SERVICE, OPERATION AND PARTS MANUAL FOR 21A/42A

1505 7th ST E. Moline, IL 61244 Phone (309) 764-9842 Fax (309) 764-9848 Email: liftit@lift-systems.com Web: www.lift-systems.com Date

Table of Contents
Specifications……………………………………………1 General Information.…………………………………….2 Always do the following…………………………………4 Never do the following…………………………………..5 Prestart Inspection………………………………………8 Power Unit Description………………………………….9 Power Options………………………………………….13 Lifting Unit Layout………………………………………15 Lifting Unit Description. ……………………………….16 Pre-operational checklist………………………………17 Preparation & Set-up…………………………………..19 Attaching the load………………………………………31 Using the Load Chart Check List……………………..31 Load Chart Check List…………………………………33 Load Chart. …………………………………………….34 Caution………………………………………………….35 Extend & Retract Sequence…………………………..35 Travel Procedure……………………………………….36 Lowering the load……………………………………...37 Options………………………………………………….38 Utilization………………………………………………..41 Maintenance……………………………………………42 Cylinder packing replacement………………………..45 Testing cylinders for bypass………………………….46 Maintenance Chart…………………………………….47 Troubleshooting.……………………………………….48 Hydraulic oil MSDS.……………………………………53 Grease MSDS…………………………………………..57 Pre-Lift Check List………………………………………61 & 62 Pre-lift Planning check list……………………………..63 & 64 Parts……………………………………………………..P1-P12 Recommended Spare parts………………………….P13 Repair section………………………………………….R1-R55

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SPECIFICATIONS
Model Number 21A/42A Weight of each lifting unit: 3500lbs Weight of power unit: 3500lbs Lifting unit dimensions: 9’ 8-1/2” H 36” W 66”L Capacity of power units in gallons: 100 Power: 220V/60Hz/3phase/10Hp/55FLA

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and without deviation from its original intended use. DO NOT operate this system if you are not familiar with its components and the principles upon which they operate.LIFT SYSTEMS Introduction The lift system consists of two or more bases. 2 . The operating condition of this hydraulic system depends upon your compliance with the procedures and precautionary measures set forth in this safety & operations manual. NOTICE Authorized personnel. All procedures are based on the safe operation of the lift system in proper operating condition. precise lifting and smooth movement of heavy loads. must demonstrate a complete knowledge and understanding of the system including:     Proper operating procedures Safety factor requirements Proper maintenance procedures Troubleshooting techniques Personnel operating the system must advise the supervisor immediately if a malfunction occurs. DESIGN This lift system is designed for accurate. trained to operate the equipment. It is also designed to be very stable when used with proper and safe rigging practices. basic direct manual hydraulic controls. low friction wheels Lifting beam attachment assembly Remote Control 220 volt three phase 60HZ GENERAL The hydraulics used on this lift system consists of one or more power units. performed by competent rigging and maintenance personnel. consists of:       Standard equipment Hydraulic powers units Double-acting telescopic cylinder High capacity. and double-acting telescopic cylinders.

warnings and cautions have been used throughout this manual to emphasize these areas of concern. WARNINGS & CAUTIONS Anyone authorized to operate and maintain the system must become completely familiar with this manual. All safety devices must be engaged prior to operation. They are defined as follows: WARNINGS If not followed could end in injury or death to personnel. MAINTENANCE RECORDS & EQUIPMENT UTILIZATION LOGS Accurate records on the usage and the maintenance of the system are highly recommended. level surface. Since the safety of personnel through the proper use of the system is paramount. DO NOT rely on past experience with similar types of lifting devices. CAUTIONS If not followed could end in damage or loss of the system. The lift system must not be operated at capacities beyond those specified by the manufacturer (see load chart on the power unit). 3 . become familiar with the system and its limitations. Authorized personnel must update the records each time the system is in use or maintenance duties are performed.OPERATING CHARACTERISTICS & LIMITATIONS Prior to operation. CAPACITIES & STABILIZATION The lift system must be operated on a firm.

Check the load chart before lifting the load to determine the exact pressure needed to lift the load. Shim the runway track every three feet. * Perform complete pre-start inspection of the system before each use. * Use runway track. * Have all lifting beams and runway track approved by a qualified professional engineer before the lift.) to verify capability of handling specified load. or when the system will be traveling over pits or open areas in the floor. * * 4 . * Check to make sure all lifting units are level and plumb at all points. etc. Use the load chart checklist provided. Check for structural verification of the capacities based upon lifting points and load distribution. Use signalmen to alert the operator of hazards he cannot see from the operator station. Verify that all safety devices are properly connected and engaged. before starting any system movement. Plan your lift in advance.IMPORTANT ALWAYS DO THE FOLLOWING: * Understand all system operations. before accepting any operating or maintenance responsibility. Check for stress level and deflection in both. * Use proper operating procedures. Use a signaling device to alert personnel that a lift or traveling operation is beginning. Perform required maintenance functions before beginning lifting or traveling. Clear the work area of all personnel not essential to the safe operation of the lift system while lifting or traveling. Check often during lifting and traveling to make sure that the system remains level and plumb. * Check all rigging (shackles. including the safety procedures. Use accurate leveling measuring devices (tapes or level-lift systems) to determine whether the system is level and plumb. * Be alert to any space problems and clearances required. including overhead cranes in the area. chokers. Shut off power unit(s) when not in use. Have a qualified professional engineer verify capacity to span lengths greater than three feet.

preparation. Use sight method of determining whether the lift beam(s) or lifting units are level and plumb. Operate a malfunctioning system. basements. Secure the twin-line hoses to the lifting unit(s) when traveling. Use accurate level measuring devices (tapes or level-lift system). Allow anyone to change or alter the plumbing. or fabricated assemblies without the expressed permission of the manufacturer. Shut down and seek qualified assistance. Leave the system controls unattended with the engine running. or when a load is suspended. Allow people to do any work under a suspended load unless safety cribs or stands are installed to support the load during the process. unless the third stage is fully retracted. Allow unauthorized or inexperienced personnel to operate the system. Cover any hydraulic lines with fire retardant material if torch or welding work will be performed near the lift system. tunnels. * 5 . or unsupported areas unless a qualified professional engineer has verified the track capacity and the foundation loading capacity beforehand. CAUTION! NEVER DO THE FOLLOWING: * Operate the system without performing all necessary inspections. Use runway track to traverse pits. Lift more than the maximum capacity of the third stage. Underestimate the power of this system. Check the pressure readings against your load chart. Take anyone's word for the weight of a load.* Keep all hydraulic hoses clear of travel area. * * * * * * * * * * Allow anyone to override or bypass safety devices. electrical. and proper set-up beforehand.

WARNING! Never crib under the base of the lifting unit.WARNING! Do Not adjust any factory-preset valves without the express permission and written technical instructions from the manufacturer. If they are not there is the chance that the lifting unit could be kicked out from under the header beam if it were to become unlevel. not any other part of the unit. By doing so it could be possible for the track to slide out from under the system causing the loss of the load. This can cause damage that could score the bores causing internal bypass and the cylinder will no longer to be able to hold a load until it is repaired. Doing so could cause an electrical arc between the cylinder pistons and the bores of the cylinders. which can cause damage. WARNING! Never set runway track up on snow or ice. The lifting unit is designed to carrying the load with the wheels. WARNING! Always make sure the ends of the header beam extend out over the edge of the header plates. 6 . WARNING! Do Not weld on any part of the system. injury. Never attach a welding ground to the lifting units. Doing so will cause the lifting unit to become unstable. or the loss of life.

