HP415, HP615 Four Post/Six Post Mobile Column Lift HP415 Capacity 60,000lbs. HP615 Capacity 90,000lbs. 15,000 lbs. per column 15,000 lbs. per column IMPORTANT This lift is wired and adjusted to operate at 460 volts. If facility voltage is different, refer to Set-Up Instructions. © November 2007 by Rotary Lift. All rights reserved. CO6989.4 IN10009 Rev. J 11/1/2007 I N S T A L L A T I O N S A F E T Y O P E R A T I O N M A I N T E N A N C E Index Set-Up Instructions ............................................ 3 Safety Instructions ............................................. 4 Owner/Employer Responsibilities ..................... 4 Operating Instructions ........................................ 5 Maintenance Instructions ................................... 7 Safety Warning Labels for Movable Lifts .......... 8 Trouble Shooting................................................. 8 Lift Lockout/Tagout Procedure ......................... 10 Operating Conditons ......................................... 10 Wiring Diagram ................................................ 11 Master Column (can be positioned at any convenient corner). Fig. 1 Master Column (can be positioned at any location). 2 Set-Up Instructions Follow these instructions to ensure a satisfactory set-up and operation of the lift. A. After unloading, remove and discard bracing blocks and protective wrapping. B. To move the column, screw M20 Bolt clockwise on wheel jack to raise column. Ground clearance is determined by how far the bolt is turned. If column is loaded, it will automatically be lowered by spring compression. C. Check oil level in oil tanks on each column: Remove cover panel off power unit. Remove oil gage and check oil level. If necessary, fill with ISO 32 (SAE 10) hydraulic oil. • After set-up and inspection of the lift, please return this booklet to the literature package and give to lift owner/operator. • Literature package should be kept attached to controls for easy access. 1. Unloading: Rotary’s Mobile Lift System units are shipped in the vertical position. The units should be lifted using a fork truck under the wooden cross ties. Wire transformer located in master control panel according to required voltage. Unit is pre-wired for 480V. Install appropriate voltage decal. V2 W1 U2 V1 W2 U1 M20 Bolt L1 V2 W1 L2 U2 V1 L3 W2 U1 208, 220-240V 60Hz 3Ø L1 L2 L3 440-480V 60Hz 3Ø 230V (H4) 28V 230V (H2) COM (H3) Electrical Requirements Lift Model HP415 HP415 HP415 HP615 HP615 HP615 24V Electrical Service Current Required 200V (H5) 208V, 3Ph. , 60Hz. 230V, 3Ph. , 60Hz. 460V, 3Ph. , 60Hz. 208V, 3Ph. , 60Hz. 230V, 3Ph. , 60Hz. 460V, 3Ph. , 60Hz. 24 Amp. 24 Amp. 14 Amp. 36 Amp. 36 Amp. 21 Amp. COM (H1) 3 COM INPUT: LINE: 200V H1-H5 CONNECT: H1-H3 & H2-H4 220V H1-H2 H1-H3 & H2-H4 480V H1-H4 H2-H3 Set-Up Instructions 3. Electrical Connections: A. Connect interconnect cable from column to column, in a circuit around the vehicle, see Fig. 1. Lock each receptacle with the connector locks provided. Plug power cord into the appropriate receptacle. B. Before operating the lift, it should be checked for functionality first, without a load. When operating the lift, please read and understand the detailed operating instructions on Page 6. C. After reviewing the operating instructions, proceed with set up and testing of lift. D. If lift does not begin to raise after 10 seconds of depressing the “UP” button, you need to stop and check motor rotation. Clockwise rotation of motor is required. Rotation of the motor can be changed. Disconnect the power cord from the receptacle. Remove the connector on the supply cord and rewire the plug by changing any two phases. NOTE: Do Not alter the wiring within the Lift System or control panel. E. Once the proper motor rotation is achieved, the lift is ready to operate. IMPORTANT The phase rotation may be different if the lift is operated at a different location. 