PEAK Manufacturer for Car Lifts
Instruction Manual for PEAK models including: 407-HP Four Post Lift, 407-HP, Four Post Lift, Post Lift, Lift
Peak 407-HP
File Info : application/pdf, 37 Pages, 3.68MB
DocumentDocumentOriginal FOUR-POST LIFT Model: 407-HP CONTENTS Product Features and Specifications ..................................................... 1 Installation Requirement .................................................................... 2 Steps of Installation ........................................................................... 4 Exploded View .................................................................................. 24 Test Run ...........................................................................................32 Operation Instruction .........................................................................33 Maintenance .....................................................................................34 Trouble Shooting ...............................................................................35 Lift Disposal.......................................................................................35 I. PRODUCT FEATURES AND SPECIFICATIONS 4-POST MODEL 407-HP FEATURES · Single cylinder drive and transmission by cable · Single point manual safety release, more convenient and reliable for decent operation. · Four mechanical locking devices, each equipped with both primary and secondly safety locks. · Power-side column can be installed at both side, front or rear. · Non-skid diamond platforms and adjustable safety lock ladders. · Optional kits: Rolling jack, caster kits,oil tray. Fig. 1 MODEL 407-HP SPECIFICATIONS Model Lifting Capacity Lifting Lifting Height Time Overall Length (Inc. Ramps) 407-HP 3200KG 2120mm 35S 5007mm Overall Width Overall Height Width Between Columns Motor 2409mm 2455mm 2167mm 220V: 3.0HP 1 II. INSTALLATION REQUIREMENT A. TOOLS REQUIRED Tape Measure (7.5m) Carpenter's Chalk Hammer Screw Sets Level Bar Pliers English Spanner (12") Lock Wrench Wrench set (12#, 13#, 14#, 15#, 17#, 19#, 24#, 30#) Socket Head Wrench (3#, 5#, 6#, 8#) Fig. 2 2 B. Equipment storage and installation requirements. The equipment should be stored or installed in a shady, normal temperature, ventilated and dry place. C. The equipment should be unload and transfer by forklift. Fig.3 D. SPECIFICATIONS OF CONCRETE (See Fig. 4) Specifications of concrete must be adhered to the specification as following. Failure to do so may result in lift and/or vehicle falling. 1. Concrete must be thickness 100mm minimum and without reinforcing steel bars, and must be dried completely before the installation. 2. Concrete must be in good condition and must be of test strength 3,000psi (210kg/cm²) minimum. 3. Floors must be level and no cracks. Fig. 4 E. POWER SUPPLY The electrical source must be 2.2KW minimum. The source cable size must be 2.5mm² and in good condition of contacting with floor. 3 100mm III. STEPS OF INSTALLATION A. Check the parts before assembly 1. Packaged lift and Hydraulic Power Unit (See Fig. 5). Fig. 5 Oil tray (Optional) 2. Open the outer packing carefully, check the parts according to the shipment list. (See Fig. 6). Parts box Shipment Parts List Power-side platform Cross Beam Fig. 6 Column Cross Beam Offside Platform Drive-in Ramp 3. Take off the drive-in ramps and columns (See Fig.7 ). Fig. 7 4. Loose the screws of the upper package stand, take off the offside platform, take out the parts inside the power-side platform, then remove the package stand. 4 5. Move aside the parts and check the parts according to the shipment parts list(See Fig. 8). 