John Bean 40HP210ES User manual

READ THIS INSTRUCTION MANUAL THOROUGHLY
BEFORE INSTALLING, OPERATING, SERVICING OR
MAINTAINING THE LIFT. SAVE THIS MANUAL.
JUL 2008 REV. A
INSTALLATION
and OPERATION
MANUAL
10K 2 POST IN-GROUND
40HP210ES
10K 2 POST IN-GROUND
40HP210ES
6-3667

TABLE OF CONTENTS
1.0 SAFETY AND OPERATING INSTRUCTIONS ........................................................ 2
2.0 SAFETY WARNING DECALS................................................................................... 4
3.0 GENERAL SPECIFICATIONS................................................................................... 5
4.0 SHIPPING CONTENTS............................................................................................... 5
5.0 TOOLS REQUIRED FOR INSTALLATION.............................................................. 6
6.0 BAY LAYOUT............................................................................................................. 7
7.0 EXCAVATION .......................................................................................................... 10
8.0 ASSEMBLY INSTRUCTIONS ................................................................................. 12
9.0 INSTALLATION INSTRUCTIONS.......................................................................... 15
9.1 POWER PACK INSTALLATION......................................................................... 16
9.2 HYDRALLIC AND AIR CONNECTIONS........................................................... 16
10.0 BLEEDING PROCEDURES.................................................................................... 17
11.0 FINAL CHECK OF ASSEMBLED LIFT................................................................ 18
12.0 OPERATING INSTRUCTIONS.............................................................................. 19
13.0 AUTOMOTIVE LIFT SAFETY TIPS..................................................................... 21
14.0 TROUBLE SHOOTING GUIDE ............................................................................. 22
15.0 REGULAR MAINTENANCE ................................................................................. 23
16.0 LIFT ASSEMBLY.................................................................................................... 24
16.1 LIFT PARTS LIST............................................................................................... 25
17.0 POWER PACK ASSEMBLY .................................................................................. 27
17.1 POWER PACK PARTS LIST.............................................................................. 28
18.0 AVAILABLE ACCESSORIES................................................................................ 30

This lift requires at least 2 persons for assembly / installation.
1.0 SAFETY AND OPERATING INSTRUCTIONS
When using this lift, basic safety precautions should always be followed, including the
following:
1. Thoroughly read all instructions in this manual and on the lift before installing,
operating, servicing or maintaining the lift.
2. Inspect lift daily. Do not operate if it malfunctions or problems have been
encountered.
3. Never attempt to overload the lift. The manufacturer’s rated capacity is shown on
the identification label. Do not override the operating controls or the warranty will
be void.
4. Before driving vehicles into the lift area, position the arms to the drive-through
position to ensure unobstructed clearance. Do not hit or run over arms as this
could damage the lift and/or vehicle.
5. Only trained and authorized personnel should operate the lift. Do not allow
customers or bystanders to operate the lift or be in the lift area.
6. Position the lift support pads to contact the vehicle manufacturer’s recommended
lifting points. Raise the lift until the pads contact the vehicle. Check pads for
secure contact with the vehicle. Check all arm restraints and ensure they are
properly engaged. Raise the lift to the desired working height.
7. Some pickup trucks may require an optional truck adapter to clear running
boards or other accessories.
8. NOTE: Always use all 4 arms to raise and support vehicle.
9. Caution! Never work under the lift unless the mechanical safety locks are
engaged.
10. Note that the removal or installation of some vehicle parts may cause a critical
load shift in the center of gravity and may cause the vehicle to become unstable.
Refer to the vehicle manufacturer’s service manual for recommended
procedures.
11. Always keep the lift area free of obstruction and debris. Grease and oil spills
should always be cleaned up immediately.
12. Never raise vehicle with passengers inside.
13. Before lowering check area for any obstructions.
14. Before removing the vehicle from the lift area, position the arms to the drive-thru
position to prevent damage to the lift and or vehicle.
15. Do not remove hydraulic fittings while under pressure.
SAVE THESE INSTRUCTIONS
2

For additional safety instructions regarding lifting, lift types, warning labels,
preparing to lift, vehicle spotting, vehicle lifting, maintaining load stability,
emergency procedures, vehicle lowering, lift limitations, lift maintenance, good
shop practices, installation, operator training and owner/employer
responsibilities, please refer to “Lifting It Right” (ALI/SM) and “Safety Tips”
(ALI/ST).
For additional instruction on general requirements for lift operation, please refer
to “Automotive Lift-Safety Requirements For Operation, Inspection and
Maintenance” (ANSI/ALI ALOIM).
Installation shall be performed in accordance with ANSO/ALI ALIS, Safety
Requirements for Installation and Service of Automotive Lifts.
3