Doing so may cause the system to become unstable.WARNING! Never allow the header plate to be attached to an unlevel object. 7 . resulting in the lifting unit being kicked out from under the load.

even if other personnel may have recently used the system. Clean all quick disconnection points in the hydraulic system before connection occurs. Proper hydraulic oil level** E. Thoroughly cleaned hydraulic connection points I. Repair as required G. No leaks or damage. Any required lubrication F. Proper engine oil level*(Gas or diesel only) C. and any foreign objects (towels. etc. gas. MAINTENANCE RECORDS Update your maintenance records each time the system is operated or maintained. LP. or dual fuel power ** With all cylinders fully retracted there should be 1 to 2 inches of air space in the power unit oil reservoir (a) Except air-cooled engines It is the user's responsibility to inspect the system before operation. Proper water level in radiator*(a) (Gas or diesel only) D. OVERALL CLEANLINESS Check all system surfaces to be sure they are free of oil. LUBRICATION Consult the lubrication chart and maintenance record to see if lubrication is necessary prior to operation of the system. The life of the system will depend upon proper care and maintenance.) which might interfere with operation or maintenance of the system. papers. tools. 8 . Lift/propel handles shifted to desired position H. fuel. All safety devices engaged * If diesel. Repair or replace as required. Adequate fuel level*(Gas or diesel only) B. EQUIPMENT UTILIZATION RECORDS Personnel authorized to operate the system must document usage of the system so that it may be properly maintained. Check for signs of physical damage or wear.PRE-START INSPECTION The Pre-start inspection and maintenance must include checks for: A.

spool valve with blocked working ports. so the operator is limited by the length of the cord. Their function is to divert the hydraulic oil into the proper hydraulic circuit by moving the spool electronically. Propel mode/reverse travel: This position works as described above. 9 . The spool directs oil into the highpressure side of the circuit. As a safety feature. spring centered. solenoid operated. send a signal to the valve which route high-pressure oil from the gear pump to extend the cylinder. causing the lift unit to travel in reverse. Propel mode/Forward travel: This position works the same as described above with the exception that the lift propel valve handle on the lifting unit must be shifted to the propel position.POWER UNIT DESCRIPTION (Refer to drawings below) Directional control valves: The control valves are a three positions. Lift mode/retract cylinder: In this position the valves are routing high-pressure oil to the retract port of the cylinder. However. Pulling the joystick will then route oil to the hydraulic drive motor causing the lift unit to travel forward. In this position. pendent is not wireless. and returns the low-pressure oil to the reservoir. the joysticks are automatically centered when they are released. Oil returning from the piston end of the cylinder at low pressure is routed to the oil reservoir. Neutral Position: When the joysticks on the pendent are centered or neutral position the oil coming from the gear pump to return to the reservoir at low pressure. Pushing the handle will then route oil to the hydraulic drive motor. The valves are controlled by a pendent that the operator can carry around. Lift mode/extend cylinders: In this position the joystick. The pendent control the hydraulic control valves. with the exception that the lift propel/valve handle on the lifting unit must be shifted to the propel position. Oil returning from the cylinder rod end at low pressure is routed to the oil reservoir. It does allow some freedom of movement so the operator can get a better view of the lift. the work ports of the valve are blocked.

10-micron filter. are monitored as described below. When the needle is into the red during operation. Systems with a 200 gallon power unit or less have a return filter with a dial type gauge. The individual lifting unit gauge will indicate pressure only when cylinders are extending. the filter element must be replaced. the filter element should be replaced.Pressure Gauges: On all Lift Systems' power units there are hydraulic oil pressure gauges to provide information to the operator. so the indicator also will vary. Lifting unit pressure gauge Lifting unit pressure gauge. This problem must be corrected before the lift proceeds. Larger systems have a highpressure. it means the unit is lifting more load. 10 . and operating condition of the main hydraulic functions of the power unit. When needle is in red Element needs to be replaced. Hydraulic Oil Filter Dirt Indicator: All systems are equipped with some sort of hydraulic filter. When one of the lift units has a higherpressure reading. and are also equipped with dirty filter indicators. The operator monitors load distribution by comparing the amount of oil pressure required by each lift unit to raise the load. When these indicators are showing red. The brands of filters used have varied over the years. The load distribution on the lifting units.

covers should be used on coupler halves any time the couplers are not connected. Refer to the replacement parts section of this manual for suction strainer specifications and instructions for replacement. WARNING! Operation of this system with this shut off valve in the closed position will cause irreparable damage to the pump. If equipped with dust covers. Periodic inspection of the strainer is recommended. Couplers must be wiped clean prior to use. must be open at all times. These must be routed to the lifting unit with the corresponding number on it. Failure to do so could allow dirt to get into the system causing premature wear on hydraulic components 11 . located in the suction line between the reservoir and the pump. (Valve in closed position) Quick Couplers: The couplers on the power unit connect to the twin line hoses. requiring replacement. CAUTION! The quick couplers must be kept free from contamination at all times. This shut-off valve is only to be used by a qualified service technician when servicing the hydraulic system. Suction Strainers: Each power unit is equipped with a 125-micron suction strainer in the reservoir. Immediate failure of the pump may result if the proper procedures are not followed. This strainer will allow the unit to run for a long period before the strainer becomes clogged.Shut-off valve: The shut-off valve.

Main Disconnect Switch Lever: This switch must be disengaged before the electrician may access the inside of the control box for wiring. Stop Switch: This switch turns off the electric motor. It must be engaged with the door in the closed position only. The switch eliminates the need to have to switch wires to get the motor to run in the proper direction. Phase Reversing Switch: This switch is used when the phase is wrong and the motor will not run. There is a phase monitor in the system that prevents the motor from running in the wrong direction.Electrical Control Switches: Start Switch: This switch starts the electric motor. unless there is a service issue with the electrical components. Emergency Stop Switch: This switch is used in case of an emergency to kill all power to the electrical circuits and motor controls. On Indicator Light: This light comes on when the start switch is pressed. and then a qualified person should only do it. Hour meter Main disconnect Phase Reversing switch 12 .

If the unit does not start the incoming. Once the unit is connected to its power source. the unit will not run. Failure to do so can be fatal. If that phase is wrong. It should start. This prevents improper rotation of the hydraulic pump. make sure that the wire supplying the power is of adequate size. Push the green start button on the gauge panel. phase maybe incorrect. A certified electrician should confirm this. there is a forward/reverse switch. There are circuit breakers inside the enclosure check to make sure one of them is not tripped. but if it fails too then the problem lays somewhere else. Most are built to the customer's specifications. However. On the door of the enclosure. which will cause pump failure.POWER OPTIONS Electric Motor Option: Caution! A certified electrician should perform this task. Warning! Before connecting the power unit to a power source. Always confirm the power is turned off and locked out before doing any work inside the enclosure. 13 . Turn the switch to the other position and try to start the unit again. Failure to do so can cause fire and/or personal injury. There is no “standard” electric option. This device checks the phase of the incoming power. turn the disconnect to the “ON” position. some things are standard such as a phase monitor.

the oil pressure should be in the range of 207 to 380 KPA (30 to 55 PSI) at full load RPM. involves several checking and servicing procedures. Within seconds after starting the engine. starting. If the engine does not start on the first attempt. Caution! Always let the engine run at idle speed without a load for at least two minutes before stopping. Observing these practices will help the user extend the life of the engine. follow their instructions for starting. After engine has reached operating temperature. the ignition switch is turned counter clockwise and held until the preheat indicator light goes out indicating that the engine is ready for starting. If it becomes necessary to use an additional source of power to start the engine. Operation Operation. Warning! Use of ether as a starting aid may cause an explosion resulting in severe personal injury and engine damage. Longer periods can ruin the heater element. check fuel supply system. operating. and stopping the engine and related equipment. wait two minutes before re-cranking. This lets the engine cool gradually and uniformly. * If the engine fails to start after 30 seconds. Do not engage the starter for periods longer than 30 seconds without allowing 2 minutes for the starter to cool. use a 12-volt battery connected in parallel. On most diesel options. and shut down instructions. * Allow the engine to warm up before applying a load. including following pre-start. Absence of blue/white exhaust smoke during cranking indicates no fuel is being delivered. Some options may have a push button that needs to be pressed and held until the light goes off.Gasoline or diesel options: Pre-heating and Starting the Diesel Engine The engine starting procedure depends on the controls and safety shutdown equipment furnished by the manufacturer. pre-heat. before the engine is started. 14 . oil pressure should exceed a minimum of 60 KPA (10 PSI). Caution! Caution! Limit pre-heating to recommended periods. * Engines equipped with a glow plug will have a pre-heat indicator light. Do not use ether as a starting aid as heat from compression or heat from glow plugs may cause a sudden ignition of the ether vapor.

LIFTING UNIT LAYOUT ITEM # 1 2 3 4 5 6 5 DESCRIPTION Lift Quick Couplers Shift Handle (Lift/Propel) Header Plate Spacer Block Clamp Block Propel Quick Couplers 4 3 2 1 6 15 .