2. Electrical Supply: IMPORTANT This lift is wired and adjusted to operate at 460 volts. If this does not match your facilites voltage, STOP; change line fuses in each column (10amp for 208-230V), motor wiring and transformer jumpers as shown. Incorrect voltage will cause internal, irreparable electrical damage. IMPORTANT Use a separate circuit for each lift. Size circuit breaker, receptable and plug based on the chart below. If connected to a circuit protected by fuses, use time-delay fuses. Wiring shall comply with all local electrical codes. IMPORTANT If facilities voltage is not listed, STOP; consult the factory. Other voltages may cause internal, irreparable electrical damage. Select the appropriate receptacle and install in a suitable wall-mounted box near the lift’s operation area. Install plug on lift’s power cord. 4 SAFETY INSTRUCTIONS • Daily inspect your lift. Never operate if it malfunctions or if it has broken or damaged parts. Use only qualified lift service personnel and genuine Rotary parts to make repairs. • Thoroughly train all employees in use and care of lift, using manufacturer’s instructions and “Lifting It Right” and “Safety Instructions” supplied with the lift. • Never allow unauthorized or untrained persons to position vehicle/lift or operate lift. • Prohibit unauthorized persons from being in shop area while lift is in use. • Do Not permit anyone on lift or inside vehicle when it is either being raised or lowered. • Always keep area around lift free of tools, debris, grease and oil. • Never Overload lift. Capacity of lift is shown on nameplate affixed to the lift. • Do Not hit or run over lift forks or base. This could damage lift or vehicle. Before driving vehicle into area, position lift units to provide unobstructed entrance onto lift area. • Load vehicle on lift carefully. Position lift forks to fully contact the vehicle tires. Release parking break on vehicle. Raise lift until tires clear the floor. Check lift forks for secure contact with vehicle tires. Raise lift to desired working height. • Do Not block open or override self-closing lift controls, they are designed to return to the Off or Neutral position when released. • Remain clear of lift and vehicle when lowering. • Avoid excessive rocking of vehicle while on lift. • Clear area if vehicle is in danger of falling. • Remove tool trays, stands, etc. before lowering lift. • Position lift units to provide an unobstructed exit before removing vehicle from lift area. • Do Not perform any maintenance on the control panels until the power has been shut off to the lift. • Do Not operate equipment with a damaged cord or if the equipment has been dropped or damaged - until it has been examined by a qualified service technician. 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/SM 93-1, ALI Lifting it Right safety manual; ALI/ST-90 ALI Safety Tips card; ANSI/ALI ALOIM-2000, 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-2000, 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-2000, 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-2000, American National Standard for Automotive Lifts-Safety Requirements for Operation, Inspection and Maintenance. • Shall display the lift manufacturer’s operating instructions; ALI/SM 93-1, ALI Lifting it Right safety manual; ALI/ST90 ALI Safety Tips card; ANSI/ALI ALOIM-2000, 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 Z244.1-1982 (R1993), 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. 5 Operating Instructions Pressing any up or down button raises or lowers all columns. All is only possible with the Green Lamp (common cycle) illuminated. All columns must be in the same control cycle. Adjust each column in single mode so that all Yellow or all Blue lamps are illuminated. F. UP: Raises the Lift. See Single/All. G. Down: Lowers the Lift. See Single/All. 2. Slave Column Control Panel Description: WARNING Permit only trained personnel to operate lift. After reviewing these instructions, get familiar with the 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. 1. Master Control Panel Description: EMERGENCY STOP EMERGENCY STOP YELLOW LAMP BLUE LAMP YELLOW LAMP BLUE LAMP GREEN LAMP POWER LAMP UP ALL LAMP UP ALL LAMP DOWN DOWN DISCONNECT SWITCH 18 PIN CONNECTOR START 18 PIN CONNECTOR SINGLE/ALL SELECTOR A. Power On (red lamp): 1. When on, the “master panel” is plugged into electrical power. 2. When off, indicates lift is not ready for operation. WARNING Disconnect electrical power before working on lift’s control panel. When the “Power On” light is out, the panel still could be electrically charged. B. Emergency Stop: 1. Pressing any emergency stop button makes all columns inoperable. 