New Product Release Sales Bulletin Service Bulletin Calibration Procedure Operation Procedure Part / Accessory Service Procedure Release Date: March 2011 Priority Status: As Subject Exists Model(s) Affected: All 12K 4-Post Lifts LR-1032-1 Cylinder Replacement on All 12K 4-Post Lifts GENERAL OVERVIEW: Due to product improvement, we have discontinued the cylinder 41148 which was used on all 12K 4-Post lifts. This cylinder has been replaced with cylinder 40393. In addition to the cylinder replacement, the cable flange will also upgraded in order to accommodate the new cylinder. To ensure all components necessary for replacement are ordered, the kits listed below have been created. PARTS LIST: PART NUMBER DESCRIPTION 01654 12K Premium Replacement Kit (12K Open & Closed Beam) Contents: 40393 (1) Hydraulic Cylinder Assembly 21037 (1) Cable Flange 61454 (2) 1-1/4 Hex Nut Gr.8 60666 (2) 3/8 Hex Bolt x 1-1/4 Lg. Gr.8 60058 (2) 3/8 Lockwasher 60665 (1) Hose Clamp 4-1/2 Dia. 60371 (1) 3/8 JIC-M Plug 61684 (1) Velocity Fuse 60796 (1) Elbow 90 o 3/8 f NPT ¼ M NP 60280 (1) Adapter, 1/8 M NPT x ¼ M JIC 63851 (1) Replacement Instructions (shown below) 01655 12K Epic Replacement Kit Contents: 40393 (1) Hydraulic Cylinder Assembly 21037 (1) Cable Flange 61454 (2) 1-1/4 Hex Nut Gr.8 60666 (2) 3/8 Hex Bolt x 1-1/4 Lg. Gr.8 60058 (2) 3/8 Lockwasher 60034 (2) 3/8 Hex Nut 60665 (1) Hose Clamp 4-1/2 Dia. 60371 (1) 3/8 JIC-M Plug 22821 (1) Hole Template 62436 (1) Flow control 12K ECONO 4P 60280 (1) Adapter, 1/8 M NPT X ¼ M JIC 63852 (1) Replacement Instructions (shown below)
LR-1032-1 Page 2 of 9 March, 2011 KIT 01654-12K 4-POST CYLINDER REPLACEMENT OPEN & CLOSED BEAM The purpose of this kit is to replace the 12K Cylinder and Cable flange on all 12K Open and Closed Beam 4-Post lifts. This kit included the following: (1) Assembly hydraulic cylinder (1) Velocity fuse (1) Elbow 90 degree 3/8 F NPT ¼ M NPT (1) Adapter, 1/8 M NPT X ¼ M JIC (1) Cable Flange (2) 1-1/4 Hex Nut (2) 3/8 Hex Bolt x 1-1/4 Lg (2) 3/8 Lock washer (1) Cable Clamp (1) 3/8 Plastic Plug Refer to the installation and operation manual shipped with the lift, for the full installation procedure. WARNING: Lift should be raised to a height which can be supported by auxiliary stands. The stands must be placed at the front and back of both runways ensuring contact will be with the traverse beams. Lower the lift onto the auxiliary stands. Ensure that lift is properly supported on the axle stands. Removal of Components Remove the cable clamp and unhook all wire ropes. Unscrew and remove the 1 hex nuts on the cylinder rod and remove the cable flange. Disconnect the end of the hydraulic hose attached to the cylinder. Insert the 3/8 plastic plug provided in kit to the end of the hydraulic hose. Unbolt the cylinder from the mount and remove the hydraulic cylinder from the lift Installation of New Components ( fittings elbows and velocity fuse) Install new components 61684 Velocity fuse, 60796 Elbow 90 degree, 60280 Adapter in cylinder where it is shown as shown in Figure 2.. NOTE: Apply teflon tape on the NPT fitting that installs into the cylinder. See figure 2 Figure 1
LR-1032-1 Page 3 of 9 March, 2011 Figure 2 Remove the plastic plug from the end of the hydraulic hose and attach the hose on the new cylinder, do not over tighten. NOTE: The cylinder rod must be extended in order to install the non-threaded end of the cables to the cable flange on the rod. Remove the breather plug at the base of the hydraulic cylinder. Use an air chuck and blow air into the breather hole in the base of the cylinder to extend the rod. As shown in figure 3
LR-1032-1 Page 4 of 9 March, 2011 Install 60280 adapter. As shown in Figure 4 Figure 3 Figure 4 NOTE: As the rod extends oil from the cylinder returns to the powerpack. The release handle on the powerpack needs to be held down (open) to allow oil to return to the powerpack. Continue to extend the rod until the non-threaded ends of the wire ropes are reached. Install the cable flange onto the cylinder rod with the counterbores facing towards the hydraulic cylinder. Install the cables as shown in the, Cable and Routing Diagram in the Installation Manual Install and tighten the hose clamp on the cable flange to secure all the wire ropes. Ensure that the two retaining nuts are positioned as shown. Use two wrenches to lock the retaining nuts against each other.
