MAHLE CES-6000 User manual

MAHLE CES-6000
EN
Operation Manual
Engine Stand

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EVERY PERSON WHO OPERATES THIS
EQUIPMENT NEEDS TO KNOW AND
UNDERSTAND ALL OF THE INFORMATION IN
THIS MANUAL – FAILURE TO DO SO COULD
RESULT IN SERIOUS INJURY OR DEATH.
READ THIS MANUAL
CAREFULLY AND
RETAIN FOR YOUR
RECORDS

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Contents
Contents
1. Safety Regulations ................................................ 4
1.1 Warnings ....................................................... 4
2. Fo ewo d ................................................................ 5
2.1 From the manufacturer ................................. 5
3. Symbols Use .......................................................... 5
3.1 Signal words ................................................. 5
4. Responsibilities ..................................................... 6
4.1 eceiving inspection ..................................... 6
4.2 Owner and/or operator responsibilities ......... 6
5. Specifications ........................................................ 6
5.1 CES-6000 ..................................................... 6
6. P oduct Desc iption .............................................. 7
6.1 Component identification .............................. 7
7. Assembly ................................................................ 8
7.1 CES-6000 assembly ..................................... 8
8. Ope ation ............................................................. 11
8.1 Mounting an engine .................................... 11
8.2 Dismounting an engine ............................... 11
9. Maintenance and Inspection .............................. 12
9.1 Inspection – before each use ...................... 12
9.2 Maintenance instructions ............................ 12
10. Maintenance Cha t .............................................. 13
11. Notes .................................................................... 15

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Safety Regulations
. Safety Regulations
. Warnings
Failure to follow all of these safety instructions can
lead to severe injury or death from a sudden loss of
the load. Contact the manufacturer at the numbers or
address printed on the back cover of this manual if
you have any questions.
Anyone who ope ates this p oduct must ead and
unde stand all the inst uctions and wa nings
p ovided with this stand befo e being allowed to
use it. All operators must be careful, competent,
trained, and qualified in the safe operation of the
stand. The owner (or other responsible individual)
must ensure that any operator observes the proper
safety procedures for using this stand at all times. If
the operator does not read well or is not fluent in
English, the owner / manager must read and review
the instructions and warnings in the manual with the
operator in the operator's native language to be sure
that the operator will use the stand properly.
The owne / manage must keep this manual fo
futu e efe ence, and make sure the warning labels
on the product are legible and intact at all times.
eplacement labels and manuals are available from
the manufacturer. Call the manufacturer using the
contact information on the back cover of this manual
if you have any questions.
Wea eye p otection that meets the requirements of
ANSI Z87.1 and OSHA.
Make su e the load does not exceed the maximum
capacity of the stand. Maximum capacity is 6000 lb.
Do not exceed. Overloading can result in equipment
failure.
Neve use pa ts, attachments, o accesso ies that
have not been p ovided by the manufactu e . Do
not use hardware with a lower grade than what is
provided by the manufacturer.
Neve modify the p oduct in any way. Modifications
may cause the dolly to perform improperly, resulting
in injury or death.
Always use caution while ope ating this device and
remain mindful of how the device and load will react
during operation of this device. Do not use anything
other than the supplied handle to rotate the engine.
Off-cente loads may make the load and handle
otate in either direction when the rotational locking
device is released.
Neve load stand ab uptly. Load stand slowly and
carefully. Never subject the stand to abnormal shocks
or loads. Your safety and that of others depends on
the proper operation of the stand.
Always use Anti-Rotation leve while moving
loaded engine stand.
Neve allow the engine’s cente of g avity to be
misaligned with the engine stand’s axis of otation.
Ensure engine is fully secured to Engine Adapter Plate
before placing on stand.
Always apply the locking sc ews when stand is
being loaded and/o emaining stationa y.
Always use engine stand on a ha d level su face.
Be sure surface is clean and free of debris, cracks,
and chips. Avoid any uneven or dirty surfaces when
moving loaded engine stand.
Neve mount anything othe than automotive
engines without accessories or attachments supplied
by the manufacturer.
Neve abuse o cause damage to the stand. NEVE
subject the stand to abnormal shocks or loads. Your
safety and that of others depends on the proper
operation of the stand.

