold Push Sleeve in (against fitting) and, at the same time, pull out on tubing. E. Run /4 air line from the Tee of the runway grommet through the guide tubes on the inside wall of the runway to the Tee in the front yoke, Fig. 5. F. Run /4 air line from the Tee at the runway grommet to the Tee in the rear yoke. G. Run /8" air line from existing facility main air supply to the FRL. Run /8" air line from FRL to reducing tee, Fig.. H. Check for air leaks by depressing air valve. Repair as required. I. Use provided cable ties to tie air line to hydraulic hose between power unit and lift. J. Actuate air valve and check latch operation on all four corners. The locking latches should pull in beyond yoke ends to clear the latch bars located in all four columns, Fig. 4. C. Use button collar to secure the air valve to the air valve bracket, Fig.. D. Attach enclosed NP80 decal (ACTUATE TO RELEASE LATCH- ES) below button on air valve bracket, Fig. 7. Run /4 air line from air valve to the slot in the fixed runway. Cut airline and attach a Tee, Fig. 5. Air Line Tubing Push Sleeve AIR LINE INTO FITTING Fig. To Main Air Supply From FRL to Reducing Tee Reducing Tee Lifts without internal air line get plug FRL /8" Air Line /8" Air Line To Slot in runway for Air Locks To Runway for Rolling Jacks (Only for use on runways with internal air Air Valve Bracket /4" Air Line PAY ATTENTION TO NUMBERING SEQUENCE ON AIR VALVE Air Valve Fig.

13 K. Use cable ties provided to tie /8 air supply to electrical supply conduit at approximately 0 intervals. 4. Bleeding: Lift must be fully lowered before changing or adding fluid. Raise and lower lift six times. The cylinder is self-bleeding. After bleeding system, fluid level in power unit reservoir may be down. Add more ATF, if necessary, following instructions in Step. To pressure test, run lift to full rise and run motor for approximately 5 seconds. Stop and check all fittings and hose connections. Tighten or reseal if required. Lower lift. If fill/breather, Fig. 9, is lost or broken, order replacement. Yoke Cylinder Locking Latch Bar Note: Some test fluid may be spilled from the cylinder breather vent during bleeding of the system. 5. Assemble ramp/chocks to rear of runways using hinge pins and cotter pins, Fig Final Adjustments: A. Load vehicle such as an RV onto lift. B. Raise lift to full height. You will hear the locking latch click through all latch slots. C. Lower lift onto topmost latch position. D. Check latch clearance.. Starting with the right front column: use a straight edge to mark the yoke height on the column, Fig. 7.. Raise lift to full height again. Mark second position. If gap between two marks is less than ", adjust locking latch bar to reach clearance of ". a. Adjust locking latch bar adjusting nut so that the bottom of the topmost latch bar slot is at least " below locking latch, Fig. 8. After adjustment, tighten jam nut underneath column top plate, Fig. 8. b. If entire " clearance cannot be attained by adjusting the locking latch bar, adjust the cable stud. Loosen cable jam nut, Fig. 7, and turn adjusting nut to raise the locking latch " above bottom of latch bar slot. Tighten cable jam nut.. Lower lift and remove vehicle. E. Raise the lift to full height. Listen and watchs the locking latches click in place. Synchronize the other three columns with the right front column by adjusting their cables so all four latches click at same time. Tighten jam nuts. Fig. 4 Locking Latch LATCHES SHOULD CLEAR LATCH BARS