62 Fig.8 6. Open the carton of parts and check the parts according to the parts box list (See Fig. 9). Fig. 9 5 7. Check the parts of the parts bag according to the parts bag list (See Fig. 10). Fig. 10 B. Use a carpenter's chalk line to establish installation layout as per Fig.11. Make sure the size is right and base is flat (see Fig. 11). Note: Reserve space front and behind the installation site. Use a carpenter's chalk line to establish installation layout 2 C A B Fig.11 MODEL 407-HP A 4164mm B 2409mm C 4811mm 6 C. Install cross beams. The cross beam opening towards inside, the power-side column need to be installed close to the rotational safety device. (See Fig.12, Fig.13). The power-side column need to be installed close to the rotational safety device(Has 4-10hole). 3 Fig.12 Fig.13 7 D. Install the Safety Ladders. 1. Take off the pulley safety cover and unscrew a nut of the safety ladders, and then adjust the four lower nuts to be at the same position. Then install the safety ladder (See Fig. 14). Unscrew a nut of the safety ladders Safety cover Insert the safety ladder from up to the bottom between the Limited Pins Take off the cross beam plastic cover Limited Pin Limited Pin Safety ladder Fig.14 Safety Ladder is inserted between Limited Pins of the cross-beam 8 2. Install Safety Ladders (See Fig. 15). 17 This height of four threaded rod of safety ladders should be the same level. 18 Fig. 15 Safety ladder pass through the hole of the top plate, then tighten the two nuts. E. Put the cross beams to the same height and lock at the safety ladder (See Fig. 16). All 4 safety device on the cross beam should lock at the same level of safety ladders. Lifting both cross beams to the same height. Fig. 16 9 Rise the cross beam to the height convenient for install the platform and other parts. Recommend height is about 1m. F. Install power-side platform. 1. Install the power-side platform on the cross beams by a fork lift or manual, offset the cross beams to outside a little until the pulleys of both platforms enter into the cross beams opening (See Fig.17). Aligning holes on the power-side platform and cross beam, then screw up the bolts. Offset the cross beam to outside a little. Illustration for rear pulleys in power-side platform Offset the cross beam to outside a little. Illustration for front pulleys in power-side platform Fig. 17 10 2. Install tire stop plate with bolts and washer on the platform: Tighten the platform on cross beam B with bolts, tighten the tire stop plate on cross beam A with bolt. Note: The bolts for the side with tire stop plate are longer than the side without tire stop plate, pay attention when choosing the bolts (See Fig.18) Car-in direction Cross beam B 24 25 26 27 28 Tighten the platform with hex bolts (M16*35), lock washer, washer Tighten the platform(car-in 5 from this end) with hex bolts (M16*30), lock washer, washer Cross Beam A Fig. 18 11 G. Install offside platform and limit block, then install the bolts for the platform strengthen plate, check the plumbness of columns with level and adjusting with the shims (See Fig. 19). Leveling instrument 29 30 31 Install bolts to strengthen the connection of the 4 platform 34 Position the slide blocks along the bent edges of the columns. Connect the slide blocks to the cross beam with bolts. 10 32 9 33 Fig. 19 Note: DO NOT completely tighten the limit slide blocks. Loosen 1/4 lap after tightening. 12 H. Illustration for cable installation 1. The cables pass through the platform to the columns according to the number of the cables (See Fig. 20). C B A B 36 D C 37 35 A D Cable installation diagram 38 Fig. 20 NO. Cable Length (inc. cable fitting) 1 2 3 4 4595mm 10156mm 5997mm 8726mm When the wire rope is tightened, the step of the wire rope connecting sleeve should be in the hole. 13 2. The cable goes through the cross beam to top plate of columns and be screwed with cable nuts (See Fig. 21). 17A 17B 17C Cable pass through top plate and be screwed with cable nuts, the cable adjustment sleeve (17B) is not installed for the first use, the cable may be stretched after loading, and the cable adjustment sleeve (17B) is adjusted as actually required. 