BLACKHAWK! PLT40 User manual

INSPLTGB
REV: 04/16
Power Pro XL / XXL
PLT40 / PLT55
OPERATING MANUAL
(Original manual)

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2
Index
Page Nr.
I. WARNINGS –SAFETY INSTRUCTIONS 3 - 7
II. INTRODUCTION 8
III. PACKING, TRANSPORT & STORAGE 8
IV. GENERAL DESCRIPTION 9
V. TECHNICAL SPECIFICATIONS 10 - 12
VI. INSTALLATION 13 - 15
VII. PULLING SYSTEM 16 - 18
VIII.OPTIONS 19
IX. MAINTENANCE 20
X. TROUBLESHOOTING 21
XI. HYDRAULIC DIAGRAMS PLT40 / PLT55 22
XII. SPARE PARTS 23 - 34
XIII.MAINTENANCE BOOKLET 35 - 38
XIV.DECLARATION OF CONFORMITY 39

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I) WARNINGS –SAFETY INSTRUCTIONS
The manufacturer hereby refuses to accept any responsibility for injury to persons or damage to equipment or
property if it appears that incorrect handling of the lift has occurred. This instructions manual only describes the
operating and safety aspects which are necessary to the people who are installing the equipment.
In order to understand the terminology used in this manual, the person performing the installation work should
have specific experience in industrial work, service, maintenance and repair activities, and must also be able to
explain the drawings and the descriptions contained in this manual to other people. At the same time, he must be
aware of the general and specific safety regulations which apply in the country where the lift is being installed.
SECURITY
It is important to read this section carefully since it contains important information about the risks which the
operator of the lift will be exposed to if the lift is not used properly. Please find below useful information about how
to avoid dangerous situations.
WARNING
The lift is designed to lift vehicles and hold them in a certain position in a covered working place.
Any other form of use is forbidden.
In short, the lift is not suitable for the following purposes:
-Washing and spraying work
-To apply force
-To be used as a goods lift
The manufacturer hereby refuses to take into account any claim for damages arising in connection with person’s
injury or damage to vehicle or other property due to incorrect and/or unauthorized use of the lift.
During lifting and lowering movements, the operator must be within the work area (1), as shown in figure 1. The
presence of any person in the safety zone (2) is strictly forbidden. The presence of people under the vehicle is
only permitted if the vehicle is in high lifting position.
Figure 1
WARNING
USE THE LIFT ONLY IF ALL THE SAFETY DEVICES ARE WORKING PROPERLY. IF THESE RULES ARE
NOT FOLLOWED, SERIOUS INJURY COULD BE CAUSED TO THE PERSON AS WELL AS IRREPARABLE
DAMAGE TO THE LIFT AND THE VEHICLE ON THE LIFT.

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GENERAL PRECAUTIONS:
-The operator is bound to follow the regulations which apply in the country in which this lift is installed.
In addition, the operator must:
-Always work in the work area as designated in the manual.
-Never remove the protective guards or dismantle or shut down the mechanical, electrical or other types
of safety arrangements.
-Read the safety regulations related to the lift and read the safety information provided in this manual
The following terms have been used in this manual to describe the various types of risk:
DANGER: there is a direct possibility of danger which could lead to serious injury or death.
WARNING: indicates situations and / or actions which are unsafe and could lead to injuries of
various
types except death.
CAUTION: indicates situations and / or actions, which are unsafe and could lead to light injuries to
persons and / or damage to the lift, the vehicle and other properties.
RISK AND PROTECTIVE MEDIA: the risk to which the operator is exposed when the vehicle is in a
raised position, together with the protective media which have been installed, in order to limit the possible
dangers.
RISK OF DAMAGE DUE TO ELECTRICITY: special safety arrangements have been made
on the lift in places where the risks are very high.
DANGER
It is strictly forbidden to use the lift before it is fixed to the ground.
(Risk of tipping over)
Fasten the lift to the ground by the means of the bolts supplied, as indicated in the chapter INSTALLATION
The vehicle must be placed on the lift in such a way that there is a uniform distribution of weight over the
platforms.
To ensure the safety of persons and materials, you must check that:
-The safety zone is kept under observation during the lifting process.

