Castex QJY4.0-D6A-PRO Guide

Model No. QJY4.0-D6A-PRO
Installation, Operation
Base Plate Two Post Lift，
and Parts Manual
Electrical Release
Lifting Capacity 4000KG
Distributed by
CASTEX ANNA BEDNARZ
LUDWIKOWO 2C
85-502 BYDOSZCZ
[email protected]
Please read this entire manual carefully and completely before installation or operation of the lift.

Installation, Operation and Parts Manual
QJY4.0-D6A-PRO
INDEX
1. Important safety instructions……………………………….…………………..3~4
1.1 Important notices
1.2 Qualified personnel
1.3 Danger notices
1.4 Training
1.5 Warning signs
2. Overview of the lift……………………………………………………………….…..5
2.1 General descriptions
2.2 Technical data
2.3 Construction of the lift
3. Installation instructions…………………………………………………………..6~15
3.1 Preparations before installation
3.2 Precautions for installation
3.3 Installation
3.4 Items to be checked after installation
4. Operation instructions…………………………………………………………….15~16
4.1 Precautions
4.2 Flow chart for operation
4.3 Operation instructions
5. Trouble shooting………………….………………………………………………… 17
6. Maintenance……………………………………………………………………….....18
7. Annex…………………………………………………….……………………………….19~34
Annex1, Packing list of the whole lift
Annex2, Overall diagram
Annex3, Floor plan
Annex4, Hydraulic working system
Annex5, Wiring diagram
Annex6, Separated drawings for the lift
Annex7, Electric control box fittings
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Installation, Operation and Parts Manual
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IMPORTANT SAFETY INSTRUCTIONS
1.1 Important notices
We will offer one-year's quality warranty for the whole machine，during which any quality problem will be properly solved to the
user's satisfaction. However, we will not take any responsibility for whatever bad consequence resulted from improper installation
and operation, overload running or unqualified ground condition.
This 2-posts lift is specially designed for lifting motor vehicles that weighs within its outmost lifting capacity. Users are not allowed to
use it for any other purposes. Otherwise, we, as well as our sales agency, will not bear any responsibility for accidents or damages of
the lift. Make sure to pay careful attention to the label of the lifting capacity attached on the lift and never try to lift cars with its
weight beyond.
Read this manual carefully before operating the machine so as to avoid economic loss or personnel casualty incurred by wrong
operation. Without professional advice, users are not permitted to make any modification to the control unit or whatever mechanical
unit.
1.2 Qualified personnel
1.2.1 Only these qualified staff, who have been properly trained, can operate the lift.
1.2.2 Electrical connection must be done by a competent electrician.
1.2.3 People who are not concerned are not allowed in the lifting area.
1.3 Danger notices
1.3.1 Do not install the lift on any asphalt surface.
1.3.2 Read and understand all safety warnings before operating the lift.
1.3.3 The lift, if is not specially designed upon customer’s request, is not fit for outdoor use.
1.3.4 Keep hands and feet away from any moving parts. Keep feet clear of the lift when lowering.
1.3.5 Only these qualified people, who have been properly trained, can operate the lift.
1.3.6 Do not wear unfit clothes such as large clothes with flounces, tires, etc, which could be caught by moving parts of the lift.
1.3.7 To prevent evitable incidents, surrounding areas of the lift must be tidy and with nothing unconcerned.
1.3.8 The lift is simply designed to lift the entire body of vehicles, with its maximum weight within the lifting capacity.
1.3.9 Always insure the safety latches are engaged before any attempt to work near or under the vehicle.
1.3.10 Make sure to place the lifting pads to the positions as suggested by vehicle makers and when gradually lift the vehicle to the
desired height, operators should be certain that the vehicle will not slant, roll-over orslide in lifting process.
1.3.11 Check at any time the parts the lift to ensure the agility of moving parts and the performance of synchronization. Ensure
regular maintenance and if anything abnormal occurs, stop using the lift immediately and contact our dealers for help.
1.3.12 Lower the lift to its lowest position and do remember to cut off the power source when service finishes.
1.3.13 Do not modify any parts of the lift without manufacturer’s advice.
1.3.14 If the lift is going to left used for a long time, users are required to:
a. Disconnect the power source;
b. Empty the oil tank;
c. Lubricate the moving parts with hydraulic oil.