The valve is used to let lifting units freewheel. Failure to do so could put the lifting unit in a side-loaded condition. remove the two (2) or four (4) bolts on top and slide the wheel box over to the next set of holes. valves and cylinders. which are retractable to 48 inches. Dust covers must be used when couplers are disconnected. When starting a lift or setting a load down these valves should always be in the Freewheel position.LIFTING UNIT DESCRIPTION Selector Valve for Lift/Propel: The lift/propel valve is used to select the mode in which the lifting unit is currently operating. Quick couplers: The large couplers on the lifting units connect to the hoses from the power unit. CAUTION! When retracting or extending wheel boxes. When the wheel boxes are extended. It is advisable to keep something such as brake cleaner at hand to clean the quick couplers before connecting them. The wheels are supplied with special anti-friction bearings to facilitate ease of movement. The upward handle position is for operating the travel. The maximum rolling capacity is only achieved on firm. Failure to do so could cause contamination of the hydraulic oil causing failure of pumps. make certain that all shims remain with the wheel box. Wheel boxes and shims must be returned to their original place on each unit if removed for any reason. To move the wheel boxes in. or the width of the lifting unit. Retractable wheel boxes: Some models feature wheels. Selector Valve for Propel/Freewheel: This feature is only found on system that have integral drives installed them. the shims must remain with the same wheel box whether extended or retracted. The small couplers connect propel devices to the lifting units. Failure to do so will cause the lifting unit to be out of level. They may also have shims for leveling. Replace bolts and tighten to between 45 to 50 foot/pounds torque. CAUTION! The quick couplers must be kept free from contamination at all times. The standard runway track is also retractable. causing a side-loaded condition. level track surfaces. The downward handle position is for operating the lifting and the lowering function. which allows them to center them selves with the load or to travel. the width is 60 inches. Some units do not have retractable wheel boxes. 16 . Couplers must be wiped clean prior to use. If the wheel boxes have been shimmed.

Check the cylinder bolts. Use the Pre-Lift Check List on pages 61 & 62.) Check for leakage around tops of cylinders. Below is a checklist of items that should be inspected. If electric option.) Check all hoses that are exposed to sunlight for cracks.) Do a visual check of all exterior welds for cracks on the lifting units. the lock washers should be fully compressed. (A damaged hose could burst under pressure.     If gas or diesel powered. If water-cooled. check the engine oil levels. they should read zero when the system is not running as well as when the pressure is dumped off by rocking the control valve handles back and forth. oil running down the cylinder is not new rod seals maybe required. Check hydraulic oil level. This would mainly be the power unit hoses. Check for strange noises coming from electric motor when running. (This means there could be water in the oil. Check power cords for damage.) Check twin line hoses for damage. (The lift cylinders must be fully retracted. Check pressure gauges. check the water level. which causes loss of lubrication and component failure. Sunlight can cause the outer cover of the hoses to become brittle and crack over time.) Check wheel box bolts for tightness.) Check oil for cloudy or milky appearance. (A damaged hose could burst under pressure. 17              . Check fuel level. (A little dampness over time is normal.PRE-OPERATIONAL CHECKLIST Before making every lift an inspection should be made of the system. check to see if there is sufficient power at job site to operate the system.) Check hose reel hoses for damage. Check power cords for proper gauge. (If the gauge will not go to zero then it is faulty. (Retighten if needed.

     18 .) With the power unit running check the indicator on the hydraulic filter to see if it reads dirty. Check quick disconnects for leakage. The maximum operating pressure will be the highest pressure shown on the load chart. (If leakage is visible the shaft seal on the pump maybe leaking. (If it is. Check track bolts for tightness. Check for oil leakage around the mounting surface of the pumps on the power units. Check track for debris. it should be changed.) With the power unit running and the twin line hoses disconnected check the operating pressure by pulling one of the control valve handles.  Check for signs of oil leakage from lifting units.

The lifting points on the beam (where the lifting links are placed on the beam) need to be kept as close to lifting unit as possible to minimize deflection.C.R. contact a qualified engineer for verification of the layout.C. The loads on all lifting links needs to be as equal as possible to minimize the chance of overload. if possible. The lifting units must be kept as close to the load as possible to minimize deflection in the lifting beams. B. The lifting beam span needs to be as short as is possible to minimize deflection. E.A.A. Lay out the lift dimensions on paper Do a dimensional layout of the lifting arrangement before doing any set-up.PREPARATION & SET UP In addition to following the steps below. It is recommended that copies are made and the original in this manual remains in the manual as a master. There are five critical dimension points which must be laid out before setting up to pick a load. This manual maybe purchased through the S. If there is any question about the load. manual. The layout of the lift must take these five critical points into consideration. website http://www. D.R.C. are followed.R. On pages. or distribution of the load equally among the lifting units. 19 . center of gravity. A. which may be used for planning a lift.A.scranet.org/store/. The wheel boxes on each lifting unit must be extended. C. by the S. Place runway track accordingly. 1. 63 and 64 of this manual is a Pre-Lift Planning checklist from the S. it is highly recommended that the practices in the published by "Recommended Practices for Telescopic Hydraulic Gantry Systems" manual. for maximum stability.

The use of runway track is required. injury or death to personnel. Make sure all bolts are tight. Warning! Make absolutely sure the track sections are bolted to each other end to end and never use the track without the cross members. Bolt the sections together using the torque specification required. Distance between the opposite track sections must be measured carefully and corrections must be made before proceeding further. If in doubt. Failure to do so could cause the track to slip out from under the lifting units causing serious damage to the load or equipment and. Alignment of the sections from end to end is critical when traveling any distance. the strength of the supporting foundation should be verified by a qualified professional engineer. 20 . Re-shim the sections if necessary after correcting alignment. Care must be taken to make certain that the supporting foundation for the track or cribbing is adequate to support the total load. The runway track must be shimmed carefully to insure that the system remains level & plumb while traveling. Runway tracks should be parallel in the direction of travel.2. Set runway track on the floor or support surface.

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until after the load is lifted completely. or track that has been manufactured by an approved vendor using Lift Systems' design. 3. Perform any walk around inspections or maintenance as required. Lifting units must be level and plumb after set-up and during all lifting and traveling.All lifting units must be used on Lift Systems' runway track. Consult the factory for proper shimming & cribbing information. Track must be supported at the proper intervals based upon the load being lifted. Set lifting units in position. Track sections must be leveled as shown in the drawing above. The lifting unit will move slightly when lifting the load to find the center of the load on the beam. Use accurate levels to check the cylinders for level. 22 . or drives. Do not connect the lifting unit(s) to the track section with the propel cylinders.

always check the level of the system once the load has become suspended. If the system is out of level the track will have to be re-leveled.CAUTION! Because there could be settling in the track after the load is lifted. Check Level here 23 .

Using a control cable supplied with the system take one end and plug it into the plug labeled OUT on the master unit (#1). Before setting the lifting beam on the header plate. The masters will be power unit number one and number two and three and four will be the slaves. If using only a 2-point system just connect the pendent to the IN on the power unit. Place the lifting beam on the header plates and clamp the safety clips in place. Setting up and making the proper connections When connecting the remote pendent and the control cables is important they are connected in the proper order otherwise the system will not work. Now take the final cable and plug one end into the IN plug on the #1 MASTER and the other end into the pendent control.4. If lifting links are to be used. Pendent Control cable and all cables are the same. 24 . Take the other end of the cable and plug it into the plug labeled IN on the unit labeled SLAVE (#3). place links onto the lifting beam. One power unit will be the master the other is the slave. 5. If you are using lifting links. Make sure lift links and rigging are straight. All the cables are the same and they are keyed so they will only go in one way. position the links for lifting the load. Tighten safety clip bolts.

Each lifting unit operates on 220-volt single phase and each power unit has an amp rating of 55 full load amps. Therefore. each unit must be on its own circuit of at least 60 amps or all of them can be on the same circuit as long as that circuit has an amp rating high enough to operate all the lifting units together. 25 . contact an electrical contractor to look over the situation. units can be connected to power.Once the pendant and control cables are connected then the power. If there is any doubt.

you can turn the lifting units on and off. Using Integral Drives To use the drives shift the selector valve handle on the jacks to the propel position. Power indicator light. grip the hydraulic line firmly just behind the coupler and pull hard to insure that the couplers are connected together properly. Turn the switch to the right and all units can be ran with just the right hand joystick. Joysticks for operating each lifting unit. it must be set for single operation. This is a very dangerous situation. Attempting to do so two legs will travel while the other two will be lifting or lowering. Indicator light for when in ALL mode. Remove protective dust covers on the hydraulic quick disconnect couplers. To operate the individually turn the selector switch to the left. severe or death could occur. Two units are equipped with drives so the selector switch must be set to single. 7. Start/stop buttons. Clean all the connectors properly before connecting.6. now each unit can be ran individually. WARNING! Do not attempt to travel with the pendent set for ALL. Using the pendent control From the pendent. turns the unit on and off. 26 . This joystick will operate all units when in ALL mode. 8. Connect the hydraulic lines between the power unit and the lifting units. You can operate the lifting units all at the same time using one joystick or separately. For selecting single operation or operating all jacks with one lever. After the quick couplers are connected. Emergency stop must be pulled out before the units will start. Connecting twin-line hoses.

