APlusLift HW-10KOH User manual

INSTALLATION & OPERATION
MANUAL
HW-10KOH 2-Post Over Head Car Li t
10,000LB Capacity
SONGA ENTERPRISES INC.
8512 122ND AVE NE UNIT 25, KIRKLAND, WA 98033
Phone [phone] or 206-289-0814 (text)
http //www.apluslift.com [email protected]
1

Important In ormation
READ THIS BEFORE INSTALLING THE LIFT! Improper installation can cause injury or
damage!
Read this installation and operation manual in its entirety before attempting to install
the lift. Manufacturer or Distributor assumes no responsibility for loss or damage of any
kind, expressed or implied, resulting from improper installation or use of this lift. Always
use professional installation companies.
All persons using the equipment must be responsible, qualified, and carefully follow the
operation and safety guidelines contained in this manual.
A level floor is required for proper lift installation and operation.
DO NOT install this lift on any asphalt surface. Recommend on concrete surface a
minimum of 6” thick and 3,500 psi tensile strength with steel or fiber mesh
reinforcement. If you always lift vehicles below 9,000LB, 4” thick concrete will be fine.
DO NOT install this lift over concrete expansion joints or cracks. (Check with your
building architect)
DO NOT install this lift on an upper floor without written authorization from your
building architect. Should only be installed on basement floor.
DO NOT attempt to lift only part of a vehicle. This lift is intended to raise the entire
body of a vehicle only. This will bend the arms and void the warranty.
NEVER lift any persons or vehicles containing persons. This lift is designed to lift
empty vehicles only.
Preparation
Concrete Rotary Hammer Drill with 3/4" Drill Bit
Rubber Hammer
Chalk Line
Sockets and Open Wrench set
Ratchet Driver
Vise grips
Tape Measure
Screwdrivers
Torque wrench
Two 10' to 12' step ladders
4' Level
12" Crescent Wrench
AW32 Non-foaming Hydraulic Fluid (4 gallons)
2

Installation Requirements
Use proper lifting techniques when lifting individual pieces. Use plenty of help when
moving lift pieces. Please wear work gloves to protect your hands.
The lift should be installed on a leveled floor with a slope of less than 3 degrees.
Do not install this lift on asphalt, wood, or any other surface other than described.
Do not install this lift outdoors unless special consideration has been made to protect
the power unit from inclement weather conditions.
Do not install lift in a basement or on any level other than ground level (such as the
second floor) without written authorization from your building engineer or architect.
Concrete surface shall have a minimum of 6" thick and 3,500 psi tensile strength with
steel or fiber mesh reinforcement (If you always lift vehicles below 9,000LB, 4” thick
concrete will be fine). Minimum size of a slab L100" x W216" x H6" 3500 psi.
Alternatively, columns can be installed on two concrete footings. 2 ft x 2 ft with 30"
deep (or 3 ft x 3 ft with 12" deep) and 3500 psi tensile strength with steel or fiber mesh
reinforcement.
Maintain a 6" minimum distance from a slab edge. Do not install this lift over expansion
joints or cracks. Check with your qualified engineer or architect.
Leave spaces on all 4 sides when placing the lift. Recommended at least 2’ distances
on all 4 sides when a vehicle is loaded.
Improper installation can cause damage or injury. Manufacturer will assume no liability
for loss or damage of any kind, expressed or implied, resulting from improper
installation or use this product.
The lift is for lifting vehicles only. It is not designed to lift a person or an equipment with
a person.
Read this installation manual in its entirely before attempting to install this lift.
Use of this lift should follow the operation and safety guidelines set forth in this manual.
3