1.4 Training
Only these qualified people, who have been properly trained, can operate the lift. We are quite willing to provide professional
training for the users when necessary.
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Attention: For environment protection, please dispose the disused oil in a proper way.
1.5 Warning signs
All safety warning signs attached on the machine are for the purpose of drawing the user’s attention to safety operation. The labels
must be kept clean and need to be replaced when they are worn-out or have dropped. Read the explanations of the labels carefully
and try to memorize them.
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Installation, Operation and Parts Manual
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OVERVIEW OF THE LIFT
2.1 General descriptions
This floor plate two posts lift is composed of posts, carriages, lifting arms, cylinders and motor unit, etc.
It is driven by an electro-hydraulic system. The gear pump delivers hydraulic oil to oil cylinders and pushes upwards its piston. The
piston drives the chain to raise the carriage and the lifting arms. During lifting process, the safety latch will automatically and
firmly bite with the safety teeth block in the posts. Therefore, no slipping will happen in case the hydraulic system breaks down.
Safety structure
2.2 Technical data
Model
Lifting capacity
Full rise time
Full rise
Height
Width
Inside columns
QJY4.0-D6A
4000kg
50 Sec
1990mm
2824mm
3520mm
2860mm
-PRO
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Installation, Operation and Parts Manual
QJY4.0-D6A-PRO
2.3 Construction of the lift
1
S/N
Description
1
top plate
6
2
oil cylinder
2
3
carriage
4
lifting arm
7
5
base plate
3
6
power unit
4
7
control box
8
8
post
5
INSTALLATION INSTRUCTIONS
3.1 Preparations before installation
3.1.1 Tools and equipments needed
✓Appropriate lifting equipment
✓Anti-abrasion hydraulic oil.
✓Rotary Hammer Drill with 3/4’’ drill bit.
✓Chalk and tape measure, magnetic plump, 8 metersФ15 level pipe.
✓Sockets and open wrenches, a set of inside hex wrenches, cross and straight screw drivers.
✓Hammer, 4pounds, sharp nose pliers, Ф17,Ф19,Ф22 socket spanners。
3.1.2 List for parts checking ---Annex 1（Packing list）
Unfold the package and check if any parts missed as per Annex 1. Do not hesitate to contact us in case any parts missed, but if you do
not contact us and insist installing upon the lack of some parts, EverLift as well as our dealers will not bear any responsibility for this
and will charge for any parts subsequently demanded by the buyer.
3.1.3 Ground conditions
The lift should be fixed on a smooth and solid concrete ground with its strength more than 3000psi, tolerance of flatness less
than 5mm and minimum thickness of 200mm. In addition, newly built concrete ground must undergo more than 28days’ cure
and reinforcement.
3.2 Precautions for installation
3.2.1 Make sure the two posts stand paralleled and are vertical to the ground. No slanting.
3.2.2 Joints of oil hose and steel cable must be firmly connected in order to avoid the looseness of steel cable and leakage of oil hose.
3.2.3 All bolts should be firmly screwed up.
3.2.4 Do not place any vehicle on the lift in the case of trial running.
3.3 Installation
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Installation, Operation and Parts Manual
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Step 1: Remove the packaging, take out the carton for accessories and cover plate.
Step 2: Firstly, put something supporting between the two posts or suspend one of the posts by a crane and then remove the bolts
on the package.
Attention：Please pay special attention not to let the post fall down for it may cause casualty or bring damages to the accessories
fixed in the post.
Step3: When the first post has been taken away, place something supporter under the second post and then remove the bolts on
the package.
Step 4: Fix the standing position for the two posts. (see Annex 3, floor plan)
1. Unfold the package and decide on which post the power unit will be mounted.
2. Draw an outline of the base plate on the ground with chalk and ascertain the position for the post.
Step 5: Erect the posts, power side post first and then the other post.
1.Drill anchor holes for expansion bolts on the ground with an electrical drill. Make sure to drill vertically.
2.After holes have been drilled, remove thoroughly the debris and dust in them and ascertain that the posts stay upon the circle
previously drawn by chalk.
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Step6: Fix mechanical safety lock assemblies.
Fix four safety locking plates and electro-magnets with two of them on each post.