14 /4 Air Line To Lift Tee Cylinder Assembly Tee Tee /4 Air Line in Runway Left Runway RUNWAY AIR LINE Fig. 5 CAUTION When making changes to adjustment nuts on cable end or latch bar stud always leave at least two threads showing between nut and end. Note: Latches may not click in at the same time when vehicle is being raised. They should be close. Be sure all four corners have passed the locking latch bar slot before lowering lift on locking latches. Note: All bolts and nuts mentioned in this booklet are grade 5 unless otherwise stated. IMPORTANT Cotter pins are usually good for one time use only. Replace any cotter pin, if removed, with a new cotter pin. Cotter Pin Should Be On Outside Of Runway 7. Rubber Stop: Install () rubber stops in /" holes 8" from front of runways. Attach using /4" Bolt, and Flanged Nut, Fig. 9. Attach () additional rubber stops " from front of runway on 000/006/00/06 Series lifts. Attach 67-/" from front of runway for 00/007/0/07 Series lifts. Cable Jam Nut and Adjusting Nut Washer Locking Latch Bar Adjustment Stud Locking Latch Bar Adjustment Nut Mark position of yoke at full rise Straight edge ruler clearance Fig. 6 Ramp/Chock Runway RAMP CHOCK ATTACHMENT Mark position of yoke at topmost latch position MARK THE YOKE HEIGHT Fig. 7 4

15 8. Rolling Jack: A. Adjust rolling jack telescopic ends until roller rests on runway track rail. Make sure wheels are on tracks and center rolling jack between runway on end sections. B. Place jack on runway track at front and rear with air pump facing ends of runway, Fig. 8. C. Recommended operating pressure 00-0 psi. D. Attach rubber stop see Fig Internal Air Line: (if installed) This lift is equipped with an internal airline that provides air to both rolling jacks and extra access point for air driven tools (Quick Disconnect Coupler), Fig. 9. All internal air lines are factory assembled. Flange Nut Rubber Stop Runway Male Fitting Air Pump Track 4" Bolt Holding Rubber Stop Fig. 8 Attach rubber bridge stops to 5/6" holes 4" off center of runways. Insert /4" bolt up through runway and stop. Attach /4" flange nut to top of stop. Recoil Hose Air Inlet APPROACH Rear Rolling Jack Tubing Assembly Hose Bracket Rear Rolling Jack Front Rolling Jack Hose Bracket Quick Disconnect Coupler Front Rolling Jack Tubing Assembly Fig. 9 5

16 0. Rear Recoil Hose Installation: A. Attach retainer brackets for the rear recoil hose with /8"- 6NC x /4" Lg. hex cap screw, flat washer, lock washer and nut, Fig. 0. B. Insert retainer cable through coils of recoil hose, Fig. 0. Run a /4"-0NC hex nut down onto each end of retainer cable. Insert each end of cable into retainer brackets. Secure each cable end with another /4"-0NC hex nut. Tighten jam nuts, Fig. 0. C. Connect one end of provided rear recoil hose to bulkhead T-fitting at midpoint of runway. Connect other end of recoil hose to coupling welded on rolling jack, Fig. and. D. Connect elbow end of rolling jack tubing assembly to air pump and male end to the coupling, Fig. and.. Front Recoil Hose Installation: A. Insert retainer cable through coils of recoil hose, Fig. 0. Connect one end of recoil hose to coupling welded on rolling jack, Fig. and 4. B. Connect other end of front recoil hose to bulkhead T-fitting in center of runway. C. Connect elbow end of rolling jack tubing assembly to air pump, and male end to the coupling, Fig. and 4. Note: Cut air line tubing with sharp blade to length as required. Tubing must be cut square with no burrs. To assemble air line tubing into fitting, use firm, manual pressure to push tubing into fitting until it bottoms, (see below). If removal of the air line tubing from the fitting is ever required, hold Push Sleeve in (against fitting) and, at the same time, pull out on tubing. /4" x 0NC Hex Nut Airline Retainer Cable/Rod Recoil Hose /8" Nut Retainer Bracket /8"-6NC x /4" Lg. Hex Cap Screw & Flat Washer /8" Lockwasher Fig. 0 6

17 To Runway Bulkhead Fitting Rear Recoil Hose Coupling Rear Rolling Jack Air Line Tubing Male End Push Sleeve Fig. Fig. Rear Rolling Jack Tubing Assembly Elbow End REAR ROLLING JACK TO RECOIL AIR HOSE Air Tubing Coupling Recoil Hose Fitting Male End Spring COUPLING ON ROLLING JACK Fig. Front Rolling Jack Tubing Assembly Elbow End Male End To Runway Bulkhead Fitting Coupling Front Rolling Jack Front Recoil Hose FRONT ROLLING JACK TO RECOIL AIR HOSE Fig. 4 7

18 This page intentionally left blank

19 This page intentionally left blank

20 Forward Lift 996 Industrial Drive Madison, IN Phone: Fax: Forward Lift; Forward Lift is a brand of Vehicle Service Group, A Dover Company. All rights reserved Unless otherwise indicated. Forward Lift, Vehicle Service Group, Dover, and all other trademarks are property of Dover Corporation and its affilates.