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SAFETY DEVICE
The following safety devices have been installed to prevent overloading and damage.
-A hydraulic protection prevents descending of the lift in case of hose fracture.
-Thermal protection switches the power off in case of overloading.
-Overpressure valve offers protection against damage due to excessive lifting.
-A limit-switch to limit the upward movements
-A mechanical safety rack.
-Bolts for fixing the lift to the ground.
RISK TO PEOPLE
- This paragraph describes the risks to which the operator or any other person near the working area
where the lift is in operation are exposed, if the lift is not used in the appropriate manner.
- Never rest any fittings or other objects against the platform and never place such objects under the
platform when there is a load on it, since this can impede the lowering operations and may cause the
vehicle to fall off the platform. (Figure 2)
-
- Figure 2
- The equipment must only be used by operators who have been adequately trained.
RISK OF USE / MAINTENANCE
BLACKHAWK ® uses material of the highest quality in its lifts. These must be used according to the standard
specified, and maintenance must be carried out regularly.
RISKS INVOLVED IN POSITIONING A VEHICLE
This type of risk may arise if the vehicle is not properly aligned with respect to the platform (figure 3). One can
avoid this by always lifting the vehicle using the car-jack support points, and placing the vehicle as far as possible
in the centre of the platform.
CAUTION
While dismantling heavy parts (for example the motor or shafts), please note that the weight distribution ratios
change.

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Figure 3
RISK FOR THE OPERATOR
This risk arises in cases when the operator is not standing in the correct place by the pump. When the lift with the
vehicle is being lowered, the operator MUST NOT stand below the descending system. It is imperative that the
operator MUST be standing in the operating zone during the lifting and lowering operations.
Figure 4
RISK OF ELECTROCUTION
Never spray water or steam of solvents or paint in the area immediately surrounding the platform and the pump.
(Figure 5)
Figure 5
RISK OF SLIPPING
This risk can be overcome by avoiding the spillage of oil or grease in the area surrounding the lift. Apart from that,
any oil spillage which may occur should be thoroughly removed from the spot. (Figure 6)
Figure 6

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Never enter the vehicle or start the motor when the vehicle is on the lift. (Figure 7)
Figure 7
RISKS DUE TO THE STRAIGHTENING
DANGER
The straightening systems have been designed for the use of important forces. Improper installation or
preparation, unsafe anchoring of the vehicle and its accessories or the use of defect, damaged or overloaded
chains or other equipment can cause damages or personal injury, even death.
CAUTION
You must wear individual protective equipment (safety boots and gloves) during both the
installation and use of the equipment.
- Do not use any other chains than those supplied with this equipment.
Display in your workshop, explain and observe the safety and storage
instructions supplied with the pulling chains.
-Always use the safety cable for pulling with the chains.
-Do not wind chains, cables or straps around sharp parts of the vehicle
or they could be damaged.
-Do not stand in front of or behind the pulling devices while in use.
-Always ensure that the anchoring, pulling accessories and clamps are correctly set up.
-Keep the jaws of the clamps clean to avoid sliding. Replace worn or damaged jaws.
-Always set up the Dozer and lock it to the frame before lifting or performing a pull. Set up the rotation-
locking axis of the arms before pulling.
-Always set up and lock the Dozer to the frame before rotating the Dozer arms to adjust the pulling angle.
Put the arms of the Dozer back in vertical position and lock your Dozer by the means of the axis before
you remove it from the frame.
-Do not exceed the maximum allowed capacity of the pump (300 bar).
-Do not use the hydro-electric pump in places where there is a risk of combustible vapours.
CAUTION
Never let any incompetent or insufficiently trained person use this equipment.
DECALS:
It is your responsibility to keep all warning and safety decals clean and legible at all times. Please contact
BLACKHAWK ® for free replacement decals.