2. Pull to reset. Push “START” to resume Operation. WARNING Pressing the “Emergency Stop” button does not turn off all electrical power to control panel. If any work must be done inside the control panel, disconnect the control panel from the power supply. C. Start Button: When pressed, Power Lamp illuminates and lift is ready for operation. D. Single Mode: Allows only the column at which you are standing to operate. Pressing the up or down button at any column, raises or lowers only that column. E. All Mode: Allows every column to operate. All the buttons on the Slave Column control Panel are similar to the Master Control Panel. See the Master Control Panel for operation and function of the Single, All, Up, Down and Emergency Stop. 3. The service area must be clear of all personnel before the vehicle is positioned. WARNING Locate lift on level concrete surface. For surface, preferably concrete of quality minimum 3000 psi required. 4. Spotting: Position the vehicle in the location where it is to be lifted. Note: See Fig. 1 for the general arrangement of each lift column. 5. Loading: A. Position one lift unit at each of the lifting wheels of the vehicle, so that the forks of the tire cradle are under the wheel, and the unit is as far under the wheel as possible. Vehicle Tire 6 Tire Cradle B. The front face of the cradle should touch the Observe pinch point WARNING decals. outside of the wheel. D. Reset the parking brake. Before attempting to lift any vehicle, be E. Move all lift units away from the vehicle to WARNING sure that: provide an unobstructed exit before removing the A. Vehicle individual axle weight does not exceed vehicle and/or lifts from lifting area. IMPORTANT Do Not drive vehicle over interconnect two lift columns combined capacity. B. Lift forks are in secure contact with vehicle tires. cables. C. Adequate overhead clearance is provided to raise 11.Emergency (no power) Lowering: vehicle to desired height. • During lowering of lifts, pay attention that vehicle D. Parking brake is released on vehicle. does not move into an inclined position. E. Adjustable forks must be equally spaced off cen- • Lower columns equally. terline of lift carriage. • Remove tool trays, safety stands, etc. from area. 6. Electrical Hook-up: • Remain clear of lift and vehicle when lowering. A. Connect interconnect cable from column to column, in a circuit around the vehicle, see Fig. 1. B. Plug the control panel into the power supply outlet. Note: This outlet must be wired with the correct polarity. Clockwise rotation of motor is required. 7. To Raise Lift: A. Turn disconnect switch at master control panel to on. B. Press Start push button. The Green (common cycle) lamp will illuminate. C. Select mode of operation with the Single/All selector switch located on the master panel. D. Select “All”. All is only possible with the Green (common cycle) Lamp illuminated. E. Press any “Up” button. Raise the vehicle until vehicle tires clear the floor. Check Fork Contact: Stop and check tire cradle for secure contact with tires. F. Continue to raise the vehicle to desired height. A. Emergency lowering due to power failure, (See Notice: While cycling the lift, you will observe the drawing of hydraulic power unit). columns stopping and starting at various stages B. Remove cover panel of hydraulic power units. of travel. This is a normal characteristic of the lift C. Keep mechanical locks open, see Fig. 2. If remaining level during the cycle. safety lock is locked, slightly lift carriage until G. Do Not go under vehicle unless all tires are in lock is free. secure contact with tire cradle. D. Loosen lock nut of emergency lowering screw, H. Lower lift and repeat vehicle and/or lift spotting (2.11) at valve housing of power unit. and loading procedure if required. E. Carefully turn emergency lowering screw coun8. While Using Lift: Avoid excessive rocking of ter clockwise about 1/2 turn. Carriage will begin vehicle while on the lift. moving. 9. Before Lowering Lift: Remove tool trays, safety F. Lower each carriage a small increment at a time stands, etc. from area. keeping the vehicle level. 10.To Lower Lift: G. Turning the emergency lowering screw clockA. Select “All”. All is only possible with the Green wise, the downward movement will stop. (common cycle) Lamp illuminated. H. After lowering is finished, close and tighten all B. Press any “Down” button and lower lift. Observe emergency lowering screws. Tighten lock nut. that all columns are lowering and vehicle reI. If lift is not operating properly, Do Not use until mains level. adjusted or repairs are made by qualified lift C. Remain clear of lift and vehicle when lowering. 7 service personnel. Maintenance Instructions • Monthly: Check Cords: Check the condition of the power supply cord, the interconnect cords from each lift, and the cords to each limit switch on each lift. Replace worn or broken cords as required. • Monthly: Check Cylinder: Check cylinder rod for nicks or scratches. Check for leaks around all hydraulic fittings. • Every 2 Years: Change Fluid: 1. Columns must be completly lowered. 