21 CR8 Operation & Maintenance Manual Capacity 8,000 lbs. (9,000 lbs. per axle) Four Post Surface Mounted Lift Maximum Wheelbases: 94" & 0" Minimum Wheelbase: 6" Table of Contents Safety Instructions... Owner/Employer Responsibilities... Operating Instructions...4 Maintenance Instructions...6 Trouble Shooting...7 Lift Lockout/Tagout Procedure...8 Operating Conditions...9 Approved Accessories...9 Installer: Please return this booklet to literature package and give to lift owner/operator. August 0 by Vehicle Service Group. OM6008 All rights reserved. CO7980. Rev. - 8//0

22 SAFETY INSTRUCTIONS Never allow unauthorized or untrained persons to operate lift or rolling jacks. Shop Policy should prohibit customers or non-authorized persons from being in shop area while lift is in use. Thoroughly train all employees in the use and care of lift and rolling jacks. Be Sure no one is standing in front or behind lift while vehicle is being driven onto or backed off the lift. DO NOT allow rear tires or portion of vehicle to interfere with ramp/chocks. Be Sure front wheel stops are in raised position before driving vehicle onto lift. Never allow front wheels to strike the front wheel stops. DO NOT permit employees or customers on lift when it is either being raised or lowered. Always stand clear of lift when raising or lowering and observe "Pinch Points" Warning. Never overload lift: capacity of lift is 8,000 lbs. (9000 lbs. per axle). CAPACITY SHOULD NOT BE EXCEEDED. Always engage parking brake and use the rear wheel chocks to keep the vehicle from rolling freely on the runways. Always lower lift on locks before working on vehicle. Keep area around lift clean of tools, debris, grease, and oil. Always keep runways clean. Replace all caution, warning, or safety related decals on the lift when unable to read or missing. For Rolling Jack Safety Instructions see Rolling Jack Installation, Operation and Maintenance Instructions in the rolling jack box.

23 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/SM07-, ALI Lifting it Right safety manual; ALI/ST-05 ALI Safety Tips card; ANSI/ALI ALOIM-008, 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 establish procedures to periodically inspect the lift in accordance with the lift manufacturer s instructions or ANSI/ALI ALOIM-008, 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-008, 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-008, American National Standard for Automotive Lifts-Safety Requirements for Operation, Inspection and Maintenance. Shall display the lift manufacturer s operating instructions; ALI/SM 07-, ALI Lifting it Right safety manual; ALI/ST-05 ALI Safety Tips card; ANSI/ALI ALOIM-008, 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. Shall provide necessary lockout/tagout means for energy sources per ANSI Z (R008), 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.