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Fo ewo d
2. Foreword
2. From the manufacturer
Thank you for your purchase. To complement the
offering of A/C, fluid and nitrogen service equipment,
MAHLE Service Solutions has partnered with Gray
Manufacturing to provide the highest quality hydraulic
and pneumatic equipment available for the professional
service technician. This equipment adheres to high
standards promised in the MAHLE guarantee including
the assurance of innovation and reliability that comes
with the Gray Manufacturing name. Please contact
MAHLE Service Solutions’ customer service at (800)
468-2321 or [email protected]le.com with any
comments or questions.
3. Symbols Use
3. Signal words
Signal words call attention to a safety message or
messages, or a property damage message or
messages, and designate a degree or level of hazard
seriousness. Signal words used in this manual include:
Keywo d P obability of
occu ence
Seve ity of dange if
inst uctions not obse ved
DANGER
Immediate
impending danger
Death
or
severe
injury.
WARNING Possible
impending
danger
Death
or
severe
injury
CAUTION
Possible
dangerous
situation
Minor
injury
NOTICE
Possible
damage to
property
Possible property
damage

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Responsibilities
4. Responsibilities
4. Receiving inspection
Before attempting to operate this equipment, thoroughly
read and understand this manual. Completely remove all
tape and packaging. Inspect the equipment immediately
upon delivery. If shipping damage is evident, inform the
delivering carrier immediately and contact the
manufacturer using the contact information on the back
cover of this manual.
4.2 Owner and/or operator responsibilities
The owner of this equipment must read these
instructions and maintain them for future reference and
for instructing any other users of the equipment. The
owner is responsible for keeping all warning labels and
instruction manuals legible and intact. eplacement
labels and literature are available from the manufacturer.
The owner must never authorize or allow anyone to use
this equipment until the operator has read and
understood the information in this manual and on the
accompanying labeling on the equipment itself.
If this equipment is being used in an occupational setting
(or workplace), the employer should ensure that all
personnel working with and around the equipment know
of the risks associated with its use. Personnel involved in
the use and operation of this equipment shall be careful,
competent, trained, and qualified in the safe operation of
the equipment and its proper use when servicing motor
vehicles and their components. Safety information
provided with this equipment should be emphasized by
the employer and understood by each employee. The
employer must make this manual available to all
personnel using this equipment and all personnel must
read and understand the contents of this manual. If the
operator is not fluent in English, the manufacturer’s
instructions and warnings shall be read to and discussed
with the operator in the operator’s native language by
the employer, making sure that the operator
comprehends its contents and observes the proper
procedures for use of this equipment.
5. Specifications
5. CES-6000
Model CES-6000 US units Met ic units
Maximum capacity 6000 lbs 2721.6 kg
Overall width 49 in 124.5 cm
Overall length 78 in 198.1 cm
Overall height 49 in 124.5 cm
Maximum swing radius 42 in 106.7 cm
Handle length 12 in 30.5 cm
Weight 835 lb 378.8 kg

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P oduct Desc iption
6. Product Description
6. Component identification
Fig. 1: CES-6000 Side view
1Adapter extension plate
2Adapter adjuster plate
3Tool tray
4Gear box
5Anti-rotation lever
6Gear box crank handle
Jack handle
8Locking screw
9Jack

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Assembly
7. Assembly
7. CES-6000 assembly
Use care while assembling engine stand. Parts are
heavy and awkward to handle. Have another person
assist with assembly where necessary.
Use figures to assist in assembly of engine stand. If
assembly instructions are not understood, contact the
manufacturer using the contact information printed on
the back cover of this manual for assistance.
Tools Requi ed
Small snap ring pliers
Large snap ring pliers
3/4” wrench
3/4” socket
7/16” wrench
7/16” socket
15/16” wrench
1-1/2” socket
Pliers
3/8” socket
1/8” Allen wrench
Fig. 2: Base assembly parts
1Caster, swivel plate, 6” diameter (2)
2Lock washer, 1/2” split type (8)
3Nut, 1/2”-13UNC (8)
4Cap screw, 1/2”-13UNC, 1-1/2” long (8)
5Threaded rod, 5/8”-8 ACME (2)
6Roll pin, 3/16” diameter, 1-1/8” long (2)
Crank handle (2)
8Engine stand base (1)
9Wheel, 8” diameter, 2-3/16” wide (2)
10 Engine stand, front wheel spacer, 3/8” wide (4)
11 Retaining ring, external, 3/4” diameter (4)
12 Engine stand, washer, 1/4” wide (4)
13 Engine stand, front wheel axle (2)
1. Use items 2, 3 and 4 to fasten item 1 to engine stand
base (Item 8).
2. Assemble locking screws, putting items 5, 6, and 7
together.
3. Screw locking screws into the engine stand base to
prevent movement while assembling engine stand.
eference Component Identification diagram if
needed.
4. Use items 11, 12 and 13 and items 9 and 10 to
assemble front wheels on engine stand. Be sure to
put item 10 on either side of item 9 when assembling.