2. Remove cover panel from power unit. 3. Remove drain plug at the bottom of each tank and catch oil until tank is empty. 4. Replace all drain plugs and refill with 8 1/2 quarts of hydraulic oil meeting ISO 32 (SAE 10) specifications, into each tank. 5. Check oil level in oil tanks on each column, add if necessary. 6. Dispose of waste oil according to legal regulations. WARNING If you are not completely familiar with automotive lift maintenance procedures Stop: contact factory for instructions. To Avoid Personal Injury: Permit only qualified personnel to perform maintenance on this equipment. • Never: Overload lift. See capacity nameplate. • Never: Lock control buttons in activated position. • Never: Direct water stream at control box or cable connections. • Never: Place sharp objects on interconnect cables or drive vehicle over cables. • Always: Keep locking latch free. • Always: Keep all bolts tight. • Always: Keep lift and lift area clean. • Monthly: Check Emergency Stop: Push the “Emergency Stop” button. None of the columns should operate. • Monthly: Lubrication 1. Lower lift, check oil level in oil tanks on each column: Remove cover panel of power unit. Remove oil gage and check oil level. If necessary, fill with ISO 32 (SAE10) hydraulic oil. 2. Grease carriage rollers, front axles and flat spring of locking brake on wheel jack, with grade # 2 wheel bearing grease, or approved equal. 3. Carriage must be raised until hole on column aligns with grease fittings of Carriage roller. Access hole for greasing upper carriage rollers (2) places. Access hole in back of column, for mechanical release of locks. Control Panel Box Cover Panel Access hole for greasing lower carriage rollers (2) places. Grease flat spring. Grease axles. Fig. 2 8 TROUBLE SHOOTING • Locating Inoperative Column for Repair: If columns are loaded, select single operation and attempt lowering. If not successful, refer to page 6, section 11. If lift is lowered, proceed with step (1) below. 1. First, check master column by plugging master column control cable into its own pin connector. 2. Test all functions in Single and All modes. If column is operative, continue with step 3. If not, skip to step 5. 3. Check master column and one slave column: if slave column operates correctly, proceed checking the remainder of the columns. Circuit of interconnect must be closed. Test all functions. 4. After locating the inoperative column as described above, proceed by checking the following. WARNING Use extreme caution when working inside the control panels. Some of the components are electrically “ALIVE” whenever the panel is plugged into the power source. Slave Control Board 8. Remove roller switch cover located above control box. Check continuity of the two switches. Slightly pull at cable and see if switches move freely. Rollers on switches should move freely. If necessary, clean and lubricate with a light machine oil. 9. Check cam that switches ride on. Look for any bent or twisted cams. All cams should be spaced uniform and straight. Roller Switch CAUTION Master Control Board CAUTION WARNING WARNING Fuse Lift to be used by trained operator only. Fuse Authorized personnel only in lift area. © CAUTION Clear area if vehicle is in danger of falling. Disconnect Switch © Remain clear of lift when raising or lowering vehicle. CAUTION © WARNING WARNING When moving lift, be careful to avoid tipping. Master Control Panel 5. Check fuses at users site and the control panels. 6. Check power cable and interconnect cables. 7. Check control system of slave column: Remove printed circuit control card out of the inoperative column and plug-in control card of fully working column for exchange. If problem still exists check ouside of control box. © Check for overhead obstructions before raising vehicle. © The messages and pictographs shown are generic in nature and are meant to generally represent hazards common to all automotive lifts regardless of specific style. 