24 OPERATING INSTRUCTIONS WARNING To avoid personal injury and/or property damage, permit only trained personnel to operate lift. After reviewing these instructions, get familiar with lift controls by running the lift through a few cycles before loading vehicle on lift. Observe and heed SAFETY and WARNING labels on the lift.. Loading: Lift must be fully lowered and no one in service bay while the vehicle is brought on lift.. If lift is equipped with rolling jacks, jacks must be fully lowered and the rear jack pushed toward center of lift to provide under car clearance.. Drive vehicle onto lift and stop when vehicle's front wheels are centered on turning radius gauges. On lifts not used for wheel alignment, stop vehicle when it is centered on runways. At all times, be sure rear wheels are forward of the ramp/chocks and the ramp/chocks will clear tires when the lift is raised, Fig.. Driver and passengers must exit before raising. 4. Place triangular wheel chocks on each side of one of the rear tires, Fig.. 5. To Raise Lift: Push the "RAISE" button on the power unit. Release button at desired height, Fig.. 6. For Rolling Jack Operating Instructions see Rolling Jack Installation, Operation and Maintenance Instructions in the rolling jack shipping carton. 7. Before Lowering Lift: Be sure no one is in the lift area and that all tools, tool trays, etc. have been removed from under the lift and vehicle. WARNING The runways, ramps and connecting yokes at each end of lift are designed to rest on the floor when fully lowered. Observe pinch point warning decals, Fig.. 8. Repeat Step. 9. To Lower Lift: If lift has been resting on the locking latches, lift must be raised high enough for all four latches to clear the latch plate slots inside the columns. 0. Actuate the latch release air button on power unit to disengage all four locking latches, Fig.. Hold button in until lift has fully lowered. Note: If button on air valve is released, the latches will automatically reset to the engaged position.. Push the lowering handle on the power unit to lower lift, Fig.. Lowering speed can be controlled by the force applied to the lowering handle.. Observe lift and vehicle to be sure lift is level while being lowered. If not, STOP repeat Steps 0 through.. Fully lower lift, remove the triangular wheel chocks and check to be sure area is clear before removing vehicle from lift, Fig.. 4. If your lift is not operating properly, DO NOT use until adjustments or repairs have been made by qualified lift service personnel. WARNING Keep hands clear of yoke ends while the lift is being raised or lowered, Fig.. Triangular Wheel Stops Rear Wheel Chock Column Cable Fig. RAISE Button Latch Release Air Button CAUTION Yoke End Sheave LOWERING Handle Keep hands clear of yoke ends during lift operation. Fig. 4 Fig.

25 MAINTENANCE INSTRUCTIONS WARNING If you are not completely familiar with automotive lift maintenance procedures, STOP. Contact factory for instructions. To Avoid Personal Injury, permit only qualified lift service personnel to perform maintenance on this equipment. Periodically: Check all column, lift/runway attaching bolts for tightness. Always raise lift when cleaning floor area with solvents and/or cleaning compounds. Daily: Check cables and sheaves for wear. There is a portion of the right side cables that cannot be viewed except thru the access hole in the middle of the yokes. Observe for frayed cable strands. Wipe cables with a rag to detect hard to see small broken cable strands. Replace cables showing any broken strands. Replace worn parts as required with genuine Rotary parts. Daily: Inspect front wheel stops and ramp/chocks for damage or excessive wear. Replace as required with genuine Rotary parts. Daily: Check locking latch operation and reset. Adjust per instructions or repair if required with genuine Rotary parts. Wear Areas Of Typical Locking Latch/Slack Cable Device Dog Check For Wear Along This Surface WARNING If slack cable arm is bent, Fig., replace immediately. Weekly: Clean foreign debris from rear wheel slip plates and turning radius gauges by blowing out with shop air. DO NOT GREASE BALL BEARINGS. Weekly: Check torque on the column anchor bolts per specifications. Monthly: Check equalizer cable tension. Adjust per lift installation instructions. If there are no more threads available for adjustment, replace the cable. Do not use washers to stand off the nut to use previously used threads. Monthly: Check level of runway. Adjust per instructions. Monthly: Lubricate Guide on each turning radius with a dry film lubricant. Clean and lubricate more often as conditions warrant. Semi-Annually: Check fluid level of lift power unit and refill if required. If fluid is required, inspect all fittings, hoses and seals. Repair as required. Semi-Annually: Lubricate front wheel stop and ramp/ chock hinge pins. IMPORTANT Cable adjustment should be checked by a Rotary Authorized Installer after the first 50 loaded lift cycles and after 00 loaded lift cycles. For Rolling Jack Maintenance Instructions see Rolling Jack Installation, Operation and Maintenance Instructions in the rolling jack box. Cable Slack Cable Arm Roller Air Cylinder Replace if Bent Sheave 5 Clevis and Jam Nut Slack Cable Latch Locking Latch