Electro-magnet
Step 7: Fix the slot base plate.
Manually raise two carriages about 800mm from the ground to have them locked by safety locks and then place the slot base plate
between two base plates of the post.
Step8: Connect steel cables.
1.Route and fix according to the following diagram of steel cable connection.
2.Raise carriages on both sides approximately 800mm above the ground. Carriages must be on the same height from the floor.
3.Make sure that the mechanical safety locks in each post are fully engaged before attempting to route cables.
4.After the cable being fixed, adjust and make the cable at both sides be with the same tightness which could be judged by the sound
emitted during lifting process. Make judge and adjustment after trial running.
5.Grease after being fixed. (It is a must.)
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Installation, Operation and Parts Manual
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Step9: Mount the power unit onto the power side post.
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Installation, Operation and Parts Manual
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Step10: Connect oil hoses.
Connect the oil hose as per the following diagram.
Step11: Connect wires.
1. Mount the control box on to the power side post.
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Installation, Operation and Parts Manual
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Control box
3. Connect quick connectors between electromagnets.
Elecro-magnet
4. Connect the wire of solenoid valve and motor wire
Step 12: Fix wire & oil hose protectors.
Step13: Install lifting arms.
Connect the lifting arm and the carriage by shafts.
Install the lifting arms onto the carriages and ensure the arm lock could work.
Elecro-magnet
Control box
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Installation, Operation and Parts Manual
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Step14: Fill with hydraulic oil.
The volume of oil tank is 10L.To insure the lift work normally, the amount of oil in it should reach 4/5 of the tank’s total volume.
32#anti-abrasion hydraulic oil for winter, 46# for summer.
Step15: Trial running.
1. Do refer to the operation instructions in advance and keep in mind that no vehicle left on the lift in the process of trial running.
2. Check if all the connections are in good condition.
Step16: Fix feet protection fenders, chain protection clothes, electro-magnet protection covers, door-opening protections, top caps
and lifting trays.
Step17: Fix base cover plate.
Screw lock
3.4 Items to be checked after installation.
S/N
Check items
YES
NO
1
Are the posts vertical to the floor?
2
Are the two posts paralleled?
3
Is the oil hose well connected?
4
Is the steel cable well connected?
5
Are all lifting arms well fixed?
6
Are electrical connections right?
7
Are the rest joints firmly screwed?
8
Are all items need lubricating added with grease?
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OPERATION INSTRUCTIONS
4.1 Precautions
4.1.1 Check all the joints of oil hose. Only when there is no leakage, the lift can start work.
4.1.2 The lift, if its safety device malfunctions, shall not be used.
4.1.3 The machine shall not lift or lower an automobile if its center of gravity is not positioned midway of the swing arms. Otherwise,
the EverLift as well as our dealers will not bear any responsibility for any consequence resulted thereby.
4.1.4 Operators and other personnel concerned should stand in a safety area during lifting and lowering process.
4.1.5 When lifting arms rise to the desired height, switch off the power at once to prevent any mal-operation done by unconcerned
people.
4.1.6. Make sure the safety lock of the lift is engaged before start working under the vehicle and no people under the vehicle during
lifting and lowering process.
4.2 Flow chart for operation
Raising
Start
Turn on the power switch
Press UP button
Motor drives the gear pump work
Cylinder piston drives the chain work
Chain drives the carriage rise
The lift is raised
Lowering
Start
Turn on the power switch
Press the DOWN button
The lift is lowered
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4.3 Operation instructions
Description
Function
Power Switch
Control power
Power indicator
Indicate if power being connected
UP button
Raise the lift
Safety lock button
Ensure safety in operation process
DOWN button
Lower the lift
Emergency stop
Ensure safety
Raise the lift
1. Make sure that you have read and understood the operation manual before operation.
2. Park the vehicle between two posts.
3. Adjust the lifting arms until they reach the supporting positions of the vehicle and make sure the gravity of vehicle located in
the center of four lifting arms.
4. Connect the power supply as per requirements on the nameplate attached, and switch on.
5. Press the”UP”button on the control box until pads of lifting arms touched the prop-position of vehicle.
6. Keep on raising the vehicle to let it have a bit clearance from the ground and check again its stability.
7. Raise the vehicle to the desired height, check it is safe or not, press the “Safety Lock” button on the control panel to have the
safety lock engaged, turn off the power and then perform maintenance or repair work underneath.