2.0 SAFETY WARNING DECALS
Be sure the operator is aware and understands all safety warning labels and
follows them accordingly.
4

3.0 GENERAL SPECIFICATIONS
Capacity: 10000 lbs. 4536 kg
Overall Width: 88” 2235 mm
Height to Lowered Lift Pads 4 ½” 114 mm
Height to Lift Pad (3” Adapter): 7” 178 mm
Height to Lift Pad (6” Adapter): 9 ½” 241 mm
Height to Lift Adapter (8 7/8” Truck Adapter): 12 ¼” 311 mm
Arm Extended Length: 41 ½” 1054 mm
Arm Retracted Length: 28 ⅛” 714 mm
Maximum Lifting Height (No Adapter): 73 ¼” 1861 mm
Maximum Lifting Height (8 7/8” Truck Adapter): 82 1/8” 2086 mm
Lifting Time (approximately): 61 sec.
Lowering Time (approximately): 126 sec.
Power Requirements: 230 Volts AC, 1 Ph., 60 Hz.
Air Requirements: 90 – 120 psi Shop Air
4.0 SHIPPING CONTENTS
Overall Weight: 2300lb / 1043kg
2 - Cylinders bolted together (93” long) with locking legs, attaching bolts, &
stainless steel cables (Cables measure 5/16” x 137 1/2” with adjusting allen bolts
on ends)
2 - Lifting Superstructures
1 - Cable Pulley Box with lid
1 - 1/2” I.D. x 21' Hydraulic Hose (lift and pump)
1 - 1/4” O. D. x 21' Nylon Airline (run from air cylinder to push button on pump air
valve)
1 - Wheel spotting plate
1 - Plastic Bag containing (located inside cable pulley box):
12 - 7/16” x 1-1/4” Bolts and Nuts (for attaching spreader bars).
4 - Screws and Anchors (for wheel spotting plate)
1 - 1-1/2” PVC through hull fitting with ‘O’ ring
1 - 1/4” l.D. Hydraulic Hose Tee
1 - Installation Booklet (“Lifting It Right Tips” and Warranty Card)
4 - 1/4” x 3” Anchor Bolts (for mounting pump to wall)
2 - 1/4” x 1” Bolts & Nuts (for attaching cable box to cylinders)
4 - 1/2” x 1-3/4” Flat Head Allen
1 Pumping Unit
With air switch attached Single Phase / 230 Volts with 6-1/2” x 24” tank and 4-
poster gears.
5

5.0 TOOLS REQUIRED FOR INSTALLATION
•Rubber mallet
•Open wrench for pulley box lid 7/16”
•Allen wrench 5/16”
•Allen wrench 1/4”
•Allen wrench for cable adjustment (900 bend) 3/8”
•Wrench 3/4”
•Wrench 7/16”
•Wrench 11/16”
•Vice grips for cable adjustment reg.
•Ratchet 6” extension and 3/4” deep socket for pulley assembly nut reg.
•Wire cutters for cutting airlines 3/4”
•Wrench for hydraulic fittings reg.
•Pliers
•Socket for attaching the lifting superstructures to the pistons 1-7/16”
•Work gloves
•3’ pry bar for manipulating cylinders
•Level 6’
•Tape measure
•Set of screwdrivers
•Impact gun
•Torque gun
•Crain for lifting and installing cylinders
•Funnel
•Hammer drill or similar, 1/4” and 1/2” concrete drill bits
•Caulking gun
Some of the supplies required:
•The necessary fittings for running shop air to air lift lock release button -
1/8” pipe, female
•3-1/2 gallons ISO-32 Hydraulic oil
•1 tube of waterproof silicone sealer20’ by 1-1/2” schedule #40 PVC pipe
and 1-1/2” PVC electrical sweep
•Spray can of silicone lubricant
6

6.0 BAY LAYOUT
1. Make certain there is at least 70” between the lowest ceiling obstruction
and the roofline of the highest vehicle to be raised. 12 ft. of ceiling height
is sufficient for passenger cars.
2. A minimum of 12 ft. of stall space is required from both front and rear of lift
center to nearest obstruction. (See Figure 1 & 2).
3. 6 ft. is the recommended dimension, plus desired work area, between the
lift center and side wall or nearest obstruction.
7

