INSTALLATION and OPERATION

MANUAL

WHEEL ENGAGING MOBILE UNIT 66,000 lbs (4 COLUMN) 99,000 lbs (6 COLUMN)

READ AND SAVE THIS INSTRUCTION MANUAL JAN. 2003 6-2816

MC-4066 / MC-6099

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Menu MENU……………………………………………………………………………………………………………………..1

SAFETY AND OPERATING INSTRUCTIONS………………………………………………………………………3

TRANSPORTATION AND STORAGE………………………………………………………………………………..3

UNPACKING PROCEDURE…………………………………………………………………………………………...3

1. SPECIFICATIONS………………………………………………………………………………………………...4

2. INSTALLATION REQUIREMENTS……………………………………………………………………………4

3. SAFETY DEVICES………………………………………………………………………………………………..4

3.1. MECHANICAL SAFETY ......................................................................................................................................... 4 3.2. FLOW CONTROL VALVE. ...................................................................................................................................... 4 3.3. COLUMN SYNCHRONIZATION .............................................................................................................................. 5

4. CONTROL DEVICES……………………………………………………………………………………………..6

4.1. MAIN CONTROL UNIT........................................................................................................................................... 6 4.2. SLAVE-CONTROL UNITS ....................................................................................................................................... 7

5. OPERATION………………………………………………………………………………………………………8

5.1. GENERAL INFORMATION ..................................................................................................................................... 8 5.2. SAFETY SYSTEMS INSTALLED IN LOGIC-SYSTEM................................................................................................. 8 5.3. SYNCHRONIZATION ............................................................................................................................................. 9 5.4. POSITIONING OF VEHICLE .................................................................................................................................. 10 5.5. LIFTING.............................................................................................................................................................. 11 5.6. ELECTRICAL CONNECTION BETWEEN THE COLUMNS ........................................................................................ 12

6. TROUBLE SHOOTING……………………………………………………………………………………………………………..13

7. MAINTENANCE AND LUBRICATION……………………………………………………………………….15

7.1. CHECK THE FOLLOWING POINTS AND PARTS EVERY 3 MONTHS........................................................................ 15 7.2. CHECK THE FOLLOWING POINTS AND PARTS ONCE A YEAR............................................................................... 15

8. MANUAL LIFT DESCENT……………………………………………………………………………………..16

ENCLS.

1. Lift dimensions 2. Hydraulic schematic 3. Electrical schematic

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Safety and Operating Instructions

1. Read and follow all instructions. 2. Inspect lift daily. Do not operate if it malfunctions or problems have been encountered. 3. Never attempt to overload the lift. The manufacturer’s rated capacity is shown on the

identification label on each column. Do not override the operating controls or the warranty will be void.

4. Only trained and authorized personnel should operate the lift. Do not allow customers or bystanders to operate the lift or be in the lift area.

5. When moving the lift, be careful to avoid tipping. 6. Always check for overhead obstructions before raising a vehicle. 7. Position the columns so that the lifting forks properly engage vehicle tires or supports. 8. Always locate the lift on firm, level surfaces. 9. When operating the lift, be sure that the columns are moving together evenly. 10. Do not drive over or pinch electrical cables. 11. Note that the removal or installation of some vehicle parts may cause a critical load shift in

the center of gravity and may cause the vehicle to become unstable. Refer to the vehicle manufacturer’s service manual for recommended procedures.

12. Always keep the lift area free of obstruction and debris. Grease and oil spills should always be cleaned up immediately.

13. Never raise vehicle with passengers inside. 14. Before lowering check area for any obstructions. 15. Using the lift at temperatures below 0°C is not recommended

Transportation and Storage • The lift will be delivered in wooden cases, with two columns in each case. Each case (LxWxH)

measures 4’ x 4’ x 10’ (3000mm x 1200mm x 1200 mm). Use a forklift to transport/move the cases.