On electric power options. If the sections do not extend and/or retract in proper sequence with a load. Turn the motors off but leave the power on. consult the manufacturer immediately. is blocked from going back in the tank. 27 . If the pressure is not dumped off. 11.9. Some newer units are equipped with a catch bottle. If any unusual noises are heard. which is shown on the hydraulic schematic. The shift handle must be in the lift position. when extending. Extend lifting units six inches. Power unit starting. Selector valve handle. there should still be power to the pendent. 10. Shift the selector valve handles on the lifting unit(s) to the proper starting position. Disconnecting twin line hoses Before the twin line hoses can be disconnected. stop and check the couplers. Gently ease into the load so the cylinders can restage properly using the load to induce the right sequence hydraulically. verify the electric motor direction prior to constant running. The relief valve protects the cylinder in the event that return oil. Start the power unit and wait several minutes for the engine to warm up. the pressure in the rod end of the lift cylinder is then blocked from returning to the reservoir. If pressure builds high enough. shut the system down. and then retract them to ensure all hoses are properly connected and the system is working properly. it will be extremely difficult to reconnect the hoses. Reference the troubleshooting section of this manual for possible problems and solutions. Extend & retract test. before operating the system. all the pressure in the lines must be dumped off the system. some system have phase monitors that prevents the motors from turn the wrong direction. If oil is squirting from this relief valve. or the electric motor to get up to speed. it will relieve to the atmosphere through a relief valve. Start the power unit and allow several minutes the motor or engine to warm up before operating the system. 12. Warning! Do not lift the load suddenly if the cylinders are miss-staging. Failure to do so may result in damage to the hydraulic oil pump. CAUTION! If the retract coupler is not connected properly.

Caution! The lifting units should always operate parallel to each other. When traveling with loads. 28 . will create side loads in the cylinder stages causing them to miss-stage and leak.13. Shim all low areas to insure that the lifting units remain level and plumb during travel. Incorrect relationship between lifting units. two legs will travel while the other two will be lifting or lowering. WARNING! Do not attempt to travel with the pendent set for ALL. it must be set for single operation. such as allowing one side to get ahead of the other while traveling. Attempting to do so. severe or death could occur. the track should be level and parallel to the direction of travel. Traveling The system lifting units must be level and plumb at all times during lifting and traveling with loads. This is a very dangerous situation.

causing the load and the lifting units to fall over. 29 .Warning! If the wheels of the lifting units are to be in the same direction as the beam length. then make sure beam deflection is at an absolute minimum. Too much beam deflection may cause the lifting units to roll out from under the beam.

30 .WARNING! Failure to follow these safety procedures may result in severely hazardous conditions and may cause serious damage to the cylinders.

further movement of the handles may result in faster movement of the load. Convert this to a load figure. use the load chart provided to determine the amount of pressure needed to lift the required load. (Make sure all rigging equipment is adequate to handle the load to include proper safety factors. "Lift Load" Pressure: First. 31 . or the foundation support under the lifting units. and valves. or greater than. pull the valve handles gradually to insure accurate readings on pressure gauges. or links. As pressure increases to the predetermined lift pressure. couplers. Before starting the lift. Before the lift. If the load begins moving before the pressure is reached. track. you may overload and break chokers and shackles. fill out the load chart checklist with the pressure required at each lifting unit. When beginning a lift. Make sure the additional weight of any rigging or lifting beams used are included in the calculation of total load. the pressure to lift or stop will be the same. which should be moving the load. and rigging in case of overload. If the load has not moved when the "stop limit" pressure is reached the operator should…. Then. the operator will know when the lifting unit(s) reaches the pressure reading. and then proceed with the lift. any and all propel or drive options should be unpinned or shifted to freewheel. Next. This figure should be equal to. with rigging equipment rated properly for the weight of the load being lifted. watch for the load to begin moving. STOP!!! If you continue to lift. The range of pressure between "lift load" and "stop load" must not be more than 200 PSI. Use the load chart again to fill in "stop limit" pressure.Attaching and lifting the load. A higherpressure reading may occur due to increased resistance with increased flow and natural frictional losses in hoses. Attach the load to the lifting beams. "Stop Limit" Pressure: Determine the smallest amount of safety factor available in lifting beams. or cause deflection in lifting beams. fill in the pressure required for each lifting unit in the "lift load" line on the form.) How to Use the Control Valve and Pressure Gauges to Verify the Load Using the Load Chart Check List. the load you have calculated above. it may want to sway a little so it can find its center with the lifting system. runway track. Identify the problem and take whatever steps are required to solve it. In the case of a maximum load for that stage. The lifting process should be stopped until the load has stopped swaying. Depending upon the weight of the load. the load weighs less than calculated. Caution! When the load starts to clear its supporting foundation.

Increasing the pressure may overload the rigging equipment (chokers and shackles). If the setup is proper. 3. Caution! Recheck for level and plumb in all directions after a substantial portion or the entire load. is applied to the system. the beams and track for deflection. STOP!!!! Check the lifting units for level and plumb. Faulty gauges. with more pressure needed to overcome the friction caused by the side load. 5. The load is actually heavier than calculated. Make sure the rigging can handle the increased load before going to higher pressures. The lifting units are not level and plumb. 32 . the load is probably heavier than expected. 4. The load is tied or fastened down. causing side loads. 2.Warning! If the pressure specified on the load chart is reached and the load is not lifting: 1. Excessive beam deflection.

LOAD CHART CHECKLIST LIFTING UNIT #1 Approximate pressure Stage Lift load Stop Limit #1 PSI PSI #2 PSI PSI #3 PSI PSI LIFTING UNIT #2 Approximate pressure Stage Lift load Stop Limit #1 PSI PSI #2 PSI PSI #3 PSI PSI Approximate lifting weight ________ Approximate lifting weight ________ LIFTING UNIT #3 Approximate pressure Stage Lift load Stop Limit #1 PSI PSI #2 PSI PSI #3 PSI PSI LIFTING UNIT #4 Approximate pressure Stage Lift load Stop Limit #1 PSI PSI #2 PSI PSI #3 PSI PSI Approximate lifting weight ________ Approximate lifting weight ________ 33 .

34 .The decal that goes on the machine is Part Number DECAL224.

 Small section second. Excessive deflection of lifting beams causes severe side loading of cylinders and boom sections. contact manufacturer immediately.  Small section first. The system must be level and plumb at all times. 35 . Extending out of sequence may result in severe damage to the cylinder. The lifting units must be extended equally and lifting beams must be kept level. Use accurate measuring devices (tapes or level-lift system) to monitor these conditions.  Large bottom section second. It moves easily even under heavy load conditions. Operator and crew should constantly monitor exact cylinder extensions. The system may move by itself if not held back or blocked properly. Watch lifting beams constantly for deflection or signs of excessive loading. Cylinder sections must extend in the following sequence:  Large bottom section first.CAUTION! The system is equipped with anti friction steel bearing wheels. If cylinder sections do not extend or retract in a proper sequence. Cylinder sections must be retracted in reverse sequence.

See the option section for instructions on using the different drive options. The connections must maintain equal distance between the lifting units while traveling. Make sure that the connection from the front to the back lifting unit. 36 . then the drives can be engaged for traveling.TRAVELING PROCEDURE After load is lifted slightly. Travel speed can be adjust with these flow controls Begin travel of the lifting units by slowly engaging the control levers. and is clear of supports. traveling on the same track. are tight. Down is for lift. Selector valve handle has to be in the up position to travel. Stop travel of the lifting units by slowly returning the control levers to the neutral position. DO NOT MOVE LEVERS SUDDENLY! It will induce a surging movement to the load.