17 Cable goes between the big pulley and tension pulley Fig. 21 14 3. Illustration for platform cables (See Fig. 22). Cable Cable Cable Cable4 Cable Cable Cable Cable2 Cable3 Cable1 Socket bolt M10*90 Cable2 Fig. 22 15 Cable4 I. Install connecting bar for safety device and release handle (See Fig. 23). Cross beam B Car-in from B Cross beam A The rotational safety device Fig. 23 Connecting bar Car-in form A 44 22 23 Connecting bar 45 View A Pass the connecting bar through middle of the rotational safety device of cross beam A/B Rotate and adjust the connecting bar, aligning the connecting holes in the rotational safety device and release handle on cross beam A, then tighten with socket bolts (M8*35) and lock washers. 43 Safety lock rotated Device 42 43A 45B 45 45A View B Rotate and adjust another connecting bar, then aligning the holes in the rotational safety device of cross beam B, then tighten with socket bolts (M8*35) and lock washers. 16 J. Install power unit, articulated casing tube Note: Power unit must be installed the same side as the safety release handle. 1. Install Power unit on the cross beam A, the installation of Connection tube is as Fig.24 Cross beam B Cross beam A 40 Car-in direction 41 40 63 40 47 9 2 47 16 9 10 47 46 42 9 47 Install socket bolt (M8*25) with lock washer to these two holes. (Connect the connecting bar and articulated casing tube) Fig. 24 17 K. Install Hydraulic System 1. For power unit install to the column at the side of cross beam A (See Fig. 25) Note: Oil hoses connected to oil cylinder must be passed above the cable to avoid the oil hose scratched by cable. a b c d Oil return hose is above the cable Cylinder inlet port upward Retainer Oil return hose a cd b 49 48 4 49A 50 55 51 55 49C 52 50 56 The oil hose and oil return hose pass through the protective hose and connect to the power unit Fig. 25 18 55 54 52 53 L. Install Electrical System Connect the power source on the data plate of Motor. Note: 1. For the safety of operators, the power wiring must contact the floor well. 2. Pay attention to the direction of rotations when using 380V, three phase motors. Single phase motor 1. Connecting the two power supply wire (fire wire L and zero wire N) to terminals of AC contactor marked L1, L3 respectively. 2. Connecting the two motor wires to terminals of AC contactor marked T1, T3. 3. Connecting A1 to L3 of AC contactor. 4. Connecting the two wires of the button switch to the terminals of AC contactor marked A2, L1. Wire of power source Powr source Button switch AC contactor Fig. 26 M. Install spring and safety cover of cross beam (See Fig. 27). 57 58 Fig.27 59 60 19 N. Install folding drive-in ramp, jack tray and plastic oil tray (See Fig. 28). According to the below diagram screw up the bolts (M16*30), then install the drive-in ramp. 76 (Optional kit) 72 (Optional kit) 7 Screw the bolts (M16*30) to the side hole of the cross beam 77- 77- Attach the drive-in ramp with the hex bolts Fig. 28 Item 7-1 7-2 7-3 7-4 Part# 1104543020A 1104543021A 1104543021 10209010 Description Folding drive-up ramp Assy. Folding drive-up ramp Assy. Connecting Pin Hair Pin 10 QTY. 2 2 4 8 O.Fold up the blocker after the installation.Fig.29 After the car is parked on the hoist, fold the front half of the board up. Fig.29 20 P. Installation of optional kits. 1. Install caster kits or Rolling jack (See Fig. 30) 74 73 Fig. 30 73-6 73-1 73-2 73-3 73-4 7-5 73-7 73-8 Item 73-1 73-2 73-3 73-4 73-5 73-6 73-7 73-8 Part# 11410042A 10209125 10209039 10209022 10209021 10410035 11410034 10209012 Description Support bracket Hex bolt M10*30 10 Lock washer 10 Washer Hex nut M10 Universal wheel(6'') Connecting pin 19*216 Hair Pin 3.2 QTY. 4 16 16 16 16 4 4 8 21 Q. Install the anchor bolts. 