• If the lifts are to be stored, be sure that the storage area is dry with adequate ventilation. • Before opening the cases, please check that there is no damage from shipping (Transport

damages must be marked in way bill when receiving the goods).

Unpacking Procedure

1. Remove the protective plastic wrapping. 2. Remove the top of the wooden crate. 3. Remove the end and side portions of the crate 4. NOTE: There is a wood block and metal frame fixed to the carriage fork/base (one side

only). DO NOT REMOVE THIS FRAME UNTIL THE COLUMN HAS BEEN FULLY RAISED.

5. There is a metal hook installed at the top of each column for lifting the towers off the base of the crate. It is recommended that a forklift or overhead crane be used for raising the columns.

6. Once the column has been fully raised, the metal frame can be removed and replaced with the roller wheel assembly located in the hardware kit.

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1. Specifications

Capacity per Column: 16,500 lbs. 7,500 kg Maximum Lifting Height: 71” 1800 mm Column Height (Carriage Lowered): 103” 2610 mm Column Height (Carriage Lowered): 146” 3700 mm Overall Column Width: 42.6” 1080 mm Overall Column Depth: 39.2” 995 mm Height of Lowered Wheel Forks: 5.5” 140 mm Minimum Wheel Diameter: 35.5” 900 mm Maximum Wheel Diameter: 47” 1200 mm Lift Time: 90 seconds Power Requirements (Standard): 230 Volts AC, 3 Ph., 60Hz. Current Draw: 35A (4 Column) 55A (6 Column) Noise Level: 70 dB Shipping Weight of Each Column: 1,069 lbs. 485 kg

2. Installation Requirements It is the users responsibility to provide a satisfactory area for lift use.

• The floor must be even with a slope no greater than ¼” per foot (2cm/m). • Minimum concrete requirements are 6” (152mm) thick, 4000psi (30MPa). Concrete should

be aged 30 days prior to use. Please consult the architect, contractor or engineer if doubt exists as to the strength and feasibility of the floor to enable proper lift operation.

• 2.5 Gal. (9.5L) of ISO 32 Hydraulic oil is required per column. Remove the cover plate at the rear of the tower to access the power unit.

3. Safety Devices 3.1. Mechanical Safety

Each column is equipped with a mechanical locking device, which prevents the carriage from coming down in a case of an oil leak.

The mechanical safety is always active and is only release when the lift is lowered. When lowering the lift, a solenoid disengages the safety allowing the carriage to lower.

3.2. Flow Control Valve.

A flow control valve is located at the base of each cylinder to control the descent speed of the carriage. In the case of a hydraulic line failure, this valve will control the descent speed of the carriage and will only allow the carriage to lower to the nearest mechanical safety.

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3.3. Column Synchronization

Column synchronization is performed using a logic system that controls the raising and lowering of each of the columns. Each column has a sensor that measures its height, and by comparing the relative height of each column, the logic system works to keep them level. If one column gets ahead or behind the others, adjustments can be made by raising the other columns (controlling the motor on/off) or by lowering the other columns (controlling the descent valve open/closed). For instance, if one carriage gets ahead of the others, the logic system will stop the motor in this column (while leaving the remaining columns unchanged) until the other columns catch up.

During normal operation, the columns operate with a maximum difference in height of 1” to 2” (25mm – 50mm). If the columns get out of synchronization by 4” (e.g. something beneath a carriage blocking its descent) then the logic system will stop the movement of all carriages.

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4. Control Devices

Raising and lowering of the lift can be performed at any of the columns by pressing the UP/DOWN buttons on the back of the column. To raise the lift, press and hold the UP button, to lower the lift, press and hold the DOWN button (releasing the buttons stops the action). In case of emergency, there are emergency-STOP buttons located on the back of each column. Pressing the emergency-STOP button will prevent raising or lowering of the lift from any column until the emergency-STOP has been reset.