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Assembly
Fig. 3: Jac and main top assembly
14 Jack with pivot block (1)
15 Cap screw, 1/4”-20UNC, 1-1/2” long (3)
16 Flat washer, 1/4” (3)
1 Jack bracket, 1/4” thick (1)
18 Jack bracket spacer, 1/8” thick (4)
19 Nut, 1/4”-20UNC (3)
20 Retaining ring, 1-1/8” diameter (2)
21 Base pivot pin, 1-1/8” diameter (1)
22 Main top (1)
5. Place item 14 on the pivot tube of the engine stand
base. Use items 17 and 18 to capture item 14. Item 17
will go over the top edges of item 14 to hold in place.
Item 18 is only used as a spacer; not all may be used.
6. Item 14 should be secured and oriented to pivot tube
of engine stand as shown. Secure with items 15, 16,
and 19. Lay pivot tube on floor.
7. Using a shop crane, lift item 22 and put onto engine
stand base (item 8), securing with items 20 and 21.
Fig. 4: Shaft assembly
23 Rotating shaft assembly (1)
24 Gardur bearing, 5-3/4” long (1)
25 Jack pivot mount (1)
26 Washer, 3” diameter (2)
2 Retaining ring, 3” diameter (2)
8. Slide items 24 and 25 over the end of item 23.
9. Slide items 26 and 27 to the end of item 25. Be sure
to secure item 27 in groove on item 23.
10. Slide remaining item 27 over to the end of item 23,
securing it in the 2
nd
groove.
11. Slide remaining item 26 to item 27 to complete shaft
subassembly.

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Assembly
Fig. 5: Gear box installation
28 Retaining ring, 1-1/2” diameter (2)
29 Jack pivot pin (1)
30 Cap screw, 1/2”-13UNC, 3/4” long (4)
31 Flat washer, 1/2” (4)
32 Gear box spacer (2)
33 Gear box (1)
34 Cap screw, 1/4”-20UNC, 1/2” long (1)
35 Flat washer, 1/4” (1)
36 Square key, 5/8”, 1-3/8” long (1)
3 Retaining ring, 3” diameter (1)
38 Flat washer, 3” diameter (1)
39 Gardur bearing, -3/8” long (1)
12. Using a shop crane, slide the shaft subassembly and
item 39 into the rotation hole of item 22.
13. Once in place, slide item 37 and 38 on the end of the
shaft subassembly.
Make sure item 37 is secured in the groove of item 23.
14. Lower the shaft subassembly so item 25 lines up
with item 14.
15. Insert item 29 through items 14 and 25.
16. Secure item 29 with item 28.
17. Put item 36 in keyway of shaft subassembly. Secure
items 34 and 35 to end of shaft subassembly.
18. Slide item 33 over the end of the shaft subassembly.
Be sure to align the keyway on item 33 to keyway of
the shaft subassembly and item 36. otate input shaft
of item 33 to align keyways if needed.
19. Insert item(s) 32 under item 33 to ensure proper
alignment of items 25 and 33. All of items 32 may not
be used.
20. Use items 30 and 31 to secure item 33 to bracket of
item 22.
Fig. 6: Installing engine plates and handle
40 Jack handle (1)
41 Anti-rotation lever (1)
42 Gear box crank handle (1)
43 Set screw, 1/4”-28UNF, 1/4” long (2)
44 1 ” long chain subassembly (1)
45 Cap screw, flange lock, 1/4”-20UNC, 1/2” long (4)
46 Tool tray (1)
4 Adapter adjuster plate (1)
48 Cap screw, 5/8”-11UNC, 1-1/2” long (4)
49 Adapter extension plate (2)
50 Cap screw, 1”-8UNC, 3-1/2” long (3)
21. Attach item 47 to front of shaft subassembly using
items 50. Torque to 150 ft-lbs.
22. Attach items 49 to item 47 using items 48. Torque to
120 ft-lbs.
23. Place item 46 on top of item 22, being sure to align
holes of item 46 to threaded hole on item 22.
24. Use items 35 to secure item 46. Be sure item 46 is
offset away from item 42.
25. Slide item 42 over the input shaft of item 33. Use
items 43 to secure item 42 to item 33.
26. Attach item 44 to bottom of item 46 and item 41.
Close s-hook with pliers.
27. Place item 41 in pocket of item 22 as shown.
28. Put item 40 in place as shown above.