1. Prepare the anchor bolts (See Fig. 31). Washer Lock washer Nut Fig. 31 2. Check the plumbness of columns with leveling instrument and adjusting with the shims. Using the prescribed rotary hammer drill, and drill all the anchor holes and install the anchor bolts. Do not tighten the anchor bolts (See Fig. 32). Note: The tightening torque for the anchor bolt is 150N.m ,Anchor bolts driven into the ground at least 90mm. 61 Drilling Fig. 32 Clearing 90mm Expand 22 IV. EXPLODED VIEW Model 407-HP 1 1 4 72 4 76 72 6 76 6 77 73 73 3 2 2 3 16 16 12 11 12 10 11 9 8 10 9 8 5 5 65 65 49 49B 49A 49 49B 49A 49C Fig. 33 23 EXPLODED VIEW of Power-side platform 19 69 22 21 20 8 23 9 12 5 19 20 67 22A 71 21 20 22A 70 8 68 66 14 23 9 39A 65 64 9 23 42 Fig. 37 Fig. 34 24 PARTS LIST FOR MODEL 407-HP Item Part# Description 1 11410075 Offside Column 2 11410074 Power-side Column 3 1104542001B Cross Beam A 4 1104553001B Offside Platform 5 1104553001A Power-side Platform 6 1104542001B Cross Beam B 7 1104543020C Folding Drive-in ramp 8 10201002 Hex Bolt M8*16 9 10209033 Washer 8 10 10209005 Self locking Nut M8 11 11423004 Cylinder fixed ring 12 1004536000 Cylinder 80*1041 13 1104533013A-01 Cable connecting plate 14 10410012 Hex Nut M24 15 10201005 Split Pin 4*50 16 81513006 Manual power unit 17 10420175A Hex nut M20 17A 10209066 Hex Nut M16 17B 1104541002 Cable adjustment sleeve 17C 1104541001 Cable cushion tube 18 11410073-01 Safety ladder L=2324 19 1104543009A Pulley pin 30*86.5 20 10481005 Wash 30 21 1104543011 Pulley 167*16 22 1004542002 Bronze Bush 36*30.1*15 22A 10620141 Bronze Bush 36*30.1*24 23 10209034 Washer 8 24 10410013 Hex Bolt M16*30 25 10420137 Lock washer 16 26 10420029 Washer 16 27 10410014 Hex Bolt M16*35 28 11410015-1 Tire stop plate 29 10206006 Washer 12 30 10420026 Lock washer 12 31 10410105 Hex Bolt M12*20 32 10410016A Slide block 81*38*38mm 33 10410017 Socket bolt M8*40 10201090 Shim(1mm) 34 10620065 Shim(2mm) 35 1004553003 Cable 8*4595mm 36 1004553004 Cable 8*10156mm 37 1004553002 Cable 8*5997mm 38 1004553001 Cable 8*8726mm 39 85090099 Socket Bolt M10*90 39A 85090332 Socket BoltM10*70 25 407-HP 3 1 1 1 1 1 2 6 44 28 1 1 1 1 1 1 8 8 4 4 4 4 21 2 6 4 22 8 8 8 4 2 8 4 4 16 16 20 20 1 1 1 1 2 1 NOTE Item 40 41 42 43 43A 44 45 45A 45B 46 47 47A 47B 48 49 49A 49C 49C 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 76 Part# 1104552001 11410024 10209032 10217005 10209056 10410025 11410026 11410100 1004554006 10209004 10209003 10209043 10217002 10420166 11420243 11420245 11209119 10201020 1004553005 10420120 1004543008-01 10209060 10420095 1004553006 1004533008 10209145A 1104542012 1004542001 10410146 10209059 114551003 1004543006 1104533013A-01 10640109 1104533017A-01 1104543019 1104543016 1104543017 1104533024 11410040 1040801 96600002 10410039 Description Connecting bar 19*1934.5mm Articulated casing tube Socket bolt M8*25 Plastic ball M10 Self locking Nut M10 Socket bolt M8*35 Safety release handle Extension release handle Handle rope Rubber ring 8*20*3 Hex Bolt M8*25 Hex Bolt M8*20 Hex Nut M8 900 Fitting Straight Fitting for cylinder 1/4JIC(M)*3/8NPT(M) Straight Fitting G3/8(F)*3/8NPT(F) Compensation Valve 90 degree fitting 1/4JIC(M)*3/8NPT(M) Oil hose (1 straight 1 bend)1/4*2318mm Extended straight fitting with nut Oil hose (1 straight 1 bend)1/4*1420mm 900 Fitting for power unit Straight fitting Oil return hose L=5249mm Protective hose 20*1*1400mm Cup head bolt with washer M6*12 Plastic cover for cross beam Spring 14*2.0*50 Spring 14*2.0*75 Anchor bolt 3/4*5-1/2 Parts box 90° installing plate Slider 106*40*29 Piston rod coupling Wash 2535*44*2 Pulley pin 25*77.5 Pulley adjustment sleeve 40*4*9 Pulley adjustment sleeve 40*4*18 Pulley 167*25 Cushion tube 40*4*23 Optional Parts Jack tray Caster kit Rolling Jack J5H Oil tray 407-HP 2 1 6 1 1 4 1 1 1 4 8 4 4 1 1 1 1 1 1 1 1 1 1 1 1 8 4 4 4 16 1 1 1 1 1 2 2 1 4 2 NOTE 1 4 1 4 26 4.1 CYLINDERS EXPLODED VIEW (1004536000) Fig. 35 Item 