4.1. Main Control Unit To select the number of columns to be operated, use selector switch on the master column (number 1)

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

1.10

1.11

1.12

1.13

1.14

Phase control Main switch Emergency-stop Circuit Start Quantity of columns in use: I = each column alone II = a pair of columns III = all columns

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4.2. Slave-Control Units

After selecting the number of columns to be operated, the lift can be operated from the slave-control columns.

Emergency-Stop Push button UP Push button DOWN

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5. Operation 5.1. General Information • Only trained and authorized personnel should operate the lift. Do not allow customers or

bystanders to operate the lift or be in the lift area. • Read and follow all instructions. • Never attempt to overload the lift. The manufacturer’s rated capacity is shown on the

identification label on each column. Do not override the operating controls or the warranty will be void.

• The lift is designed for lifting vehicles, no other type of equipment should be raised using this lift.

• When lifting a vehicle, all doors must be closed. • Before beginning any work under the vehicle, ensure that each column is making full

contact with the floor. If any column is sitting unevenly, lower the vehicle and reposition the lift.

NOTE: AXLE STANDS WITH A MINIMUM CAPACITY OF 16,500lbs (7500kg) MUST BE USED AT EACH COLUMN BEFORE WORKING UNDER A VEHICLE. • Inspect the lift regularly for any signs of wear or damage. Inspect all wear areas, safety

systems and control systems. If there are any signs of wear or damage, or if the lift is not functioning correctly, contact your authorized service representative before using the lift.

• Keep the working area clean.

5.2. Safety Systems Installed in Logic System

When the power is switched on, the logic-system automatically checks the circuit for the lift. If the circuit is not complete, (e.g. one of the slave columns is not connected) – the logic-system will prevent the function of the lift, until the circuit is complete.

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If the circuit is not complete, an LED light, Q0.5 will appear on the PLC.

The Emergency-STOP-circuit is isolated on a separate servo-cable line. If this circuit is broken (e.g. the Emergency-STOP button has been pressed or the cable is damaged), lift operation is stopped immediately and the lift must be reset at column 1. If there is a problem with the function of the Emergency-STOP-circuit, a light at led Q0.4 to be seen, at the output side of the logic-system.

The operation of the columns is also controlled by the logic-system, for example: when operating the lift, if one of the columns is blocked (upwards or downwards), the logic-system will automatically stop the movement of all the columns. To start to the lift again, the columns must be moved in the opposite direction so that the obstacle can be cleared, before continuing in the desired direction.

A photocell sensor will detect when the lift is at full stroke, and the lift will stop automatically. When the lift at full stroke, the logic-system will only allow the lift to be lowered. Similarly, the lift will detect when it is in the fully lowered position, and the logic system will only allow the lift to be raised.

If the movement of the lift stops during the upward or downward movement (for example, the Emergency-STOP button is pressed) – the lift stops and the locking device is switched on automatically.

5.3. Synchronization The synchronization of the columns is controlled using photocell sensors in each column. These sensors monitor the height of each column and the logic system will control the movement of each column so that the height of each column is kept within 1” to 2” (25mm – 50mm). If only 2 columns are being used (QUANTITY OF COLUMNS at pos. 2), only the height between those 2 columns is compared. If one column is moving faster than the

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other, the logic system will stop its movement and wait until the other column is at the same height, before it continues to move again. This functions the same whether the lift is being raised or lowered. If 4 or 6 columns are being used (QUANTITY OF COLUMNS at pos. 3), the logic system compares the height of each column separately and balances the lift accordingly in all loading situations. In pos. 3, the logic-system counts also the difference for each pair of columns (the pos. 2 is here noticed) and this guarantees that the movements to change the balance do take place in length-direction. If there is a failure in the photocell itself, it will no longer send impulses to the logic system and lift operation will be stopped. Operation cannot be resumed until the problem has been corrected. When using the lift for 4 or 6 columns use, there is a safety mechanism built into the logic system, to ensure that the lift is balanced before lifting a second vehicle. After each use, the lift must be fully lowered before it can be raised again.