Lower the lift
1. Switch on.
2. Press the “DOWN” button on the control box. Meanwhile the lifting arms automatically go upwards about 5CM which releases
the safety lock. The lift lowers.
3. After the lifting arms lower to the lowest position, pull them out from under the vehicle and clear up all the obstacles.
4. Drive the vehicle away.
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TROUBLE SHOOTING
TTENTION: If the trouble could not be fixed by yourself, please do not hesitate to contact us for help .We will offer our service at the
earliest time we can. By the way, troubles could be judged and solved much faster if more details or pictures could be provided.
TROUBLES
CAUSE
SOLUTION
Abnormal noise
Abrasion exists on insider surface of the posts.
Grease the inside of the post.
Trash in the post.
Clear the trash
The wire connection is loose.
Check and make a good connection.
Motor does not run and
The motor is blown.
Replace it.
will not rise
The limit switch is damaged or the wire connection is loose.
Connect it or adjust or replace the limit
switch.
The motor run reversely.
Check the wire connection.
Overflow valve is loose or jammed.
Clean or adjust it.
Motor runs but will not
The gear pump is damaged.
Replace it.
raise
Oil level is too low.
Add oil.
The oil hose became loose or dropped off.
Tighten it.
The cushion valve became loose or jammed.
Clean or adjusts it.
The oil hose leaks.
Check or replace it.
Carriages go down
The oil cylinder is not tightened.
Replace the seal.
slowly after being
The single valve leaks.
Clean or replace it.
raised
Solenoid valve fails to work well.
Clean or replace it.
Steel cable is loose or not with same tightness
Check and adjust the tightness.
The oil filter is jammed.
Clean or replace it.
Oil level is too low.
Add oil.
Raising too slow
The overflow valve is not adjusted to the right position.
Adjust it.
The hydraulic oil is too hot ( above 45°）.
Change the oil.
The seal of the cylinder is abraded.
Replace the seal.
Inside surface of the posts is not well greased.
Add grease.
The throttle valve jammed.
Clean or replace.
Lowering too slow
The hydraulic oil is dirty.
Change the oil.
The anti-surge valve jammed.
Clean it.
The oil hose jammed.
Replace it.
The steel cable is
No grease when installation or out of lifetime
Replace it.
abraded
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MAINTENANCE
Easy and low cost routine maintenance can ensure the lift work normally and safely. Following are requirements for routine
maintenance. Frequency of routine maintenance is determined by working condition and frequency.
THE FOLLOWING PARTS ARE NEEDED TO BE LUBRICATED
S/N
Description
1
UP pulley
2
Steel cable
3
Chain wheel
4
Chain
5
Sliding block
6
Pin
7
Arm lock
8
Lifting arm
9
Tray
10
Down pulley
6.1. Daily checking items before operation
The user must perform daily check. Daily check of safety lock system in very important –the discovery of device failure before action
could save time and prevent great loss, injury or casualty.
·Before operation, judge whether the safety locks are engaged by sound.
·Check whether oil hose well connected and whether it leaks or not.
·Check the connections of chain and steel cable and check the power unit.
·Check whether expansion bolts are firmly screwed.
·Check if arm lock works well or not.
1.2. Weekly checking items
·Check the flexibility of moving parts.
·Check the working conditions of safety parts.
·Check the amount of oil left in the oil tank. Oil is enough if the carriage can be raised to highest position. Otherwise, oil is insufficient.
·Check whether expansion bolt s firmly screwed.
6.3. Monthly checking items
·Check whether expansion bolts are firmly screwed.
·Check the tightness of the hydraulic system and screw firm the joints if it leaks.
·Check the lubrication and abrasion circumstance of axial pins, carriages, lifting arms and other related parts and replace in time
with new ones if they failed to work well.
·Check the lubrication and abrasion circumstance of steel cable.
6.4. Yearly checking items
·Empty the oil tank and check the quality of hydraulic oil.
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·Wash and clean the oil filter.
If users strictly follow the above maintenance requirements, the lift will keep in a good working condition and meanwhile
accidents could be avoided to a large extent.