Anchoring Tips
Check the following diagram for the footprint of columns with anchor bolts positions.
Use a concrete rotary hammer drill with 3/4” drill bit. Do not use excessively worn or
incorrectly sharpened drill bits.
Keep the drill in a perpendicular position when drilling. Let the drill do the work. Do not
apply excessive pressure.
Lift the drill up occasionally and clean residue in the hole.
Drill the holes 1" deeper than the length of the anchor bolts. Drill through the concrete
is recommended (when you move the lift to a new location, you may hammer down the
anchor bolts instead of cutting them off).
For better holding, power blow dust from the hole.
Place a flat washer and hex nut over threaded end of anchor, leaving approximately
1/2" of thread exposed. Carefully tap anchor. Do not damage threads. Tap anchor into
the concrete until nut and flat washer are against base plate. Do not use an impact
wrench to tighten. Tighten the nut two or three turns after the concrete is cured (28 day
minimum cure). If the concrete is very hard, tighten only one or two turns.
4

Asymmetrical Arm Diagram
5

Installation Instructions
Step 1 (Preparation)
Please carefully remove all the parts from the package.
◦Remove any loose cables, hoses, part boxes, hydraulic power unit, etc. if they are
inside the columns or banded to the columns.
◦Remove the power unit box and four swing arms.
◦Remove the bolts holding the two columns together. Remove top and bottom
columns out of the skid and discard the steel rack.
◦Remove two column extensions from two columns.
Compare the parts with the part list (at the end of the manual) and contact us if there
are any parts missing.
Please read the installation requirements and anchoring tips in previous pages for
concrete requirement, layout, and drill holes for anchor bolts. The area where the lift
will be installed should be free of overhead obstructions such as heater, building
support, or electrical lines.
Once a location is determined, use a carpenter’s chalk line to layout a grid for the
column locations
After the post locations are marked, use a chalk to make an outline of the posts on the
floor at each location using the post base plates as a template.
Double check all dimensions and make sure that the layout is perfectly square.
6

Step 2 (Installing Columns)
Bolt each column extension to each column.
Determine the side that power unit column will be located. The power unit column can
be located on either side. Keep in mind this is the column where your main electrical
power supply will be connected. It is recommended to locate the power side with the
passenger side of the vehicle when loaded on the lift in order to save steps during
operation.
Double check measurements and make sure that the base plate of each column is
square and aligned with the chalk line.
Stand up the power unit column (the one a power unit bracket welded on) and position
it inside the chalked lines. The column should face straight toward the other column.
Stand up the other column opposite to the main power unit column inside the chalk
lines.
Using a tape measure, measure from back corner to back corner of the base plate to
assure columns are square to each other. Adjust the columns as needed to obtain the
best fit.
Drill anchor holes with 3/4 inch drill bit into concrete following Anchoring Tips on page
4.
Assemble washers and nuts on the anchors and then tap into each hole with a rubber
hammer until washers rest against the base plate. Do not tighten anchor bolts at this
time.
Use a level to check the level of each column. Place horseshoe shims under the base
plate (near the anchor bolts) as needed. This will prevent bending column bases.
Tighten 10 anchor bolts and recheck for level. Hammer the anchor bolts all the way
down. Tighten anchor bolts using a torque wrench to 125 ft. / lb. DO NOT use an
impact wrench when tightening the anchor bolts!
Manually lift the carriage on each column about waist high. Let carriages down and
allow them to set on safety latch stops. Make sure they are at the same height. Double
check the latches before working under the carriages.
7

Step 3 (Installing Overhead Beam)
Assemble overhead beam by connecting two short beam pieces with the connector.
Bolt two pieces the connector together
Bolt the overhead beam to two columns. Make sure to bolt them together by installing
the bolts from inside the beam to avoid interference with the cables when operating the
lift.
Step 4 (Installing Equalizing Cables)
Take the equalizer cables. Using vise grips and a socket, tighten the cable nut half way
down the threads.
Stand in front of each carriage and find two holes on the top of the carriage.
Take the threaded end (the end without nut) and run it up inside the carriage through
the front hole on the right side of the carriage. See figures below for cable routing. Do
not tighten cables at this time. Just start them on the treads.
8