26 AIR CYLINDER REPLACEMENT INSTRUCTIONS. Lower lift onto blocks so that the latches are free to rotate.. Remove air line from cylinder elbow.. Remove bolt that holds the cylinder to the yoke. 4. Rotate the latch and cylinder assembly until the clevis pin is above the yoke end. 5. Remove the hair pin cotter from the clevis pin. 6. Remove clevis pin. 7. Remove cylinder, then do items -6 in reverse. 6

27 Trouble Motor does not run. Motor runs but will not raise lift. Motor runs raises unloaded lift bu will not raise vehicle. Lift slowly settles down. Slow lifting speed or fluid blowing out filler breather cap. Lift going up unlevel. Lift stops short of full rise or chatters. TROUBLE SHOOTING Cause. Check fuse or circuit breaker.. Check for correct voltage to motor.. Inspect all wiring connections. 4. Switch burned out. 5. Motor windings burned out.. Open lowering valve.. Pump sucking air.. Suction stub off pump. 4. Low fluid level.. Motor running on low voltage.. Trash in lowering valve.. Improper relief valve adjustment. 4. Overloading lift.. Trash in check valve seat.. Trash in lowering valve seat.. External fluid leaks.. Air mixed with fluid.. Air mixed with fluid suction.. Fluid return tube loose.. Cables out of adjustment.. Lift installed on unlevel floor. Low on fluid. Remedy. Replace blown fuse or reset circuit breaker.. Supply correct voltage to motor.. Repair and insulate all connections. 4. Replace switch. 5. Replace motor.. Repair or replace lowering valve.. Tighten all suction line fittings.. Replace suction stub. 4. Fill tank with Dexron III ATF.. Supply correct voltage to motor.. Clean lowering valve.. Replace relief valve cartridge. 4. Check vehicle weight and/or balance vehicle weight on lifts.. Clean check valve.. Clean lowering valve.. Repair external leaks.. Change hydraulic fluid to Dexron III ATF.. Tighten all suction line fittings.. Reinstall fluid return tube.. Adjust slack out of cable.. Shim lift to level columns (Not to exceed / " per column). Note: Shim thickness of " is possible by using optional shim kit #FC59. Contact your authorized Rotary Parts Distributor for ordering information. Check fluid level and bleed cylinder If fluid is required inspect all fittings, hoses, and seals. Repair as required. Clean power unit pickup stub filter. Anchors will not stay tight.. Holes drilled oversize.. Concrete floor thickness or holding strength not sufficient.. Use a fast setting cement to pour into oversize holes and reset anchors -or- relocate lift using a new bit to drill holes.. Break out old concrete and repour new pads for lift. Lift will not lower.. Insufficient air supply to lift.. Latches out of adjustment.. Check air pressure. Air supply to lift should be between: min. 00 p.s.i. and max. 0 p.s.i. Check all lines and fittings for leaks or crimps. Repair or replace as required.. Check latches 7

28 LIFT LOCKOUT/TAGOUT PROCEDURE Purpose This procedure establishes the minimum requirements for the lockout of energy that could cause injury to personnel by the operation of lifts in need of repair or being serviced. All employees shall comply with this procedure. Responsibility The responsibility for assuring that this procedure is followed is binding upon all employees and service personnel from outside service companies (i.e., Authorized Rotary Installers, contactors, etc.). All employees shall be instructed in the safety significance of the lockout procedure by the facility owner/manager. Each new or transferred employee along with visiting outside service personnel shall be instructed by the owner/manager (or assigned designee) in the purpose and use of the lockout procedure. Preparation Employees authorized to perform lockout shall ensure that the appropriate energy isolating device (i.e., circuit breaker, fuse, disconnect, etc.) is identified for the lift being locked out. Other such devices for other equipment may be located in close proximity of the appropriate energy isolating device. If the identity of the device is in question, see the shop supervisor for resolution. Assure that proper authorization is received prior to performing the lockout procedure. Sequence of Lockout Procedure ) Notify all affected employees that a lockout is being performed and the reason for it. ) Unload the subject lift. Shut it down and assure the disconnect switch is OFF if one is provided on the lift. ) The authorized lockout person operates the main energy isolation device removing power to the subject lift. If this is a lockable device, the authorized lockout person places the assigned padlock on the device to prevent its unintentional reactivation. An appropriate tag is applied stating the person s name, at least x 6 in size, an easily noticeably color, and states not to operate device or remove tag. If this device is a non-lockable circuit breaker or fuse, replace with a dummy device and tag it appropriately as mentioned above. 4) Attempt to operate lift to assure the lockout is working. Be sure to return any switches to the OFF position. 5) The equipment is now locked out and ready for the required maintenance or service. Restoring Equipment to Service ) Assure the work on the lift is complete and the area is clear of tools, vehicles, and personnel. ) At this point, the authorized person can remove the lock (or dummy circuit breaker or fuse) & tag and activate the energy isolating device so that the lift may again be placed into operation. Rules for Using Lockout Procedure Use the Lockout Procedure whenever the lift is being repaired or serviced, waiting for repair when current operation could cause possible injury to personnel, or for any other situation when unintentional operation could injure personnel. No attempt shall be made to operate the lift when the energy isolating device is locked out. 8