LR-1032-1 Page 5 of 9 March, 2011 NOTE: The decks will need to be leveled and wire ropes will need to be adjusted. Please refer to Leveling Procedure Cables and leveling procedure safety ladder in the installation manual, for the full procedure.
LR-1032-1 Page 6 of 9 March, 2011 KIT #0-1655: 12K 4-POST CYLINDER REPLACEMENT EPIC Scope: The purpose of this kit is to replace the 12K Cylinder and Cable flange on 12K Epic 4-Post lifts. This kit included the following: (1) Hydraulic Cylinder Assembly (1) Flow control 12K Econo (1) Adapter 1/8 M NPT (1) Cable Flange (2) 1-1/4 Hex Nut (2) 3/8 Hex Bolt x 1-1/4 Lg. (2) 3/8 Lockwasher (1) Cable Clamp (1) 3/8 Plastic Plug (1) Hole template (2) 3/8 Hex Nut (2) SHCS, 3/8-16UNC x 1-1/2 Lg. Not included in kit required for installation: 1-5/8 Hole Saw Lubrication for drilling / sawing Refer to the installation and operation manual shipped with the lift, for the full installation procedure. WARNING: Lift should be raised to a height which can be supported by auxiliary stands. The stands must be placed at the front and back of both runways ensuring contact will be with the traverse beams. Lower the lift onto the auxiliary stands. Ensure that lift is properly supported on the axle stands. Removal of Components Remove the cable clamp and unhook all wire ropes. Unscrew and remove the 1 hex nuts on the cylinder rod and remove the cable flange. Disconnect the end of the hydraulic hose attached to the cylinder. Insert the 3/8 plastic plug provided in kit to the end of the hydraulic hose. Unbolt the cylinder from the mount and remove the hydraulic cylinder from the lift Rework of Cylinder Mount ( If required) NOTE: Newer lifts will already have the correct holes in the cylinder mount to fit the larger cylinder and rotate the fitting to the 45 o position shown in Figure 1. If this is the case, the cylinder mount does not be to be reworked. Bolt the hole template provided in the kit into place on the cylinder mount, using the 3/8 bolts just removed, along with the 3/8 nuts provided in the kit. Follow figure 1 to orient the drilling template.
LR-1032-1 Page 7 of 9 March, 2011 Figure 1 1. Using the 1-5/8 Hole saw and lubrication enlarge the hole in the cylinder mount to the size of the template. Deburr any rough edges and remove the template. 2. Drill 2 13/32 holes on the 45 o 3. Remove the 3/8 bolts and remove the hole template. Installation of New Components 1. Apply Teflon tape to the NPT side of the flow control that installs into the cylinder 2. Connect the flow control to the hydraulic cylinder. 3. Remove the plastic plug from the end of the hydraulic hose and attach to the flow restrictor on the new cylinder. Do not over tighten. NOTE: The cylinder rod must be extended in order to install the non-threaded end of the cables to the cable flange on the rod. 4. Remove the breather plug ( Figure 2) at the base of the hydraulic cylinder. Use an air chuck and blow air into the breather hole in the base of the cylinder to extend the rod.
LR-1032-1 Page 8 of 9 March, 2011 Figure 2 NOTE: As the rod extends oil from the cylinder returns to the powerpack. The release handle on the powerpack needs to be held down (open) to allow oil to return to the powerpack. 5. Continue to extend the rod until the non-threaded ends of the cables are reached. 6. Install the 60280 adaptor ( Figure 3) Figure 3 NOTE: Apply teflon tape on fittings before installing. Figure 4
LR-1032-1 Page 9 of 9 March, 2011 Figure 4 7. Use the new 3/8 bolts attach the cylinder to the runway in the new 45 o holes drilled earlier. 8. Install the cable flange onto the cylinder rod with the counterbores facing towards the hydraulic cylinder. 9. Install the cables as shown in the, Cable and Routing Diagram in the Installation Manual 10. Install and tighten the hose clamp on the cable flange to secure all the cables. Ensure that the two retaining nuts are positioned as shown ( Figure 5). Use two wrenches to lock the retaining nuts against each other. Figure 5 NOTE: The decks will need to be leveled and the cables will need to be adjusted. Please refer to, Leveling Procedure Cables and Leveling procedure safety ladders in the installation manual, for the full procedure.