Step 5 (Installing Power Unit and Routing Hydraulic Hoses)
Mount the power unit onto the main side column with four hex bolts.
Connect two 4 1/4" fittings to both cylinders. Connect T-fitting to the power unit.
Connect short hydraulic hose to the power unit and the cylinder in power unit post.
Connect long hydraulic hose to the power unit and the cylinder in the opposite post.
Run the long hose over the overhead beam.
See figures below for hose layout and routing to the power unit. Do not over tighten the
fittings.
9

Step 6 (Installing Swing Arms)
Locate the 4 swing arms and swing arm pins. Take one of the arms and insert it over
the hole in the carriage torsion tube. Line up the holes and insert the pin. Repeat for
the three other arms.
Step 7 (Electrical Connection to Power Unit)
Warning: the wiring must comply with local code. Find a certi ied
electrician to connect the power unit to a power outlet. Protect each circuit
with a time delay use or circuit breaker.
The car lift uses a 220V single phase power unit. The running amperage is 10A.
Recommend a 30A breaker and a 10-gauge wire.
Yellow/Green is ground wire.
For 220V single split phase with two hot wires, wire blue to Hot 1 and wire brown to
Hot 2.
For 220V power from one hot and one neutral, wire blue to neutral and brown to hot.
See the figure below for the reference.
10

Step 8 (Adjustment)
Cable Adjustment
Place a pair of small or medium vise grips around the shoulder of the long threaded
adjusting bolt on the cable to make any adjustments.
Use a deep socket to adjust the slack out of the cable. Adjust tension to cables
equality.
DO NOT over tighten. Note If one of the cables is tighter than the other, the carriage
will go up uneven. These should be tightened like a Banjo String or Fan Belt.
Carriage Adjustment and Synchronization
One of the most important things to remember is not to tighten down one side more
than the other. The key is to tighten one side a half dozen turns then the opposite side
a half dozen turns. After getting both cables equally tight (YOU SHOULD BE ABLE TO
MOVE THE CABLES ABOUT AN INCH BACK AND FORTH WITH SLIGHT
PRESSURE LIKE A FAN BELT OR A BANJO STRING) raise the lift all the way up by
pressing the UP Button on the power unit. Do not bottom the lift out at the top by
holding down on the switch.
Raise the lift off the latch (lock) by pushing the power button, this will enable you to pull
each release cable ring located at the bottom of both carriages. Pull down on the
lowering valve handle (lever) on the power unit and lower the lift all the way to floor.
Raise the lift again and listen for the clicking of the safety locks in each column.
Determine which side is slower and tighten the adjusting bolt on the opposite side
carriage. Remember to only tighten a few turns at a time until the both locks click at the
same time when raising the lift. Cycle the lift up and down. Repeat the adjustment until
the carriages are within a 1/4” of each other or the clicks are almost at the same time
with each side. When cables are adjusted properly they should be fairly tight.
Sa ety Latch Adjustment
If the safety latch in either column does not operate. Use the following procedure to
adjust it.
◦DO NOT set lift on safety latch for this adjustment. Allow the hydraulic system to
hold the lift during the adjustment. DO NOT put a vehicle on the lift
◦Remove the plastic cover. Raise the lift until you can see the latch through the
access hole on the column.
◦Locate the latch
◦If the latch is not working during descent, loosen the adjustment bolt one full turn.
Test the latch and follow this procedure until the latch operates.
◦If the latch is not working during ascent, tighten the adjustment bolt one full turn.
Test the latch and follow this procedure until the latch operates.
11

Step 9 (Installing Sa ety Bar)
Mount safety bar to the overhead beam
◦Mount switch bracket at the power unit side so that limit switch can be mounted and
connected to the power unit
◦Bolt the safety bar to the overhead beam with the long bolt on the other end.
See the figure below for the reference.
Step 10 (Installing Limit Switch)
Open the power unit panel
12

Remove the wire in the picture
Connect the limit switch wire
to the connector and
start button.
Mount the power unit panel and screw tight
13