29 OPERATING CONDITIONS LIFT IS NOT INTENDED FOR OUTDOOR USE AND HAS AN OPERATING AMBIENT TEMPERATURE RANGE OF 4º-04ºF (5º-40ºC). APPROVED ACCESSORIES Item Capacity Part Number Air/Electric Utility Box FA95 Air/Electric Utility Box Without FRL FA96 Rolling Jack 9,000 lbs. RJ9000 9

30 NOTES 0

31 NOTES

32 Forward Lift 996 Industrial Drive Madison, IN Phone: Fax: Forward Lift; Forward Lift is a brand of Vehicle Service Group, A Dover Company. All rights reserved Unless otherwise indicated. Forward Lift, Vehicle Service Group, Dover, and all other trademarks are property of Dover Corporation and its affilates.

33 CR8 Parts Breakdown Capacity 8,000 lbs. (9,000 lbs. per axle) Four Post Surface Mounted Lift Maximum Wheelbases: 94" & 0" Minimum Wheelbase: 6" August 0 by Vehicle Service Group. PB6008 All rights reserved. CO7980. Rev. - 8//0

34

35 Item Description... Part Number Right Hand Runway Weld 000 & 006 Series... S06 00 & 007 Series... S04 00 & 06 Series... S06 0 & 07 Series... S04 Left Hand (Fixed) Runway Assembly (Includes cylinder, cables and sheaves) 000 & 006 Series... S0 00 & 007 Series... S0 00 & 06 Series... S0 0 & 07 Series... S0 /"- NC x -/", Flg. Whiz Lock HHCS (High Strength) Wheel Stop... FC Ramp Chock Assembly Standard Length... FC580-4 Extended Length... S /" x " Lg. Cotter Pin /8" Pushnut Fastener... FC Hinge Pin... FC Ramp Chock... FC Ramp Chock Slide... FC4- #0-4 PHMS x /4" Lg #0-4 Hex Nut /4"-0NC Hex Nut Wheel Chock... FC7 5 Hydraulic Cylinder... FC Cable Pull Bar... FC /4"-0NC X -/4" HHCS /4"-0NC NUT /8" Anchor Bolt... FC58 9 -/"-6NC Hex Nut /"-6NC Hex Jam Nut Latch Bar... FC584- Front Yoke Ass'y (Including Latches)... FC5786 Standard Column... FC584 4 Rear Yoke Ass'y (Including Latches)... FC Power Unit Column... FC585 6 Power Unit Phase... *P006/P006 Phase... *P049/P460 7 "-8NC Hex Nut "-8NC Hex Jam Nut " Flat Washer /4"-0NC Hex Jam Nut Front Yoke Weld... FC5786- Rear Yoke Weld... FC5787- Retainer Bar... FC Glide... FC560-5 Elbow... P Control Box... FA766 Capacitor Box... FA747- Capacitor Box Cover Plate... FA766- Drum Switch... FA764 Drum Switch Lever... FA764- M5 x 45 PHMS, Plated /6"-8NC x -/" HHCS Full Thread /6"-8NC Flanged Locknut /6" Pushnut... FC509 * Two different power units were used. Please verify your exact model number before ordering replacement parts.