5.4. Positioning of Vehicle

When using the lift ensure that the floor is level and of sufficient strength. A maximum slope of than ¼” per foot (2cm/m) is permitted. Position the columns and connect the cables as shown in the figure below. All the plugs are marked and can only be connected to the correct column.

Ensure, that the carriage-fork is suitable for the wheels of the vehicle - minimum wheel diameter 35.5” (900mm), maximum wheel diameter 47” (1200mm). If the vehicle has smaller wheels, wheel adapters must be used.

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Push the carriage-fork as far as possible under the wheels and check that the wheel is positioned in the middle of the carriage-fork.

Consult the vehicle manufacturer for any special lifting instructions to be followed when lifting the vehicle from its wheels – please follow these instructions.

When the electrical cables have been connected, the lift is ready for use. At the main control box a light will show that the connections are complete.

5.5. Lifting The lift can be operated in three different modes:

1. Single column operation 2. Two column operation 3. Multiple column operation (4 or 6 columns)

To start the lift, turn the circuit-switch on and push the START-button; a green light will be seen at the circuit-switch. When the green light is on, choose the QUANTITY OF COLUMNS.

To switch operating modes, use the QUANTITY OF COLUMNS switch on the main control unit (column number 1).

NOTE: if the cables for all of the columns are not connected, there will be a system fault and the lift will not operate.

Once the operation mode has been selected at the main control unit, the lift can be raised or lowered at any of the columns by pressing the UP/DOWN buttons on the back of the column. To raise the lift, press and hold the UP button, to lower the lift, press and hold the DOWN button (releasing the buttons stops the action). In case of emergency, there are emergency-STOP buttons located on the back of each column. Pressing the emergency-STOP button will prevent raising or lowering of the lift from any column until the emergency-STOP has been reset. Until the lift has been reset, the load will be held on the hydraulic safeties.

When first lifting the vehicle, choose single column operation and first raise each fork until it makes contact with the wheel at each individual column. Check that all wheels are properly engaged before continuing to raise the vehicle. Once the forks are making contact with each wheel, switch the operating mode to multiple columns and raise the vehicle (from any column). By engaging the forks individually we set the “zero” point from which the logic system compares each columns height. To lower the lift, press the button DOWN, which opens the load holding solenoid valve and releases the mechanical locking device. The Flow control valve controls the descent speed. Once the lift has reached its lowest position, select the single column operation mode and lower each column to the ground, and pull the column away from the vehicle. This procedure will leave the lift in the correct START position for the

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next vehicle (i.e. in multiple column operation, all columns must be fully lowered before raising another vehicle). If one of the carriages is held by the mechanical safety, press the UP button for about 1-2 sec to release the carriage, and then push DOWN button again.

5.6. Electrical Connection Between the Columns

The electric-cables must be assembled as shown below. Each plug has a marking on it, so that assembly is easy and the connections will be correctly made.

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6. Trouble shooting PROBLEM REASON

1.14.1.1.1 TO REPAIR IT The lift does not start. The main switch is switched off.

The circuit –switch is switched off. The START button has not been pressed.

Turn the switch to position ON. Turn the switch to position I Push the START button - the green light should be seen.

One (or more) of the Emergency –STOP buttons has been pressed.

Reset the Emergency–STOP buttons and push the START button - the green light should be seen.

Automatic –fuses (F1 and F2) inside the electric box are not on.

Turn the fuses to position ON.

Electrical supply disturbed. Phases have not been correctly installed.

Light must be visible at Phase control. If not, check the polarity.

AS-1 connection not completed: in logic system is the light on: LED 0,5.

Check the plugs and if these are correctly assembled. Check the servo –cable.

AS-1 power is not available – the green light for AS-1 is not to be seen.

Contact the service representative.

AS-1 Slave (E1) in Electric box 2-6 is defective (no green light seen) or the red light is on.

Contact the service representative.

The Emergency –STOP circuit is defective if the logic shows light in LED Q 0,4

Check if any of the Emergency-STOP buttons have been activated. Check the motor protection switch (if it is activated). Check the plugs and their correct assembly. Check that the servo –cable is not defective.