12-1 12-2 12-3 12-4 12-5 12-6 12-7 12-8 12-9 12-10 Part# 10420059 10420060 11420061 10420062 1004536001A 1104536002 11420065 10420066 10420067 11420068 Description Dust Ring30*38*(56.5) Y- Ring 30*40*8 Head Cap O- Ring 81.5*3.55 Bore Weldment Piston Rod Pin Support Ring 74*80*15*3 Y- Ring OSI 70*80*6 Piston 407-HP 1 1 1 1 1 1 1 1 1 1 Note 27 4.2 CROSS BEAM EXPLODED VIEW (10410003/10410006) Item 3-2 3-4 3-5 3-7 3-8 3-9 3-10 3-11 3-12 3-13 3-14 3-15 3-16 3-17 3-18 3-19 3-20 3-21 3-22 3-23 Fig.36 Part# 10206032 10410099 1104542008-01 1104572003A 1104542011A-01 1104542006-01 1104542007 10209010 10420035 11420174 11420171 11420175 11420172 10206019 10420037 11420038 10420138 10209149 10420045 11420044 Description Snap ring 25 Spring 14*2.5*100 Connecting bar for safety lock Self locking Nut M12 Rotational safety lock device Pulley Pin 30*100 Pulley pin sleeve 40*4*51.5 Snap ring 10 Tension pulley Spacer 18*4*5.5 Pin 19*98 Slack-cable safety lock (Left & Right) Pin Bush 25*3*31 Snap ring 19 Snap ring 16 Pin 16*98 Socket Bolt M6*16 Lock washer 6 Washer 6 Limit block 407-HP 2 2 2 4 2 4 4 4 4 4 12 2/ea. 8 24 16 8 8 8 8 4 Note 28 4.3 Power unit (81513006) exploded view Fig.37 29 Parts list for 220V/50Hz, Single Phase Item Part No. Description Qty 1 81400180 Rubber Pad 2 2 81400250 Starting capacitor 1 3 81400200 Running capacitor 1 4 1061K052 Cup Head Bolt with washer 6 5 81400527 Cover of Motor Terminal Box 2 6 81400363 Motor Connecting Shaft 1 7 80101013 Manifold block 1 8 10209149 Washer 4 9 81400276 Iron plug 1 10 81400259 Red rubber plug 1 11 85090142 Socket bolt 4 12 81400280 Gear pump 1 13 10209034 Washer 2 14 81400295 Socket bolt 2 15 81400365 O ring 1 16 10209152 Ties 1 17 85090167 Magnet 1 18 81400290 Filter 1 19 81400413 Steel Motor 1 20 80101036 Push button 1 21 10420070 Switch button 1 22 41030055 AMGO power unit label 1 23 80101037 Motor terminal box cover 1 24 81400560 Throttle valve 1 25 81400266 Relief valve 1 26 81400284 Inner hex iron plug 1 27 81400452 Hair pin 1 28 81400451 Release valve handle 1 29 10209020 Plastic ball 1 30 81400421 Release valve nut 1 31 81400422 Shim 1 32 81400449 Valve Seat 1 33 81400567 Release Valve 1 34 80203001 Check Valve 1 35 81400375 Oil suction pipe 1 36 81400376 Oil return pipe 1 37 81400364 Clamp 1 38 81400263 Oil tank cap 1 39 81400320 Oil tank 1 30 Illustration of hydraulic valve for power unit Oil return port Oil outlet Release valve Check valve Handle for relief valve Relief valve Throttle valve Fig.38 V. TEST RUN 1. Fill the reservoir with Hydraulic Oil about 6L (Note: In consideration of Power Unit's durabilityplease use Hydraulic Oil 46#). 2. Press the control button, the cables will be strained. Check whether the cables match the pulley. Make sure the cables are not across. 3. Press the release valve handle to lock the cross-beam to the safety ladders, and then adjust the platforms to be level by adjusting the nuts of safety ladders. 4. Adjust the cable fitting hex nuts to make platforms and four safety locks work synchronously. You need to run the lift up and down for several times, meanwhile do the synchronous adjustment till the four safety devices can lock and release at the same time. 5. Adjust the clearance between the column and the plastic slider of cross-beam to about 2mm, do not tighten the bolts of the sliding block, let the sliding block can be turned after installing the bolts 6. After finishing the above adjustment, test running the lift with load. Run the lift with platforms in low position first, make sure the platforms can rise and lower synchronously and the safety device can lock and release synchronously. And then test run the lift to the top completely. If there are anything improper, repeat the above adjustment. 