Step 10 (Final Setup)
Hydraulic Fluid
Remove the vent plug from the top of reservoir. You are going to fill the tank with fluid.
AW 32 or 46 Hydraulic oil is recommended. We do not recommend the transmission
fluid as it is too thin. The unit will hold approximately 2.64 gallons (10 liters) of fluid.
If the arms go all the way to the top, hydraulic oil will flow to two cylinders. If the arms
go all the way to the bottom, hydraulic oil will flow back to the pump.
Check Assembly
Check all bolts and nuts to make sure they are tight. Do not use an impact gun on
concrete Anchors.
Check all fittings or leaks. If necessary, make sure the arm lock restraints are engaging
properly and smoothly. If not, tap the main lock forward or backward as needed with a
rubber mallet to insure proper engagement on all 4 gears with the arm restraint locks.
Cycle lift up and down to insure carriages are synchronized.
Test & Adjust Li t
With the power properly hooked up and hydraulic oil in the Pump Reservoir, push the
Push Button on the side of the Motor to raise the Carriages off the locks. Release the
Push Button and then pull the Lock Release Cable under each carriage to release the
locks. Run the lift all the way up and down two more times to bleed all the air from the
system.
While running the lift, listen to safeties clicking. Each side should click simultaneously
or with-in a 1/2 second of each other. If they are not clicking together, then adjust the
cables to compensate by tightening the side opposite the one that is clicking last at the
cable bolt at the top of the carriage on the same side.
Remember not to over tighten cables – they should be firm, much like a banjo string or
a fan belt in a car.
Bleed Air rom Cylinders
Place a vehicle on the lift and raise until swivel pads are contact with frame of the
vehicle. Raise the vehicle about 3 feet and then lower the vehicle until the tires touch
the floor. Keep raising and lowering the vehicle a few times and increase the height
each time until the vehicle completely reaches to the top. This procedure pumps all the
air from the system.
Lifting speed will be faster (be normal speed) after air is bled out.
Please check Operation, Sa ety, and Maintenance be ore use.
14

Operation
Only authorized personnel can operate the li t. Please read operating and sa ety
procedures care ully be ore operating the li t.
Maintain and inspect lift in accordance to owner’s manual. Never exceed the capacity.
Do not operate a lift that is damaged or in need of repair.
Allow only authorized personnels in the lift area.
Keep the lift area clear when raising or lowering the lift. NO RIDERS.
Keep hands and feet away from pinch points at all times.
Never override the lift's operating and safety controls.
If a vehicle is suspected of falling, clear area immediately.
Do not rock vehicle while positioned on the lift.
Always use safety jack stands when removing or installing heavy components.
Vehicle Loading
Position vehicle at the center of gravity between the pads. Make sure vehicle is neither
front nor rear heavy.
Place pads at vehicle manufacturer’s recommended pick up points. Make sure the
pads are in proper and safe positions to support the vehicle.
Use caution before lifting pickup trucks, SUV’s and other framed vehicles.
Use truck adapters as needed. Never exceed 9" of pad height.
Raising Li t
Push Up switch to raise lift (make sure arm restraints engage or stop and slightly move
arm to allow gear to mesh) until tires clear floor.
Stop and check for secure contact on adapters and vehicle weight distribution. If
secure raise to desired height.
ALWAYS lower the lift into the nearest lock position by pressing the lower lever to
relieve the hydraulic pressure and let the latch set right in a lock position.
Never work under a lift when the lift is not in a locked position.
Lowering Li t
Clear all obstacles under the lift and ensure only the operator is near the lift area.
Stay clear of lift and raise the lift off the safety locks by 2”.
Pull safety latch releases cable ring one by one on each carriage and press the lower
lever to lower the lift.
Unload the lift by first completely lowering lift and then swinging arms to drive through
position before moving vehicle.
15