The foundation area supporting the track and lifting units must be firm enough to support the combined weight of the load. Use a level-lift system. it may come out of level rapidly when retracting the cylinders. or measuring tapes. creating rapid packing wear and possible damage to the cylinder rods. 37 . lifting units.TRAVELING CAUTIONS! The system must be level and plumb at all times during lifting and traveling with loads. Any change in the support area under the runway track or lifting units. during lifting or while traveling. Keep the load level! 1. The lifting units must operate parallel to each other. lifting beams and track without any settling or sinking. must be avoided. the track should be level. parallel to line of travel. and properly shimmed for correct floor loading. such as one side getting ahead of the other while traveling. The load increases the speed of the cylinders when retracting. The more the control levers are moved. Incorrect relationships between lifting units. PROCEDURES FOR LOWERING THE LOAD If the load is heavier on one side. and prior to hose disconnection. gently rock the directional control valve levers back and forth several times to relieve any trapped pressure in the lines. Lower the load slowly and cautiously. NOTE: After shutting off the power unit. These conditions will create side loads in the cylinders. Caution must be exercised. Move the control levers slowly. When traveling with loads. is extremely dangerous and must be monitored by the operating personnel at all times. the faster the load moves. to monitor the load condition.

Follow the instructions for the specific propel option with which your lifting units are equipped. a) Pin the cylinder onto the two ears located just below the quick couplers using the 7/8" x 6-1/2 hitch pin supplied. The runners of the shoe should sit on the center rail of the track. front to back. You can now extend and retract the cylinders by moving the control valve handles on the 38 .OPTIONS Level-Lift System The unique design of the Level-Lift system puts accurate information instantly at the operator's fingertips. and integral. Warning!! Never propel with a load that is raised higher than is required for clearance. and use of the Level-Lift system. Load corrections can be made immediately. pin on hydrostatic drive. Using the Propels 1) Cylinder type. cylinder type. please refer to the instruction manual provided in each carrying case. c) Connect the hoses of the cylinder to the right hand couplers on the base. as well as side to side. The Level-Lift system consists of two (2) main components packaged in a handsome carrying case for easy storage and mobility. For set-up. Propels Lift Systems offers three propel options. The interior of the case is custom fit to the LevelLift components giving durable and safe transport from job to job. calibration. d) To operate the cylinder. All components are calibrated and tested at the factory. The sensor(s) will transfer information on the horizontal level of the load directly to the readout. The higher the load the less stable the system. shift the valve handle on the base to propel position. b) Using the 7/8"x4 1/2" hitch pin connect the propel shoe to the rod of the cylinder.

There is a valve handle labeled propel/freewheel. When traveling. d) Use the ratchets to raise the housing until the tires are no longer making contact. Make sure you keep the load even. When lifting or lowering a load. shift both the lift/propel and the propel/freewheel handles to propel. You may now control the drive from the power unit control valve. If the cylinders come to the end of their stroke. simply shift the valve handle to the freewheel position. 39 . 2) Pin on chain drives with ratchet jacks. then unpin and extend them. ` 3) Integral drives a) These are built into the lifting units. make sure the cylinders are not pinned to the center rail. However. For Model 2020SC with the propel controlled from the remote pendant. then use the lift/lower switches to control lifting unit movement of the lifting unit. a) Pin the drive housing onto the tangs located just above the wheel boxes. retract the cylinders until you reach the desired position. use the above procedure starting with the cylinders retracted and extend to move the load. and re-pin them as before and repeat until the desired position is achieved. The lifting units must center themselves with the load. The lifting units must center themselves with the load. shift the valve handle into the lift position and make sure the cylinders are not pinned to the track. b) Pin the ratchets to the tangs that are located on the top of the housings. There is a small lever on the ratchets to change their direction.power unit. f) If you want to pull the load. e) Now you can lift the load. Using the control valve. h) When you are ready to lower the load. g) If you want to push the load. extend the cylinders to the furthest hole on the center rail and pin the shoe to the rail with 3/4" x 6. move the Lift/Propel switch to the Propel mode.1/4" hitch pin. c) Extend the ratchet until you can pin the other end to the tangs located on the base.

Side shift or “Trolley” systems allow safe movement of the load latitudinally. a professional engineer should be consulted regarding the use of side shifts or “Trolleys”. 1) Cylinder type with slider pad dolly. If you order a side shift system. the capacity of the system is de-rated by a minimum of 40% when using side shift systems. Warning! Always move slowly and smoothly when using side shift or “Trolley” systems. or perpendicular to the direction of movement of the lifting units. As with all other phases of the lift plan. 40 . span. 4) Continuous chain drive with wheeled dolly. Due to stability and capacity factors. Warning! The header beam should never be more than ½” of level over a 20ft.Side Shifts Lift Systems offers four types of side shifts or “Trolley” systems. The inertia of a rapidly moving load may exceed the stability of the lifting units causing loss of the load and possible injury or death to personnel. 3) Continuous hydrostatic drive with wheeled dolly. instructions specific to that system will be included at the end of this section. 2) Cylinder type with wheeled dolly.

Utilization Chart Date Operator Location Hours Utilized 41 .

WHEEL LUBRICATION The wheels on which this lift system moves are equipped with grease fittings located on the hub of each wheel. DO NOT start or operate any hydraulic power unit without a complete understanding of all the recommended operation and start-up procedures. Wheels must be shimmed snuggly in place. the individual lifting units should be raised with a forklift and blocked up to allow you to move. Careful selection of oil should be made with the assistance of a reputable supplier. Manufacturer recommends the use of Mobil DTE 24 or equivalent. CAUTION! Care should be taken not to change the proper placement of any shims when moving or removing the wheel. OIL Oil in a hydraulic system performs the dual function of lubrication and transmission of power. * The oil must have proper viscosity to maintain adequate sealing and lubricating qualities at the expected operating temperature of the hydraulic system. 42 .MAINTENANCE SECTION SUMMARY The preceding guidelines are intended for use with the hydraulic power units and lifting units as supplied by Lift Systems. Bearings should be filled with a good grade of EP (extreme pressure) grease. helping to ensure the satisfactory operation and life of this system and its components. and should be greased on a regular basis. remove or service the wheels. Some of the factors important in selecting a good grade of hydraulic oil are: * The oil must contain the necessary additives to insure high anti-wear characteristics. * The oil must have rust and oxidation inhibitors for satisfactory system operation. (Specifications for this oil may be found in the maintenance section of this manual). To gain access to the grease fittings.

and covered with plugs and caps when not in use. CAUTION! DO NOT OPERATE THIS UNIT WITHOUT OIL UNDER ANY CONDITION. Remove the strainer. then clean it with solvent and blow it out with an air gun or replace the strainer with a new one. An adequate filter can be purchased at your local fluid power distributor or an industrial supply house.OIL LEVEL Oil level must be checked when cylinders are fully retracted and prior to the operation of this system. Remove the cover on the reservoir. Then open the shutoff valve. Fill the reservoir with oil that has been filtered to 10 microns. When it becomes necessary to add oil to this system. Clean the reservoir out with solvent and wipe it completely dry with a lint free cloth. Apply a Teflon type sealant generously to the threaded area of the strainer. make sure that all oil added to the reservoir is strained through a 10-micron filter. 43 . SUCTION STRAINER To gain easy access to the strainer. it must be replaced. Cleanliness is imperative to the long life and the good operating condition of this system. We recommend that the reservoir lid be installed with new gasket material and silicone sealant. The strainer is screwed into the pipe coupler behind the shut off valve. OIL MAINTENANCE Cleanliness! Hydraulic components are precision built. If it has not. Screw the new suction strainer into the pipe coupler until the strainer is snug. Keep all the quick couplers clean when on the job site. pump the oil into drums for storage. The major cause of hydraulic system failure is dirt in the oil and related hydraulic components. Clean and install the shut off valve. The old oil can be reused only if it has been analyzed and has been found to be acceptable.

and all hydraulic lines and cylinders will need to be flushed out. all filter elements should be replaced. To change the filter. all of the oil in the system and inside the reservoir should be cleaned or replaced.HYDRAULIC FILTER The hydraulic filter used on heavy-duty machines is a high-pressure 10-micron filter the filter unit has a built-in PSI bypass valve to show when the filter is clogged. To change the filter on newer systems screw off the bowl of the filter. On the older systems the dirty filter indicator has a reset button that you push after changing the filter. remove the spring. clean the bowl and then insert the new element and screw the bowl back on. Install a new suction strainer. In the event that the oil has been highly contaminated with something such as water. 44 . being sure to strain the oil through a 10-micron filter. If there is a major failure of the pump. Pump oil back into the reservoir. and the filter element(s). In addition. Wipe out the inside of the reservoir to remove all dirt. On older systems remove the top with a wrench. In this event. Then assemble in reverse. remove the element. * * * Pump the oil out of the reservoir into clean container(s) of suitable size. it is best to send the system back to the factory to have the system cleaned and flushed. The newer system only reads dirty when the system is running. or other system components. the spring spacer. changing the filters or filtering the oil through a filter cart will not be enough. The oil will need to be replaced.