1992 by ALI,Be Inc. sure intended lifts Locate lift are moving together on firm, level surface, evenly. preferably concrete. © © WARNING WARNING Slave Control Board All lifting forks must properly engage vehicle tires © or supports. WARNING Do not drive over or pinch electrical cables. © The messages and pictographs shown are generic in nature and are meant to generally represent hazards common to all automotive lifts regardless of specific style. Funding for the development and validation of these labels was provided by the Automotive Lift Institute, PO Box 33116 Indialantic, FL. 32903-3116. They are protected by copyright. Set of labels may be obtained from ALI or its member companies. © 1992 by ALI, Inc. 9 Keep feet clear of lift while lowering. They are protected by copyright. Set of labels may be obtained from ALI or its member companies. © © ALI/WL400w ALI/WL400c SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS Read operating and safety manuals before using lift. Proper maintenance and inspection is necessary © for safe operation. © SAFETY INSTRUCTIONS The messages and pictographs shown are generic in nature and are meant to generally represent hazards common to all automotive lifts regardless of specific style. Funding for the development and validation of these labels was provided by the Automotive Lift Institute, PO Box 33116 Indialantic, FL. 32903-3116. Slave Control Panel © Funding for the development and validation of these labels was provided by the Automotive Lift Institute, PO Box 33116 Indialantic, FL. 32903-3116. They are protected by copyright. Set of labels may be obtained from ALI or its member companies. Do not operate a damaged lift. © © 1992 by ALI, Inc. ALI/WL400s TROUBLE SHOOTING Trouble Remedy Cause Emergency-Stop button locked. Plug and socket connections not plugged-in correctly. No line voltage or low supply voltage. Unlock emergency-Stop button. Plug in all cable connections correctly, circuit must be closed. Check power supply at user’s site for tripped circuit breaker. Interconnect cable is damaged. Replace cable. After pressing START-button, START lamp lights up, but no green lamp, lifting/lowering only possible with operation SINGLE. Lifting columns are not in common control cycle. Re-establish common control-cycle with operation SINGLE until lamps are all blue or all yellow and green light illuminates. After pressing START-button, START lamp illuminates, green lamp illuminates, motor runs when pressing UP, but no lifting/lowering is possible. Motor rotation incorrect. Change phase rotation,(clockwise rotation necessary). page 3, section 3. Lift UP until locking mechanical lock is disengaged. When moving DOWN, carriage can not be lowered to bottom position. Carriage clings to tire. After pressing START-button, START lamp does not illuminate, lifting equipment can not be started. Carriage has lowered slightly, mechanical lock engaged. Free tire from carriage. Use suitable wheel adapters for smaller tires. If all columns are fully lowered and Check adjustment of roller switchout of cycle. (No green light). es and cam. Adjust switch assembly until all columns register same cycle and green light illuminates. Lifting equipment will not restart after completing one complete cycle. Required to wait for a short period of time, before raising again. Low supply voltage. Mulitiple equipment running on same circuit. Motor protection switch tripped. Check and correct voltage supply. Isolate equipment to a single dedicated circuit. Let motor cool. When moving DOWN, carraige continues to drift down onto locks after control button is released. Contaminated lowering check valve. Replace. Lift does not operate after observing the above mentioned points. Inoperative electric controls. Faulty motor. Repairs by qualified lift service personnel. 10 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 1) Notify all affected employees that a lockout is being performed and the reason for it. 2) Unload the subject lift. Shut it down and assure the disconnect switch is “OFF” if one is provided on the lift. 3) 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 3” 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 1) Assure the work on the lift is complete and the area is clear of tools, vehicles, and personnel. 2) 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. OPERATING CONDITIONS Lift is not intended for outdoor use and has an operating ambient temperature range of 41º-104ºF (5º-40ºC). 11 MASTER COLUMN WIRING DIAGRAM 12 SLAVE COLUMN WIRING DIAGRAM 13 NOTES 14 NOTES 15 Installer: Please return this booklet to literature package, and give to lift owner/operator. Thank You Trained Operators and Regular Maintenance Ensures Satisfactory Performance of Your Rotary Lift. Contact Your Nearest Authorized Rotary Parts Distributor for Genuine Rotary Replacement Parts. See Literature Package for Parts Breakdown.