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II) INTRODUCTION
III) PACKING, TRANSPORT AND STORAGE
CAUTION
Any action involving the operation, transportation or unpacking of the equipment must ONLY be performed by
trained personnel with a proper knowledge of the lift and of the contents of this operating manual
LIFTING AND MOVING PACKAGES
The wooden crates must be lifted and moved with the help of a fork lift or a crane.
The chosen equipment must be capable of lifting and moving the equipment safely, keeping in mind the
dimensions of the vehicle, the weight, the centre of gravity, as well as the fragile parts.
WEIGHT OF THE LIFT (PLT40): 1080 Kg
WEIGHT OF THE LIFT (PLT55): 1800 Kg
WEIGHT OF THE PUMP: 40 Kg
WEIGHT OF THE PULLING ARM WITH CLAMPS AND ACCESSORIES: 540 Kg
STORAGE
The packed lift must always be placed in a protected area at a temperature between -10°C and +40°C and must
not be exposed to direct sunlight.
OPENING THE PACKAGES
Make sure the equipment has not been damaged during transport, and whether all the components mentioned in
the packing list are physically present.
WARNING
- This instruction manual has been prepared for professional workshop personnel, used to work with lifts, as well
as for the technicians who are in charge of the lift’s installation and maintenance.
-The straightening system BLACKHAWK ® POWER PRO XL / XXL (PLT40 / PLT55) can be used with the
measuring systems BLACKHAWK ®.
This instruction manual has been prepared to explain to highly-qualified professional workshop personnel the
way this equipment functions, not to explain to amateurs the rudiments of vehicle repair. Therefore it does not
give a list of all the possible damages that can be encountered, nor the equipment needed for a particular
straightening job, nor all the possible combinations of accessories and equipment.
If you have questions relating to the POWER PRO XL / XXL system, please contact BLACKHAWK ®, or its
distributor.
It is strongly recommended to carefully read the safety instructions first.

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IV) GENERAL DESCRIPTION
The electric hydraulic lift PLT40 or PLT55 can be placed on the floor. It has been designed and manufactured for
lifting cars and holding them in elevated position.
The main parts of the lift are:
-welded base
-moving parts
-control part
-lifting parts
-safety devices
- control cabinet (pump)
The PLT40 or PLT55 set is composed of all these elements plus a pulling arm, a vertical extension (PLT480), 4
anchoring clamps, 4 wheel supports and various pulling accessories (clamp, chain, safety cable…).
It has been designed for lifting vehicles and keeping them at working height, securing them with the anchoring
clamps and straightening them.
PLT40 PLT55
Figure 8
Control cabinet (pump): (Figure 9)
1 - Descent button (remote control)
2 - Lifting button (remote control)
3 - Emergency stop (remote control)
4 - Voltage monitoring lamp
5 - Main switch
(Figure 9)

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V) TECHNICAL SPECIFICATIONS
Max. Oil pressure of pump: 300 bar
Air Pressure 8 bar
Sound Level of Pump: 78dB (A)
Hydraulic Oil: LX22X / LX22Y
Stroke of Hydraulic Rams: 315 mm
Force of Hydraulic Rams: 10 t
Operating Temperature: -10°c / +40°c
Operating Environment: covered
Electromotor
Power: 1.8 kW
Voltage: 220 / 400V, 3 ph, +/-10%
Frequency: 50 Hz
Amperage: 220V / 3PH: 8 A
400V / 3PH: 4,5 A
Number of Wires: 3 + Earth
Speed (Star): 1400 rpm
Speed (Triangle): 1690rpm
PLT40
Lifting Time: 30 sec.
Lowering Time: 33 sec.
Total Length With Ramps: 4570 mm
Pulling Capacity –Dozer Type: 10 T
DIMENSIONS
Bench Frame
Frame Length: 4060 mm
Frame Width: 1000 mm
Frame Height: 140 mm
Weight: 550 kg
Scissor Lift
Mini. Height: 140 mm
Lift Height: 1300 mm
Lift Capacity: 2800 kg
Weight: 530 kg
Total Weight: 1080 kg