Figure 1 - Bay Layout (Option A)
8

Figure 2 - Bay Layout (Option B)
9

7.0 EXCAVATION
1. Dig a hole to accommodate the lifting unit to a minimum dimension of
24”Lx 84”W x 100”D. (See Figure 3).
2. Dig a 9” deep trench (pipe chase for hydraulic and air lines) from the
cylinder pulley box center fitting to the location you have selected to mount
the pump and controls.
Figure 3 - Plan and Excavation
10

Figure 4 – Elevation
11

8.0 ASSEMBLY INSTRUCTIONS
1. Adjusting Cable Tension: With the locking legs extended approximately 8
inches, tighten both the left and right side cable bolts equally. (See Figure
5). To check tension, grab cable in center and pull up on it with about 30
pounds of force. Cable should deflect about 1-3/4” to 2”. This would be the
proper cable tension. To adjust the cables for equal rise, measure exactly
the amount of locking leg that is extended. If for instance, the left side
locking leg is extended further than the right, loosen the right cable bolt
and tighten the left cable bolt. Continue this procedure until both locking
legs are extended equally. NOTE: When adjusting cables, hold the fitting
on the end of the cable with vice grips to prevent turning.
2. Attach the 1/2” O. D. hydraulic lines to the tee fitting provided so that it will
be next to the PVC through hull fitting (halfway between the pulleys). Tape
the open ends to prevent any foreign objects from entering during
installation. (See Figure 6).
12

Figure 5 - Cable Routing
13

Figure 6 - Hydraulic and Air Connections
14

9.0 INSTALLATION INSTRUCTIONS
Before Installing:
After unpacking the lift, check shipping list to ensure that you have all
required parts.
Check unit carefully for shipping damage.
Handle unit with care. Dropping could cause internal damage.
Store unit indoors or under cover to prevent rusting or pitting from
condensation.
DO NOT ATTEMPT TO RAISE THE LIFT WITHOUT SUPERSTRUCTURES
ATTACHED.
1. Attach a lifting chain to the upper spreader bar and lower cylinder
assembly into excavation, making sure the PVC through hull fitting is
facing the front of the bay where pumping unit will be installed.
2. Secure cylinders to a finished height of 1/8” above finished floor grade.
Wooden 6” x 6” planks and 1/2” threaded rod help achieve proper
positioning. NOTE: Slope concrete away from lift in all directions.
3. Place a spirit level across the top of the pistons (not the cylinder
flanges) in two directions and adjust until pistons are plumb. Use a 6 ft.
level from one piston to the other to make sure they are level with each
other. Correct by adjusting as necessary.
4. Pour concrete around bases of both cylinders to a minimum of 10”
deep and 6” up the cylinders. (See Figure 3). Allow 24 hours for
concrete to cure.
5. Backfill with a clean dry washed sand fill to a level of 24” below floor
grade. Firmly tamp and check for plumbness frequently while
backfilling.
6. In the 9” deep trench from the pulley box to the wall where the pump
lines will be installed, use only 1-1/2” PVC electrical sweep as it makes
its turn up the wall to the pumping unit (leave the PVC sweep at least
6” above the floor grade to prevent water from entering the box).
7. Connect the PCV sweep fitting to pulley box assembly. NOTE: Make
sure to place an “O” ring gasket between the PVC fitting and the outer
surface of the pulley box assembly. Fully tighten the nut to prevent
leakage upon pouring of the concrete. (See Figure 5).
8. Complete backfill to a level of 9” below floor grade.
9. After rechecking plumbness in all directions, pour and finish concrete
making certain that cylinder flanges are 1/8” above finished grade.
Note: It is recommended to slightly taper concrete up the cylinder to
prevent any standing water around cylinder flange.
10.Install wheel-spotting dish in proper location. (See Figure 1 & 2).
11.After allowing 48 hours for concrete to cure, attach lifting structures to
pistons and equalizer struts.
15

9.1 POWER PACK INSTALLATION
1. POWER UNIT REQUIREMENTS: 230 volts, single-phase power. Use
separate circuit for each unit and protect each unit with 30 AMP time delay
fuse or circuit breaker.
2. Have a certified electrician wire your pump to the pump motor. The
electrical diagram is provided. (See Figure 7).
3. Attach pumping unit (tank down) to location selected in front of lift. The
connecting fittings should be at least 36” off the floor.
4. Install the hydraulic lines and air lines through the 1-1/2” PVC.
5. FILLING PUMPING UNIT: Fill pumping unit with AW-32 hydraulic oil,
I.S.O. 32 with anti-rust and anti foam agents (approx. 14 quarts). DO NOT
USE TRANSMISSION FLUID.
9.2 HYDRALLIC AND AIR CONNECTIONS
1. Install the 1/2” O. D. x 21’ hydraulic line and the 1/4” O. D. x 21’ airline
from the pump to the pulley box through the 1-1/2” PVC sweep.
2. Connect the hydraulic line to the tee and the air line to the air cylinder
elbow fitting, both located inside the pulley box.
3. Connect the other ends to the pumping unit hydraulic fitting and air lift lock
release button (safety release valve) making sure that all fittings are
properly tightened. (See Figure 5).
4. Run an air supply line from shop air to the 1/8” pipe fitting at the base of
the air lock release button on pump.
16