The fuses for the circuit control (F3 and F4 in main control unit and F9-F10 in control units 2-6) are blown.

Check the fuses.

The lift starts but the movement stops abruptly.

Electrical breakdown or the main fuse has blown.

Check the electrical supply and the fuses.

One of the columns is overloaded. Check the vehicle load is less than the capacity of the lift.

The height difference between the columns is so large, that the safety system stops the movement.

Push the down button for 1-2- sec, and then the up button If the problem occurs again: - Check the function of the photocell sensor (a red light must be seen, when the photocell sees a hole passing by it). If this does not occur, the photocell is defective.

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Try cleaning the photocell (may be dirty) Check that the rail with holes is functioning properly. The rail is not allowed to move sideways more than 0.10” (2.5 mm). Check the motor protection switches. Check that there are no leaks in the hydraulic systems and that the working pressure is normal.

The lift does not come down. Emergency –STOP circuit not

completed. Check the Emergency –STOP push buttons.

Fuses for the circuit blown. Check/change the fuses. Solenoid valve does not work

correctly. See instructions page 19. Solenoid valve (manual descent).

The lift comes downwards, but stops abruptly.

The height difference between the columns is too large and the safety system stops the movement of the carriage.

Push the up button 1-2 sec. Try lowering again.

There is a mechanical device under the lift/vehicle.

Check the working area, remove axle stands, trolleys, etc.

Photocell defect. Check the function of the photocell sensor (a red light must be seen, when the photocell sees a hole passing by it). If this does not occur, the photocell is defective. Try cleaning the photocell (may be dirty)

The rail with holes (the photocell is reading) is not correctly positioned.

Check the position of this rail.

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7. Maintenance and Lubrication

The lift must be inspected and lubricated regularly.

7.1. Check and Inspect Every 3 months

- Check the hydraulical oil level. Re-fill if necessary. - Check for leaks at the hydraulic joints. - Check the condition of the circlip`s and pins holding the bolts and axle’s.

- Check the function of the mechanical locking device and ensure that it is well lubricated.

- Check that the roller bearings and the gliding pieces are lubricated. - Inspect the control units and electric cables.

- Inspect the steel construction of the columns, especially the carriages.

7.2. Check and Inspect Every Year

- Complete examination of the lift as per the lifting machine regulations. - Change the hydraulic oil (all columns). - The manufacturer recommends the following oil types:

Viscosity: 32 sSt (40 C) Viscosity index: 150 Additives: Against foaming, wearing, oxydieren and anticorrosion.

BP Bratran hv 32/shf 32 ESSO STATOIL Hydraway hv 32 GULF – Q8 Q8 haydn 32 MOBIL Mobil 24 dte SHELL Tellus 32 CASTROL Hyspin awh 32. Oil required 2.5 gal (9.5 L) /column.

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8. Manual Lift Descent

During normal descent, the lift has the following electrical devices: the solenoid to release the mechanical locking device and the solenoid valve in the hydraulic unit. In case of a power failure or emergency, the lift can be lowered manually using the following procedure.

NOTE: It is extremely important to take the utmost care when lowering the lift manually.

1. Remove the cover plate over the control unit. The mechanical locking device can

be seen and released manually. 2. Remove the cover plate under the control unit. The solenoid valve can be seen on

the power unit.

3. Remove the nuts (with a 19 mm key) at the top of this valve. Under the nut, there is a screw (1x3 mm screwdriver).

4. Pull the mechanical safety back by hand to the open position (note: the safety

should be in position to move back to locking position, if necessary).

5. Slowly turn the solenoid valve to the OPEN position using your fingers (not the screwdriver), and lower the carriage about 2” to 4” (5cm-10cm), and then close the valve again.

6. Repeat the process of lowering each column by 2” to 4” (5cm-10cm) sequentially

until the lift has come down in a balanced, controlled way.

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