ANNEX
Annex 1, Packing List of the whole lift
S/N
Material #
Name
Drawing#
Property
Qty
1
Power side post assembly
QJY4.0-D6A-PRO-A1
Assembly
1
2
Post assembly
QJY4.0-D6A-PROF-A2
Assembly
1
3
Carriage assembly
QJY4.0-D6A-PRO-A3
Assembly
2
4
Power unit
Assembly
1
5
Oil cylinder
QJY4.0-D6A-PRO-A4-B3
Assembly
1
6
Drive oil cylinder
QJY4.0-D6A-PRO-A4-B2
Assembly
1
7
Electrical system
Assembly
1
8
Control box
1
9
Wire package
1
10
Steel cable L=8740mm
QJY4.0-D6A-PRO-A6
Assembly
2
11
Long arm
QJY4.0-D6A-PRO-A7
Assembly
2
12
Short arm
QJY4.0-D6A-PRO-A8
Assembly
2
13
Slot base plate
QJY4.0-D6A-PRO-A9
Powder-coating
1
14
Base cover plate
QJY4.0-D6A-PRO-A10
Powder-coating
1
Carton(include the following
）
17
Post cap
QJY4.0-D6A-PRO-A1-B6
ABS
2
18
Arm shaft
QJY4.0-D6A-PRO -A12
Zinc-plating
4
19
Height adapter
QJY4.0-D6A-PRO -A15
Zinc-plating
4
20
Short feet-protection fender
QJY4.0-D6A-PRO –A8-B3
Powder-coating
2
21
Long feet-protection fender
QJY4.0-D6A-PRO–A7-B4
Powder-coating
2
22
Lifting tray assembly
QJY4.0-D6A-PRO –A7-B3
Assembly
4
23
Rubber oil hose L=3100mm
Assembly
1
24
Rubber oil hose L=2930mm
8224E-B4-B2
Assembly
1
25
Safety locking plate
QJY4.0-D6A-PRO–A1-B2
Zinc-plating
26
Electromagnet protection cover
QJY4.0-D6A-PRO –A1-B4
ABS
4
27
Positioning block
QJY4.0-D6A-PRO–A1-B3
Zinc-plating
28
Hose & wire cover
QJY4.0-D6A-PRO–A1-B8
Powder-coating
6
29
Chain protection cloth
QJY4.0-D6A-PRO -A11
Assembly
2
30
Rod of chain protection cloth
QJY4.0-D6A-PRO -A13
Zinc-plating
4
31
Rubber protection pad
QJY4.0-D6A-PRO–A3-B7
Rubber
2
32
Nylon washer
QJY4.0-D6A-PRO -A17
Rubber
10
33
Steel braket for height adapter
QJY4.0-D6A-PRO –A1-B4
Powder-coating
4
34
Hex head full swivel nut
M10*35
Standard
4
35
Hex socket cylinder head screw
M8*12
Standard
8
36
Cross cap screw
M6*10
Standard
28
37
Cross cap screw
M6*30
Standard
12
38
Cross cap screw
M6*16
Standard
4
39
Cross sunken head screw
M8*16
Standard
4
40
Class C flat washer
M6
Standard
8
41
Class C flat washer
M10
Standard
4
42
Spring washer
M10
Standard
4
Hex nut
M6
Standard
8
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S/N
Material #
Name
Drawing#
Property
Qty
Hex nut
M10
Standard
4
Type B circlip
38
Standard
4
Expansion bolt
M18*160
Standard
10
Annex2, Overall diagram
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Annex3, Floor plan
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Annex 4, Hydraulic working system
1.
Drive oil cylinder
2.
Assistant oil cylinder
3.
Manual unloading valve
4.
Throttle valve
5.
Motor
6.
Coupling
7.
Gear pump
8.
Single –way valve
9.
Over-flow valve
10.
Anti-surge valve
11.
Cushion valve
S/N
Name
Qty
1
Motor
1
2
Hydraulic block
1
3
Overflow valve
1
4
Removable plug
2
5
Cushion valve
1
6
Oil absorbing pipe
1
7
Oil filter
1
8
Throttle valve
1
9
Oil pipe tie-in
1
10
E-magnetic unloading valve
1
11
One-way valve
1
12
Gear pump
1
13
Plastic oil tank
1
14
Oil tank cover
1
15
Oil back pipe
1
20