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Ope ation
8. Operation
WARNING - This section discusses the appropriate and
safe methods for using the stand. Failure to follow all of
the steps outlined in this section could result in serious
injury or death.
8. Mounting an engine
The engine stand is designed to hold and rotate
engines weighing no more than 6000 pounds.
1. Prepare the engine to be mounted to the stand.
emove all components that will be in the way of
attaching the engine adapter plate to the engine.
2. Attach engine adapter plate to the side of the engine.
Make sure the bolts are securely fastened.
3. Using a shop crane or other suitable means, move the
engine into position for attaching to the adapter
extension plates.
4. Align the engine’s center of gravity within 2” of the
engine stand’s axis of rotation by raising or lowering
the engine.
5. Align the adapter extension plates with the closest
5/8”-11UNC holes of the adapter adjuster plate.
6. Secure the adapter extension plates to the adapter
adjuster plate on the engine stand. Torque bolts to
120 ft-lbs.
7. Slowly transfer the engine’s weight to the engine
stand.
If the engine or stand shifts, moves, or rotates, check
that the engine’s center of gravity is in line with the
engine stand’s axis of revolution and that all hardware
is properly tightened. If something seems wrong,
remove the engine stand from service and inspect it
according to the Inspection Instructions in this
manual.
8. otate gear box crank handle to rotate engine. Use
jack and handle to raise and lower the engine as
necessary. When engine stand is stationary, use
locking screws to prevent the engine stand from
moving.
8.2 Dismounting an engine
1. Prepare engine for moving and engine’s destination
for accepting engine.
2. Make sure the Anti-rotation lever is inserted, capturing
the crank handle. Be sure the locking screws are
lowered, and the engine stand does not move.
3. Using a shop crane or other suitable means, capture
engine and transfer engine’s weight to equipment
being used to move engine. Follow instructions
provided with equipment being used to move engine.
4. Carefully detach engine adapter plate from the
adapter extension plates.

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Maintenance and Inspection
9. Maintenance and Inspection
 WARNING - The engine stand must be inspected
according to the requirements of this section. Failure
to properly inspect the engine stand could lead to
severe injury or death. The engine stand must be
removed from service and inspected immediately if it
is subjected to an abnormal load or a shock load. If
any irregularities or problems are detected during an
inspection, the engine stand must be removed from
service immediately and repaired. Contact the
manufacturer using the contact information printed on
the back cover of this manual.
9. Inspection – before each use
Visual inspection of the engine stand must be made
before each use. The engine stand should be
immediately removed from service if any of the following
conditions are detected or observed:
Any part is cracked, chipped, bent, or shows signs of
excessive wear or any other type of damage.
The wheels and/or casters do not roll freely or the
axles appear bent or otherwise damaged.
Any abnormal condition or sign of damage that
suggests the engine stand will not work properly.
Check that all hardware is properly tightened and in
good condition.
Check that the engine mounting plates and mounting
hardware are not bent or stretched.
Verify that all warning and instructions decals are in
place and legible before the lift is put back in service.
If any decals are missing or illegible, contact the
manufacturer for replacements.
If any irregularities or problems are detected during an
inspection, the stand must be removed from service
immediately and repaired. Contact the manufacturer
using the contact information on the back cover of
this manual.
9.2 Maintenance instructions
WARNING - All inspection and maintenance procedures
must be performed after the jack has been removed
from service. Failure to do this may result in personal
injury and/or property damage.
All warning and capacity labels should be readable
and complete. Wash external surfaces of stand,
labels, and decals with a mild soap solution.
Lightly oil or grease any places where the paint has
worn off to prevent corrosion and lubricate
movement.
Grease front wheel axles.

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Maintenance Cha t
0. Maintenance Chart
Action Date Details Pe son
esponsible
eceiving inspection
Assembly

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Maintenance Cha t
Action Date Details Pe son
esponsible

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Notes
. Notes

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TSL
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670
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90811
MAHLE Afte ma ket Inc.
10 Innovation Drive
York, PA 17402 U.S.A.
Phone: [phone]
Fax: [phone]
E-mail: tec[email protected]hle.com
www.servicesolutions.mahle.com