Sa ety
NEVER WORK UNDER OR NEAR THIS LIFT WITHOUT THE LOCKS BEING ENGAGED.
THE POWER UNIT IS NOT DESIGNED TO BE A LOADING-HOLDING DEVICE. NOT
USING THE LOCKS WILL RESULT IN A PREMATURE FAILURE TO THE CYLINDERS,
PUMP, AND/OR CABLES AND CAN CAUSE SERIOUS PROPERTY DAMAGE OR
PERSONAL INJURY! FAILURE TO HEED THIS WARNING WILL RESULT IN IMMEDIATE
TERMINATION OF YOUR WARRANTY!
FAILURE TO PERFORM THE DAILY PRE-OPERATIONAL CHECK CAN RESULT IN
EXPENSIVE PROPERTY DAMAGE, LOST PRODUCTION TIME, SERIOUS PERSONAL
INJURY, AND EVEN DEATH. THE SAFETY LATCH SYSTEM MUST BE CHECKED TO BE
WORKING PROPERLY BEFORE THE LIFT IS PUT TO USE.
NOTE IT IS CUSTOMER’S OR USER’S RESPONSIBILITY TO MAINTAIN THE PROPER
TENSION ON THE EQUALIZER CABLES. ASK A QUALIFIED TECHNICIAN TO MAINTAIN
THE CABLE ADJUSTMENT AFTER THE LIFT IS INSTALLED.
IF AT ANY TIME YOU ARE NOT SURE HOW TO SAFELY OPERATE THE LIFT, STOP
USING THE LIFT AND CALL YOUR DISTRIBUTOR FOR ASSISTANCE.
Lubrication. Lubricate all nylon block corners inside each column with heavy duty
bearing grease before the first operation and once every six months. Lubricate chains
every six months.
Anchor Bolts. Check anchor bolts daily in the first week of use. DO NOT use an
impact wrench. After the first week, check them monthly for the first six months.
Tighten the anchor bolts if necessary.
Concrete. Check concrete for stress cracks daily in the first two weeks of use. After
the first two weeks, check it monthly.
Bolts and Nuts. Check all bolts and nuts every six months.
Hydraulic Oil. The hydraulic oil should be changed once a year, along with cleaning
the suction filer.
Sa ety Tips
◦Never allow unauthorized persons to operate lift. Thoroughly train new employees
in the use and care of lift.
◦Be aware that the power unit operates at high pressure.
◦Remove passengers before raising vehicle.
◦Prohibit unauthorized persons from being in shop area while lift is in use.
◦Total lift capacity is 10,000 lbs. @ 2,500 lbs per lifting pad. Do not exceed maximum
weight capacity of lift.
◦Before lifting vehicle, walk around the lift and check for any objects that may
interfere with the operation of lift and safety latches such as tools, air hoses, and
shop equipment.
◦When approaching the lift with a vehicle, make sure to place the center the vehicle
between the columns so that the tires will clear the swing arms easily.
◦Slowly drive the vehicle between the columns. It is recommended to have someone
outside the vehicle guide the driver.
16