All hydraulic filters should be changed when the indicator shows the filter is dirty. Details on components with replacement parts list and specifications on parts are available. You may be asked to provide the cylinder serial number. 5. 3. Cylinder packing replacement procedures consult the factory for specific information. 4. 7. Inspect hoses and gaskets for wear yearly and replace as needed. high-pressure grease. If you choose to attempt this task yourself. or once a year. Cylinder Packing Replacement Procedures Lift system has used various cylinders from various suppliers over the years. For more detailed component data. refer to other sections of manual or contact manufacturer. you will first need to contact the factory for the replacement seals and information on the seal locations and procedures. Bleeding procedures for lifting units consult the factory for specific information. whichever comes first. If high water content is suspected (milky in color with low lubricity) ask for a Carl Fischer method of water content tests. Have a hydraulic oil sample tested once a year for general wear. Wheels and all bearings should be greased at least once a month with a good grade. For engine maintenance consult the engine manual supplied with the system. This is a task that should not be attempted it at a job site. 45 . they are experienced with this type o9f cylinder and are willing to stand behind their work in the event there are problems. 2.SYSTEM MAINTENANCE 1. 6. If you choose to take the cylinders to someone other that Lift Systems for resealing make sure. You will need the system model number and serial number. It is best to send the system back to the factory where we are fully equipped to service the cylinders. we are also equipped to load test the system when the re-sealing is complete. In addition. metal and water contamination tests.

Try to retract the cylinder and hold it there for one minute. damage to the cylinder and injury may be possible. 4. first is the easiest. Watch the cylinder while it is in retract mode. if it extends even slightly there is oil bypassing the piston seals. LSI CYLINDER 1. Extend the cylinder an inch or two.Testing a Cylinder for Bypass There are two types of testing to check for cylinder bypass. Take a marker and make a mark on the chrome of the cylinder at the wiper. Done incorrectly. Please consult the factory to determine which type you have. someone who has knowledge of hydraulics and how cylinders work should do this test. See section B. The. 2. some brands of cylinders have cast iron piston rings which will have some bypass and these require a different test. 5. In addition. 3.) 46 . The cylinder will need servicing. In addition. Disconnect the extend side of the twin line hose (this will be the male coupler on the base or the female on the power unit) then cap and plug off and pilot line going to the counter balance valve located on the bottom of the cylinder. a very small amount could acceptable so please consult factory to determine what is acceptable. (However.

Maintenance Chart Date Hour Meter Reading Maintenance Performed Service Performed By 47 .

E. then the problem is isolated to the lifting unit. E. Load heavier than expected or held down in some way. If the problem no longer exists. If the same problem exists in all of the lifting units. as listed below. Always check the basic things as listed below first. 3. B. C. D. D. If the problem remains. A. A. A. 48 . switch the hydraulic lines at the power unit. Isolate the problem.Troubleshooting GENERAL TROUBLESHOOTING 1. Dirty track can cause propel problems The system may not be level or plumb. All bolts may not have been removed. Look for simple solution first. C. If the power unit is for #1 and #2 take the lines for #1 and plug them into #2 and #2 into #1. B. Is the pump working properly? Are the filters dirty? Is the hydraulic tank full of oil? Is the oil clean or contaminated? Are relief valves set to proper pressures? 2. the problem could be in the control valve or elsewhere in the power unit or couplers. Lift/propel lever may not be shifted properly. If a lifting unit is not working properly. B. look for a problem in the power unit.

Ruptured hose in lifting unit I. 49 . Level track F. Track is not parallel. Replace hose I. Cylinders rebuild maybe required. Clean track D. uphill condition may exist F. SOLUTIONS: A.PROPEL DRIVES PROBLEM: Drives will not move the system CAUSES: A. wheels are binding on guide bar. Shift to propel position C. C. Ruptured hose in lifting unit I. Internal oil leakage in cylinder. Lift/propel lever shifted to lift C.PROPEL CYLINDERS PROBLEM: Does not extend or does not retract: CAUSES: Couplers not connected Lift/propel lever shifted to lift Dirt or obstruction on track System pressure set too low Track is not level. wheels are binding on guide bar. E. shift valve to propel J. uphill condition may exist Track is not parallel. E. Dirt or obstruction on track D. H. G. C. Align track properly H. B. Check all clearances with the surface. could be worn piston seals TROUBLESHOOTING . Couplers not connected B. D. Use flow meter to check for bypass. F. F. Align track properly G. Adjust relief valves E. Freewheel/propel valve in freewheel J. Connect couplers properly B. Load is still in contact with surface or against an obstruction SOLUTIONS: Connect couplers properly Shift to propel position Clean track Adjust relief valves Level track A. or against an obstruction. D. Track is not level. Load is still in contact with surface or against obstruction. Check all clearances and be sure all tie down bolts are removed H. A. Ratchet style drives not making contact G. B. Replace hose I. Ratchet drives down onto track. System pressure set too low E. all tie down bolts are removed H. G.TROUBLESHOOTING .

Open flow controls. It is advisable. L. TROUBLESHOOTING . beam or runway track deflection. D. C. B. Work packing. Cylinder rebuild may be required. Internal oil leakage in cylinder. 50 . Verify weight.LIFTING UNITS PROBLEM: Lift cylinder does not extend: CAUSES Faulty hydraulic pump. C. after a lift is completed. and there has been some leakage around the rods seals. C. Couplers not connected. B. Clean track. Load is heavy in area closest to that cylinder. Severe side loading A. Remove bolts. Flow controls. closed off K. to cycle the cylinders a few times to see if the leakage stops. If it does. the rod seals needs attention and the factory should be contacted. Ruptured hose.K. B. B. A. Reposition rigging and the load. PROBLEM: Slow extension: A. F. L. Check for lifting units out of level. A. Lift/propel lever shifted to propel. SOLUTIONS Repair pump. Change to larger system. E. Couplers not fully connected B. the leakage was probably due to side loading of the cylinder. Check for oil in base and replace hose. could be worn piston seals. Connect couplers properly. Load is tied down. Replace packing B. F. if equipped. E. D. Shift lever to lift position. Load is too heavy. Use flow meter to check for bypass. If the leakage continues. Oil on track causing wheel to slip. C. PROBLEM: Leakage when extending: A. Connect couplers properly. A.

Consult factory immediately. Drain and flush system. Water in oil B. Lower the load & reset properly A. Couplers not connected D.PROBLEM: Not staging properly: A. Replace oil B. PROBLEM: Deflection in cylinder stages: A. Faulty coupler G. Replace valve H. Adjust relief valves B. Check for oil in base and replace hose F. Lift/propel lever shifted to propel E. Change coupler on lifting unit and try a different hose G. Shift lever to lift position E. runway track could be settling. Check blocker valves in base. System pressure set too low B. PROBLEM: Vibration in cylinder: A. WARNING! Severe side loading. Safety holding valve at base of cylinder is faulty H. No pressure to wedge lock control cylinders. beam or runway track deflection WARNING! Operating with cylinders mis-staging can cause severe damage to cylinders and hazardous lifting conditions due to cylinders restaging under the load. C. Severe side loading. Pilot line from retract line to safety holding valve is plugged or restricted A. C. Ruptured hose F. Check for lifting units out of level. Replace pilot line A. VERY DANGEROUS! System is out of level. Bulged or deformed cylinder stage(s) PROBLEM: Lift cylinder does not retract: A. A. Connect couplers properly D. Replace stage(s) 51 .

Air in upper cylinder area D. tank low on oil C.Replace oil E.PROBLEM: Slow retraction: A. Bulged or deformed cylinder PROBLEM: Erratic extension or retraction: A. PROBLEM: Slow extension and retraction on all lifting units: A. E. Replace pump if flow is too low 52 . Drain and flush system. Hydraulic oil filters dirty B. Bleed system B. System pressure too low B. Replace oil C. Drain and flush system. Bleed cylinder D. Replace filters B. Replace bulged or deformed cylinder section(s). Pump cavitations. Contamination in system and cylinder causing blockage or restriction of oil flow. Contaminated oil C. Contamination in system A. Shift lever completely C. Replace oil A. Drain and flush system. Check with flow meter. Fill with oil and check pump C. Adjust relief valve B. Air in system B. Lift/propel lever shifted only part way to lift position C. Worn pump A.