36 YOKE END DETAIL ITEM DESCRIPTION PART NO. ITEM DESCRIPTION PART NO. 5/6"-8NC HHCS x /4" Lg Latch FC58-9 Sheave Pin Assembly FC54-5 Spacer FC58-8 Sheave FC /8" Snap Ring TRUARC # Yoke Sheave Spacer FC Slack Cable Roller FC55-5 Slider FC Slack Cable Latch FC /4" 0NC HHTS x /" Lg Extension Spring FC5-5 7 Rubber Guard FC /4"-0NC x -/" HHCS /4" Plain Washer Air Cylinder FC Cotter Pin, /8" X /4" 40 Elbow FC Latch Shaft FC54-7 Clevis FC Washer FC /4" - 8NF Hex Nut 406 /4" Hairpin Cotter Pin (.05" dia. wire) /8" NPT PLUG FC Clevis Pin FA0-6 4 /4"-0NC Hex Nylon Insert Locknut 4064

37 To Air Valve ITEM NO. AIRLINE DETAIL DESCRIPTION Airline Tubing (50' roll) Union Tee PART NO. FA0- FC55-46 To FRL Air Input Air Output To Latches OPTIONAL MOUNTING ON SIDE 5 0 AIR LOCK RELEASE VALVE DETAIL ITEM NO. DESCRIPTION PART NO #8 SAE Flat Washer /8" Plug Union Tee /4" Tubing Nameplate Control Ass'y. Swivel Elbow Filter / Muffler /8" tubing (40ft roll) Air Lock Handle Control Bracket #8-NC x -/" PHMS #8-NC Nylon Locknut FA0-6 FA4- FC0- NP80 T4007 T40074 T40075 FA0-5 T409 FA CABLES ITEM DESCRIPTION PART NO. Left Front Cable FC580- Right Front Cable FC580- Left Rear Cable 000/006/00/06 Series FC580-00/007/0/07 Series FC586-4 Right Rear Cable 000/006/00/06 Series FC /007/0/07 Series FC /8" x -/4" Roll Pin Cable Pull Bar FC

38 ITEM NO. 4 SHEAVE DETAIL DESCRIPTION Sheave Bearing 5/6"-8NC x /" lg. HHCS Runway Pin Assembly PART NO. FC580-0 FC FC Left Hand Runway Hydraulic Cylinder View Beneath Runway HYDRAULIC HOSE DETAIL ITEM DESCRIPTION PART NO. Cylinder Pin FC580-7 /6" x " lg. Cotter Pin 45 Runway Grommet S006 4 Hydraulic Hose 000/006/00/06 Series FC /007/0/07 Series FC Elbow FJ74 6

39 ITEM NO. FRL DETAIL DESCRIPTION #0-4 x /4" Hex SHCS PART NO. AP #0-4 Nylon Lock Nut Adapter Bracket Elbow Filter/Regulator/Lubricator 408 S0674 FC47-7 S INTERNAL AIRLINE PARTS ITEM NO DESCRIPTION Recoil Hose Male Elbow Female Bulkhead Runway Tubing Tubing Male Run Tee Male Branch Tee PART NO. FC47-4 FC47-7 FC47- FC47-6 FC5- FC47- FC47-5 Retainer Cable Detail ITEM NO DESCRIPTION /4" x 0NC Hex Nut Airline Retainer Cable (8"/06") Airline Retainer Cable (58") Recoil Hose /8" Nut /8" Lockwasher Retainer Bracket /8"-6NC x /4" Lg. HHCS /8" Flat Washer PART NO S0078 XS FC

40 Forward Lift 996 Industrial Drive Madison, IN Phone: Fax: Forward Lift; Forward Lift is a brand of Vehicle Service Group, A Dover Company. All rights reserved Unless otherwise indicated. Forward Lift, Vehicle Service Group, Dover, and all other trademarks are property of Dover Corporation and its affilates.