◦Always lift vehicle using all four pads.
◦Never use lift to raise one end or side of vehicle.
◦Always raise vehicle about 3” and check stability by rocking vehicle.
◦Prior to lowering vehicle, walk around the lift and check for any objects that might
interfere with the operation of the lift and safety latches; tools, air hoses, shop
equipment.
◦Always lower lift to the lock position before going under vehicle.
◦Never allow anyone to go under the lift when raising or lowering.
Maintenance
The following periodic maintenance schedule is the minimum requirements at the minimum
intervals. Periodic maintenance is to be performed on a daily, weekly, and yearly basis.
WARNING!! OSHA AND ANSI REQUIRE USERS TO INSPECT LIFTING EQUIPMENT AT
THE START OF EVERY SHIFT. THESE AND OTHER PERIODIC INSPECTIONS ARE
USER'S RESPONSIBILITY.
FAILURE TO HEED THIS WARNING CAN RESULT IN PROPERTY DAMAGE, SERIOUS
INJURY, OR DEATH. IF YOU HEAR A NOISE NOT ASSOCIATED WITH NORMAL LIFT
OPERATION OR IF THERE IS ANY INDICATIONS OF IMPENDING LIFT FAILURE, CEASE
OPERATION IMMEDIATELY! INPECT, CORRECT, AND/OR REPLACE PARTS AS NEEDED.
Daily Pre-Operation Check (8-Hours)
1. Check safety lock audibly and visually while in operation
2. Check safety latches for free movement and full engagement with rack.
3. Check hydraulic connections, and hoses for leakage.
4. Check chain connections - bends, cracks-and loose links.
5. Check cable connections- bends, cracks-and looseness.
6. Check for frayed cables in both raised and lowered position.
7. Check snap rings at all rollers and sheaves.
8. Check bolts, nuts, and screws and tighten if needed.
9. Check wiring & switches for damage.
10.Keep base plate free of dirt, grease or any other corrosive substances.
11. Check floor for stress cracks near anchor bolts.
12.Check swing arm restraints.
Weekly Maintenance (every 40-Hours)
1. Check anchor bolts torque to 125 ft/lbs for the 3/4 inch anchor bolts. Do not use an
impact wrench to tighten anchor bolts.
2. Check floor for stress cracks near anchor bolts.
3. Check hydraulic oil level.
4. Check and tighten bolts, nuts, and screws.
5. Check cylinder pulley assembly for free movement or excessive wear on cylinder yoke
or pulley pin.
17

6. Check cable pulley for free movement and excessive wear.
Yearly Maintenance
1. Lubricate chains
2. Grease rub blocks and column surface contacting rub blocks
3. Change the hydraulic fluid. It is an important maintenance procedure to keep hydraulic
fluid clean. No hard fast rules though. Operating temperature, type of service,
contamination levels, filtration, and chemical composition of fluid should be considered.
If operating in dusty environment a shorter interval may be required.
Special Maintenance Tasks (per ormed by a trained maintenance expert only)
Replacement of hydraulic hoses.
Replacement of chains and rollers.
Replacement of cables and sheaves.
Replacement or rebuilding air and hydraulic cylinders as required.
Replacement or rebuilding pumps / motors as required.
Checking of hydraulic cylinder rod and rod end (threads) for deformation or damage.
CAUTION! Relocate or change components may cause problems. Each component in the
system must be compatible. An undersized or restricted line may cause a drop in pressure. All
valve, pump, and hose connections should be sealed and/or capped until prior to use. Air
hoses can be used to clean fittings and other components. However, the air supply must be
filtered and dry to prevent contamination. Most important is cleanliness. Contamination is the
most frequent cause of malfunction or failure of hydraulic equipment.
18

Part List
Item Description Quantity
1 Overhead beam (two beam pieces and one connector) 1
2 M10×30 hex bolts, washers, and nuts (connect overhead beam pieces) 10
3 M10×30 hex bolts washers and nuts (connect overhead beam to columns) 8
4 Safety bar 1
5 Switch bracket for safety bar (mount on power unit side) 1
6 M6×130 bolt for safety bar (mount on the other side) 1
7 Limit switch 1
8 Top columns extension 2
9 Columns (preassembled with cylinders) 2
10 Hex bolts, washers, and nuts (connect column extensions to columns) 16
11 Lift arms 4
12 Arm pins (connect arms to carriage) 4
13 Racks (toe guard) 2
14 Socket bolts (mount the racks to arms) 8
15 Tool box (put on the racks) 2
16 Power unit (220V single phase with manual release handle) 1
17 M8×20 bolts, washers & nuts (mount power unit on the column) 4
18 Hydraulic long hose 30 feet (connect cylinder to T-fitting) 1
19 Hydraulic short hose 3 1/2 feet (connect cylinder to T-fitting) 1
20 Extended fitting 4 1/4 inches (connect two hoses to two cylinders) 2
21 T-fitting (connect power unit to two hoses) 1
22 Truck adapters 4
23 Screw-in pads 4
24 Wire rope equalizer cables with M18 thread-on nuts & washers 2
25 Anchor bolts (3/4" x 6") 10
19