53 .

54 .

55 .

56

57

58

59 .

60 .

Pre-Lift Safety Meeting Check area for debris. 61 . Check for overhead crane operation. Pre-Lift Telescopic Hydraulic Fuel supply Fluid levels. Notify area foreman of impending operation. Make sure there are clear access routes for the crew to use in case of an emergency. Gantry legs for plumb. etc. 5. Company Name____________________________ Location__________________________________ 3. Very personnel understand their tasks. Confirm method(s) of communication to be used during the lift. Do not allow other equipment or crews to work in the area that are not directly related to the lift. Ensure quick disconnects are engaged. Identify escape routes and other emergency procedures. Notify job site engineer of impending lift and pre-lift meeting. water. Notify Owner Notify job site security/safety department of impending lift. Shut down and lock out if telescopic hydraulic gantry system extends higher than overhead crane. Check for hazards: electrical. Explain what will be done under different emergency situations. 4.Pre-Lift Checklist Date Job# 1. Gantry System Check. wind. Move heavy equipment clear of lift area. Assign personnel to specific tasks. Lift Plan 2. Clear non-essential personnel from the area. Secure Area Close off with caution tape and other visible working signs or barriers necessary to prevent unauthorized entry into work area. Explain in detail how lift will be safely accomplished.

Gantry legs for parallel alignment. Site Specific Pre-Lift Items ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ Lift Supervisor Name_________________Gantry Operator Name_____________________ Lift Supervisor Signature______________Gantry Operator Signature__________________ 62 . Header beam height indicating system. Header beams for levelness per lift plan. Operational check of all functions Control levers in proper positions to begin lift.Rigging for plumb. 6. Clearances.

Pre-Lift Planning Checklist PROJECT DATA Project: Project Number: Client/Owner: Date of Lift: Location of Lift: Description of Lift: Number of Gantry legs Used: LIFT TYPE O Straight Up and Down O Straight up and Down with Travel O Stand Up and Lay Over O Straight Up and Down with Side Shifting O Multiple Beam Lifts O Load on Top of Header Beams O Combination Lifts O Other: LIFTED LOAD DATA Description: Weight: How Determined Determined by Whom Load center of Gravity is: O Centered O Off-center LIFTING COMPONENTS DATA Lift Link Capacity Header Beams Sling Capacity Shackle Capacity Special Lift Devices Size/ Capacity ___________ ___________ ___________ ___________ ___________ Deadweight __________ __________ __________ __________ __________ TOTAL CALCULATED LOAD MAXIMUM CALCULATED LOAD PER GANTRY LEG 63 .

GANTRY DATA Gantry Model: Serial Number: Manufacturer: Number of Stages: Gantry Weight: Gantry is: O Externally Propelled O Self-Propelled GANTRY SUPPORT SURFACE O Concrete Floor on Grade O Elevated Floor O Timber Mats O Hardwood O Softwood O Crib Stack O Soil O Other: Have calculated bearing pressures been checked against allowable pressures on bearing surfaces?: O Yes O NO GANTRY SYSTEM CONFIGURATION Gantry will begin lift in what stage? Gantry will finish lift in what stage? Any special Lifting Devices? Header Beam Span: Loading Points(s): RATED CAPACITY PER GANTRY LEG MAXIMUM CALCULATED LOAD PER GANTRY LEG AS PERCENT OF RATED CAPACITY Prepared by: Lift Planner Signoff: Project Manager Signoff: Date: Date: Date: 64 .

101302 BREATHER P1 .Part Section 1 1.

MG05 0-3000psi gauge 3 2 2. HF05 RETURN FILTER FE06 REPLACEMENT FILTER 3. MG09 DIRTY FILTER INDICATOR P2 .Part Section 1 1.

F084 C83 C82 PIPE NIPPLE MALE COUPLER DUST CAP PIPE NIPPLE FEMALE COUPLER DUST CAP P3 . F084 C84 C81 2.Part Section 2 1 1.

Part Section 1 1. 112446 Control valve 2 2. 112656 Pump P4 .

Part Section 1 1. 3. DV102 Lift/propel selector valve. 106287 Control cable 2 3 4 2. C84 ½” male coupler ½”Female 4. C83 P5 .

HR11 Safety relief valve counter balance valve Hose Reel P6 . RV033 2. CBV04 3.Part Section 1 3 2 1.

FCV12 Crossover relief Flow divider P7 . RV003 2.Part Section 1 2 1.

42HO05 3. 42HP06 4. CYL46 Header plate Spacer block Clamp block Pin 50-ton 2-stage cylinder 6. 42HP14 5. HHCS004 Bolt(4total) P8 . 42HPA01 2.Part Section 6 2 2 3 3 1 4 5 1.

75-016 Large packing gland Small packing gland P9 . 30-013 Barrel Large sleeve Rod 3. 05-011 2.Part Section 1 2 3 4 5 1. 50-011 4. 75-017 5.

26-4610-36X Loader and 26-4610-36A Piston seal P10 . W-027 Wear ring 4. 26-5004-13 Cast iron piston ring 5.Part Section Large piston seals 1 1 2 1. W-020 Wear ring 2. 26-4610-35X Loader and 26-4610-35A Piston seal Small piston seals 5 4 4 3 3 3.

Part Section
Large packing gland

7 1 2

3

6 4

5

1. 26-4173-50A

O-ring

2. 26-5044-2 Bronze backup ring 3. W-022 Wear ring

4. 26-5043-9X Loader and 26-5040-9A Bronze buffer seal 5. 26-3980-83 6. 26-3707-38 Polypac Wiper

7. FS420-712 Bleed screw and 55-996 1/4" seal washer
P11

Part Section
Small packing gland

7

1 4 3 2 6 5

1. 26-4173-44A

O-ring

2. 26-5044-5 Bronze backup ring 3. W-002 Wear ring

4. 26-5043-3X Loader and 26-5043-3A Bronze buffer seal 5. 26-3980-54 6. 26-3707-32 Polypac Wiper

7. FS420-712 Bleed screw and 55-996 1/4" seal washer

P12

Part Section
Recommended parts list
 CBV11  CBV04  RV033  C83  C84  C79  C80  THL50-1  HHCS004  42HO05  42HP06  FE06  101301  MG04  55-996  FS420-714  K272-0203  HA033T Counter balance cartridge Counter balance cartridge Safety relief ½” Female coupler ½” Male coupler Male coupler Female coupler Twinline hose clamp block bolts Spacer block Clamp block Return filter elements Breather Pressure gauges Seal washers Bleed screws Cylinder seal kit Hose reel hose 2pcs 2pcs 2pcs 2pcs 2pcs 2pcs 2pcs 1pc 8pcs 2pcs 2pcs 2pcs 1pc 2pcs 6pcs 6pcs 1pc 1pc

 Any other items depend on the power option which can be supplied upon request.

P13

Using a fork lift.Repair Section Steel wheel and bearing replacement 1. Grease gun and multipurpose grease. lift the lifting unit up off the wheel box. With ¾” wrench remove the two ½” hex head bolts holding the wheel box in place. ½” hex head bolts. Items required a. 2. Dead blow hammer c. ¾” wrench or socket with ratchet b. 3. R1 .

6. keep track of where they go so that they can go back in the same locations when reinstalling the wheel. Lift the wheel but take note there are spacers on each side of the wheel. But use caution and keep a good grip on the wheel don’t let if drop down to where it can pinch your fingers Keep a good grip on the wheel when pulling the axle out. There will be spacers with both bearings. Roll the wheel box over on to it top and remove the ½” hex head bolt with a ¾” wrench.4. 5. make sure to keep track where they go. R2 . Tap on the end of the axle with a dead blow hammer until the end with the tab is out to where it can be grasped and then pull the axle out while holding on to the wheel.