31 Circuit Diagram of Hydraulic System 1. Filter N 2. Gear pump 3.Check valve O 4. Relief Valve T 5. Motor 6. Throttle Valve E 7. Release Valve 8. Cylinder For Four-post lift Fig.39 VI. OPERATION INSTRUCTIONS To lift vehicle 1. Keep clean of environment near the lift. 2. Drive vehicle to the platform and put on the brake. 3. Take off the drive-in ramp, install rear wheel stop plates to the drive-in ramp position. 4. Turn on the power and press the control button, raise the lift to the working position. Note: make sure the vehicle is steady when the lift is raised. 5. Press the release valve handle to lock the lift in the safety position. Make sure the safety device is locked at the same height. To lower vehicle 1. Be sure the clearance of around and under the lift, only leaving operator in lift area. 2. Press the control button, the lift will be raised for 3-5 seconds, then pull down the cable from safety release handle, make sure the safety device released, press the release valve handle by the other hand, then the lift starts being lowered automatically. 3. Drive away the vehicle when the lift is lowered to the lowest position. Take off the rear wheel stop plates and install drive-in ramp, then left the lift. 4. Turn off the power. 32 VII. MAINTENANCE SCHEDULE Monthly: 1. Lubricate cable with lubricant; 2. Check all cable connection, bolts and pins to insure proper mounting; 3. Make a visual inspection of all hydraulic hoses/lines for possible wear or leakage; 4. Lubricate all rollers, safety devices with 90wt. gear oil or equivalent. Every six months: 1. Make a visual inspection of all moving parts for possible wear, interference or damage. 2. Check and adjust as necessary, equalizer tension to insure level lifting. 3. Check columns for plumbness. Oil cylinder maintenance: In order to extend the service life of the oil cylinder, please operate according to the following requirements. 1. Recommend to use N46 anti-wear hydraulic oil. 2. The hydraulic oil of the lifts should be replaced regularly during using. Replace the hydraulic oil 3 months after the first installation, Replace the hydraulic oil once a year afterwards. 3. Make at least one full trip raising and lowering per day. For exhausting the air from the system, which could effectively avoid the corrosion of the cylinder and damage to the seals caused by presence of air or water in the system. 4. Protect the outer surface of the oil cylinder's piston rod from bumping and scratching, and timely clean up the debris on the oil cylinder dust-ring and the piston rod. 33 VIII. TROUBLE SHOOTING TROUBLE CAUSE REMEDY 1. Start Button does not work 1.Replace start button 2.Wiring connections are not in good 2.Repair all wiring connections Motor does condition not run 3. Motor burned out 3.Repair or replace motor 4. AC contactor burned out 4.Replace AC contactor 1.Motor runs in reverse rotation 1.Reverse two power wire Motor runs but the lift is not raised 2. Release valve in damage 3. Gear pump in damage 4.Relief valve or check valve in damage 5.Low oil level 2.Repair or replace 3.Repair or replace 4.Repair or replace 5.Fill tank 1. Release valve out of work Lift does not 2 Relief valve or check valve leakage. stay up 3.Cylinder or fittings leaks Repair or replace 1.Oil line is jammed 2.Motor running on low voltage Lift raises 3. Oil mixed with Air too slow 4.Pump leaks 5.Overload lifting 1.Clean the oil line 2.Check electrical system 3. Fill tank 4. Repair or replace pump 5.Check load Lift cannot lower 1. Safety device are not in activated 2. Release valve damaged 1. Operate again 2. Repair or replace IX. LIFT DISPOSAL: When the car lift cannot meet the requirements for normal use and needs to be dispose d, it should follow local laws and regulations. 34 PEAK CORPORATION No. 3 Luomu Road,Shishan Town,Nanhai District,Foshan(528225),Guangdong,China Tel:86-757-81102815 81102805 Fax: 86-757-81102809 Email:peak@peaklift.cn http://www.peaklift.cn Manual Part No.: 72203502 Revision Date: 2022/12