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Space area required
4060
335
1000
6990 335
4600
3930
POWER PRO XL - PLT40
7325
Figure 10
FLOOR
The lift must be installed on a flat, horizontal and uncracked floor surface, made of concrete 20cm thick and with
a minimum resistance of 35N/mm².(C35/45 according to EN206-1)
PLT55
Lifting Time: 30 sec.
Lowering Time: 33 sec.
Total Length With Ramps: 6000 mm
Pulling Capacity –Dozer Type: 10 T
DIMENSIONS
Bench Frame
Frame Length: 5560 mm
Frame Width: 1000 mm
Frame Height: 140 mm
Weight: 740 kg
Scissor Lift
Min.Height: 140 mm
Lift Working Height: 1300 mm
Lift Capacity: 4500 kg
Weight: 1060 kg
Total Weight: 1800 kg

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Space area required
POWER PRO XXL - PLT55
3358490
8825
5560
4600
3930
1000
335
Figure 11
FLOOR
The lift must be installed on a flat, horizontal and uncracked floor surface, made of concrete 20cm thick and with
a minimum resistance of 35N/mm².(C35/45 according to EN206-1)
WEIGHT OF THE VEHICLE
The lift can be used with nearly any vehicle provided that the maximum loading capacity (2800 Kg for PLT40) or
(4500 Kg for PLT55) is not exceeded.
The safety zone (Figure 12) is to some extent determined by the dimensions of the vehicle to be lifted.
Figure 12

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VI) INSTALLATION
1. Place the lift on its place and leave free surface around it, taking into account the dimensions of the
passage of the stands and the user.
-Sufficient room for operations.
-Sufficient room to carry out maintenance, as well as space for access and exit-routes.
-Position in relation to other machines.
-The lift must be installed near a power supply point, to enable problem-free power connection.
2. Remove the safety lock (1 for PLT40 / 2 for the PLT55), which is fastened with a screw on the upper side
of the scissors lift (Figure 13).
(Figure 13)
3. Connect the hydraulic hose, which is assembled on the pump, to the hydraulic cylinder. Check that the
connectors are clean.
4. Assemble the wire between the safety lock and the pedal.
5. Fasten the hydraulic hose and the wire in the opening of the bottom frame of the scissors lift with the
bracket.
6. Connect the air hose to the hydraulic pump. Drive the lift up and down 5 / 6 times without any load, to
allow the air to escape from the hydraulic system. Oil the slide trucks between the scissors lift and the
bench frame.
7. Using a concrete drill, bore holes of 16 mm, 110 mm depth in the floor. With the help of a hammer, insert
the supplied male expansive bolts (4 for the PLT40) / 8 for the PLT55) in the floor. With a torque wrench,
tighten the wedge bolts with a torque of 50 Nm.
8. Check the mechanism of the safety lock works. Check that all screws; shafts and connections are
correctly fastened.
9. The scissors lift is ready to operate.
LIGHTING
The lift must be adequately and uniformly lit.
WARNING
INSTALLATION OF HOSES
1. Remove the packing from the lift
No unauthorised person must be present during installation.

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2. Lower the lift to the place where it is to be installed using a load lifting equipment with sufficient capacity. While
doing this, keep in mind the locations of the hose connections.
Lay the hydraulic pipes and the pneumatic hoses on the ground, between the pump and the elevator and
cover them with the plates supplied for this purpose.
3. Now connect the hydraulic and pneumatic hoses to the valve block of the pump. (Figure 14)
4. Now connect the electric cables of the lift to connection 3. (Figure 14)
FILLING THE HYDRAULIC SYSTEM
Fill the tank with BLACKHAWK ® LX22Y hydraulic oil around (6L for PLT40 / 11L for PLT55). (Figure 14)
Figure 14
Oil filler cap
HYDRAULIC AND PNEUMATIC CONNECTIONS
Mounting on PLT40
Figure 15 Mounting on PLT40 or on PLT55 (twice)
Mounting on PLT55
Figure 16 Figure 17