10.0 BLEEDING PROCEDURES
After filling the unit, there will still be trapped air in the system. You must bleed
the system as instructed for proper operation of lift.
1. To bleed the air from the hydraulic system, raise the internal cylinders
approximately 12”, using the pumping unit. (LIFTING STRUCTURES
MUST BE OFF).
2. Loosen the 1/4” hex head bolt at the end of each internal cylinder, using a
7/16” socket wrench. (DO NOT ALLOW THE INTERNAL CYLINDER TO
ROTATE WHILE LOOSENING OR TIGHTENING THIS PLUG).
3. Step down on the end of each cylinder to force the trapped air from the
system. Repeat if necessary to remove all air till oil begins to flow from the
plug.
4. Once this is completed make sure to properly apply sealant to these plugs
and tighten to prevent leaking.
5. Open lowering valve on pump. Step on the ends of these cylinders to
force them back down.
6. Add oil till recommended level in the tank is met.
7. Attach the arm structures. Torque 7/8” bolster bolts to 250 lbf-ft.
8. Raise lift fully and wipe pistons down with a light coat of silicone lubricant
or WD-40.
9. Lower the lift and record oil level in the pumping unit.
10. Pressure check bleed-plugs by inspecting them through the hole in the
center of the lifting structures.
11. Check the hydraulic tee and the fitting on the pump for any leaks, tighten
if necessary.
CAUTION!
DO NOT FULLY RAISE LIFT WITHOUT SUPERSTRUCTURES
ATTACHED. THE PISTONS WILL COME OUT OF CASINGS AND
MAY BE DIFFICULT TO LOWER WITHOUT THE WEIGHT OF THE
SUPERSTRUCTURE ON THEM.
WHEN BLEEDING CYLINDERS, DO NOT ALLOW INNER
CYLINDERS TO ROTATE. THIS MAY CAUSE HOSE KINK.
KEEP ALL LIQUIDS AWAY FROM LIFT (water, cleaners, acids,
etc). ANY LIQUID WHICH GETS INSIDE THE LIFTING UNIT WILL
CAUSE INTERNAL DAMAGE AND WILL NOT BE COVERED
UNDER WHEELTRONIC’S WARRANTY.
17

11.0 FINAL CHECK OF ASSEMBLED LIFT
1. Check for air and hydraulic leaks. ___
2. Ensure all safety lock mechanisms are working correctly. ___
3. Check all fasteners, tighten if necessary. ___
4. Operate lift to full stroke then lower to ground while checking for proper
functionality. ___
5. Ensure Customer Care Kit is complete and given to operator. ___
a. Operation Manual ___
b. ANSI / ALI Lift It Right Manual ___
c. ANSI / ALI Safety Tip Card ___
d. ANSI / ALI ALIS Safety Requirements for Installation and Service
of Automotive Lifts ___
e. ANSI / ALI Quick Reference Guide ___
6. Train end user on operation of the lift. ___
18

12.0 OPERATING INSTRUCTIONS
It is the responsibility of the Owner/Operator to be thoroughly familiar with the
Operation, Inspection, and Maintenance of this lift.
Before Lifting: DO NOT RAISE CYLINDERS WITHOUT
SUPERSTRUCTURES ATTACHED.
IMPORTANT:
When lifting the vehicle, the flip pad adapters must be
positioned as shown in Figures 7 and 8.
• ALL FLIP PADS MUST FACE OPPOSITE DIRECTIONS
• FLIP PADS CANNOT POINT IN THE SAME DIRECTION
1. Rotate arms to provide tire clearance.
2. Center vehicle left and right over lift with wheel in proper spotting plate
according to vehicle size.
3. Position adapter pads at vehicle manufacturer’s approved lifting points.
4. If adapters are raised, face front and rear in opposite directions. Make
sure the height adapters are positioned in a proper designated location.
(See Figures 7 – 9).
Figure 7 - CORRECT positioning of flip pad adapters
Figure 8 - CORRECT positioning of flip pad adapters
19