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CONNECTING TO THE MAINS
WARNING
First check the following points before connecting the device to the mains:
-The electrical system in the workplace must have the protective and safety devices required by the
applicable standards.
-The power cables must have the following dimensions: for 400V, the dimension must be at least 1,5 mm².
In the case of 230V, 3-phase power supply, there must be at least 2.5 mm².
-The supply cable must have an earth wire and must be able to be connected to a fixed plug.
Connect the power supply line to the control cabinet. Put the main switch in the «ON». Check the direction of
rotation of the motor by pressing the lifting-motion switch.
AIRING THE SYSTEM
Air the system by lifting and lowering the lift several times.
POSITIONING THE LIFT
(See pages 11 and 12)
The lift must rest evenly on the floor.
DANGER
It is strictly forbidden to use the lift before it is fixed to the ground.
(Risk of tipping over)
THE FOLLOWING ACTIONS SHOULD BE CARRIED OUT BY AUTHORISED PEOPLE ONLY.

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VII) PULLING SYSTEM
VEHICLE SET-UP
-Bring the vehicle on the lift and centre it.
Figure 18
-Place the 4 wheel stands and lower the vehicle to make it rest on the stands.
Figure 19

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CLAMPS SET UP
-Set up the 4 arms.
-Set up the 4 clamp supports.
-Tighten the bolts of the clamps’ jaws.
-Lock the clamp supports by the means of the wedges.
-Lock into place the 4 arms with the plates and the wedges.
-Lift the whole system and remove the wheel stands.
Figure 20
SET UP OF THE FRAME STRAIGHTENER
-Lower the lift until it stops automatically, at about 450 mm from the floor.
-Position and fix the frame straightener where needed to perform the straightening.
Figure 21

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SET UP OF THE MEASURING SYSTEM:
Look at the operating manual supplied with your measuring system.
PULLS
-Set up the clamps or the pulling accessories.
-Set up the safety cable.
-Place the arms of the Dozer in order to obtain the pulling angle required. Lock them into place by the
means of the pin.
Figure 22 DOWNWARD PULLS
EXTENSION
Use the vertical extension PLT480 to perform high pulls.
Figure 23
WARNING
Remove the vertical extension as soon as you have finished the high pull.
REMINDER: Do not carry out any pull without having first correctly installed a safety cable.

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VIII) OPTIONS
PLT19 –ANCHORING SYSTEM FOR CHASSIS TYPE VEHICLE AND 4WD
PLT4001 –VECTOR PULLING ARM PLT4003 - 2 SUPPORTS FOR PLT553
PLT4002 –MANUAL WINCH AND SUPPORT
Not shown.

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IX) MAINTENANCE
Keep the floor and the lift clean to avoid any risk of slipping. Do not store anything under the platform
(parts, screws, pipes, etc.).
Keep all parts clean. Be especially careful with keeping the hydraulic hoses and quick connectors
clean.
Check that the safety slide to scissor lift is free of any dirt or other material which can stop its
function. Make sure that the safety lock does not meet any resistance.
Keep the accessories and tools at a determined place.
Check regularly and make sure that the lock-screws of / the axles and the connections are tightened.
Lubricate the surfaces, the axles, pivots and guiding pads (lower and upper) regularly.
Check the oil level regularly. Add oil if necessary.
In the event of a leak on the ram or pump, have it repaired immediately by an approved
BLACKHAWK ® centre.
The scissor lift should be driven up and down a number of times unloaded, to avoid eventually air in
the hydraulic system.
Check the chains and accessories frequently. (See instructions supplied with the chains). Replace
them if necessary.
Clean the frame and its accessories after each use.
WARNING
Waste oil should be disposed of according to local legislation.
In accordance with the legislation, check your lift on a periodic basis.
(Different depending on the country where the equipment is used).
WARNING
Do not repair yourself any defect part of the lift or the straightening system.
Repair jobs MUST be performed by a BLACKHAWK ® representative.