Tap here when tapping new race into the wheel. Use caution not to damage the tapered surface. at this point use a piece of brass to tap the race in until it is seated against the shoulder. If it is damaged it will need to be replaced. To install the new race the simplest way is to press it in with a small hydraulic press. 8. R3 . Press the race in until it is seated against the shoulder inside the wheel. It will be necessary to tap around the entire diameter of the bearing. With the wheel lying on its side with the damaged race on the bottom side. If a press is not available the race can be tapped in with a soft faced hammer of some kind until it is flush with the hub of the wheel. Use a brass bar to tap the race out of the wheel. making sure to go around full diameter of the race when doing so. 9. this will only cause the race to become jammed. do not try tapping just in one location.7. If it appears to be in good condition then there is no reason to replace it. If replacing just the bearings thoroughly clean the wheel and inspect the bearing race for damage. The back side of bearing race. Tap here to remove the race. Use a piece of round stock that is slightly smaller than the outer diameter of the race so that the tapered surface is not damaged.

Slid wheel and bearing into pocket.10. 12. R4 . Before inserting the new bearings make sure they have been packed with grease with a bearing packer or by hand. 11. With the wheel box on its side take the wheel with the bearings and slid them in to the pocket. Then slide the upper spacers into place. this will help hold the bearings in place. lift so that the bottom spacers can be slid in. Slide upper spacers in. With the wheel in the pocket. Lift the wheel enough to slide in the bottom spacers. Make sure to leave a thick coat of grease on the outer portion of the bearings.

Reinstall the hex head bolts. 17.13. With the unit off the ground slide the wheel box in to place. R5 . 14. lock washers and tighten. Then insert the axle and then line up the lower spacers. Using a grease gun pump the wheels full of grease until it just starts to come out from around the bearings. 16. It maybe necessary to use a screwdriver or something to move the spacers around. Since the wheel box will not stand up straight so that the lifting unit can be sat over the top of it. Line the wheel and spacers up with the axle holes. 15. Align the hole in the retainer on the axle with the tapped hole and install the keeper bolt and tighten. Repeat with the other wheel if required. It’s easier to line up the upper spacer first. 18. sliding the box back into place seems to work best. Lift the unit an inch or so off the ground and slide the box into place until the bolts hole are lined up.

R6 . Two (2) Pieces of #8 SAE male plug. e. i. d. f. h. b. Lift System # F129 One (1) piece of #4 O-ring face cap Lift Systems # C51 One (1) piece of #4 O-ring face -plug Lift Systems # C52 One (1) piece of #6 O-ring face cap Lift Systems # C29 One (1) piece of #6 O-ring face plug Lift Systems # C33 Two (2) large wire ties Two (2) 10” adjustable wrenches External snap ring pliers for 1” pin One (1) 3/4” socket with ratchet. k.Cylinder removal 1. Use snap ring pliers to remove 1” snap ring and slide pin out while header plate is being supported. j. l. Uses the external snap ring plies to remove one of the snap rings from the header plate pin. 2. c. Lift Systems # F131 One (1) piece of #4 SAE male plug. Items needed a. 1-1/8”socket and ratchet. g. #3 Phillips screwdriver. have the header plate supported with slings or hoist rings and slid the pin out and then lift the header plate off.

Use caution. Since there could be pressure built up inside the cylinder. Bleed screw. Slowly disconnect the hose from the top of the cylinder. R7 . there may still be pressure trapped in the cylinder. Using two large wire ties. Wrap two large wire ties around the hose and the roller guide. Slowly remove the hose. loosen up the bleed screws on the cylinder to help release that pressure. wrap them around the hose and the roller guide on the hose reel. Use a rag to wipe up the oil as it is comes out around the screws. 5. this will keep the hose from being unwound. 4.there is one in each gland nut and the rod.3. cap the fitting and plug the hose.

R8 . 8. Holding valve. Starting with the upper handrail clamp remove the two bolts holding the hand rail clamp. 10.6. Extend line. At the bottom of the cylinder disconnect the pilot line from the holding valve. then remove the larger elbow and plug the port with a #8 SAE male plug. 9. Then disconnect the extend line and cap the hose with a #8 O-ring plug and cap the fitting with a #8 O-ring flat face cap. Plug the hose with the #6 O-ring face plugs. cap the fitting with a #6 O-ring flat face cap and plug the hose with a #6 O-ring flat face plug. Remove the small elbow fitting and plug the port with a #4 SAE male plug. Remove the fittings at the top of the cylinder and plug the port with a #8 SAE male plug. Cap off the 45 degree fitting to which the hose was attached to with the #6 O-ring face cap. remove the handrail. 7. Pilot line. Then remove the ¾” bolt holding the lower portion of the hand rail.

Loosen the lower bolts of the support arms on the end of the lifting unit that the handrail came off of.Remove the bolts from here. Take this arm and fold it back. Loosen the lower bolts but do not remove them. R9 . Remove the ¾” bolt here and remove the handrail. The arm that the upper bolt was removed can be folded back away from the cylinder. 11.

Take the other end of the sling and put it between the cylinder ears. Remove the bolts on this half only and remove that half of the clamp. Make sure there isn’t any oil on the cylinder which could cause the sling to slip. Remove bolts. 14. clean it off. making sure it is tightly wrapped around the cylinder.12. This will allow the cylinder to hang fairly straight when lifting it out of its base. Wrap the 14’ sling twice around the cylinder in a choker. R10 . Fold this arm back away from the cylinder. 13. insert the header plate pin and attach the snap ring. Then remove the two bolts in the lower clamp and remove that half of the clamp. Remove the bolts for the upper clamp and fold the support arm back away from the cylinder. If there is.

Torque these bolts and the lower ones to 165ftlbs. Tighten these so the gap between the ears is equal on both sides. Torque the ¾” bolts to 165ftlbs. 16. To reinstall just reverse the steps. R11 .15. The upper clamp bolts should be tightened so that the gap between the ears is equal on both sides.

When the cylinder is fully installed it will need to be bled. Then continue to the next one down. start here and work down. Bleed screw. Leave the screw loose until there is oil coming out from around it. Put the cylinder into retract and loosen the bled screws starting with the top one.17. 18. Bleed screws R12 .

Pull the cartridge out once it is completely unscrewed. 4. Using compressed air. Caution! The cartridges need to be properly set at the factory. 2. Using a 1-1/8” wrench. a cartridge may not be properly adjusted and therefore may not hold the load. and there will be no way to control it. turn cartridge counter clockwise to remove it. It will retract on its own and it cannot be stopped once the counterbalance is removed. c. If not supplied by the factory. 9/16” wrench b. Use compressed air to remove dirt from around the cartridge. the cylinder will retract on its own once the counterbalance is removed. blow any dirt or foreign particles out from the counterbalance cartridge. R13 .Replacing the A-line Counterbalance Valve 1. Items required a. Foot pound torque wrench. Warning! Do not ever remove the A-line counterbalance valve with the cylinder extended or in a loaded condition. Make sure the cylinder is fully retracted and not loaded. 1-1/8” wrench or 1-1/8” socket and ratchet. 3. If it isn’t.

Insert new cartridge and turn it clockwise to tighten until the cartridge is seated.5. make sure the o-rings are not left in the valve body. At times these o-rings will roll off when removing the cartridge. If this happens. 6. R14 . then torque the cartridge to 30-35ftlbs. Occasionally the o-rings on the cartridge may roll off the cartridge when removing.

Attach twin line hose to the lifting unit and the power unit. Using the 5/32” allen wrench. c. R15 . 3. Items required a. Foot pound torque wrench. b. blow any dirt or foreign particles out from around the counterbalance cartridge. Using compressed air. Use the following steps to relieve the pressure: a. The valve may have pressure trapped in it. c. turn the adjustment screw all the way in a clockwise direction.Replacing the B-line Counterbalance Valve 1. b. 2. Loosen the jam nut on the adjustment screw with the 9/16” wrench. B-line counterbalance valve. d. 9/16” wrench 5/32” allen wrench 1-1/8” wrench or 1-1/8” socket and ratchet.

d. Very slowly. 5. the cartridge will be difficult to turn. As the pressure is released. Once the cartridge is removed. using the 1-1/8” wrench. e. the cartridge will become easier to turn. Adjustment screw. make sure the o-rings did not roll off and are not in the valve body. Do not start the power unit. turn the cartridge counter-clockwise. Install the new cartridge and torque to 30-35ftlbs. it will be necessary to hold the valve body with another wrench to prevent the valve body from turning. If there is a lot of trapped pressure. Pull the control valve handle to the extend position to which the lifting unit is connected. 4. Have someone hold it in that position. R16 .

Items required a. then the pressure has been relieved. Remove hose. R17 . Once the cartridge can be easily turned by hand. Since the cartridge of the relief in pointed towards the hose reel it maybe necessary to turn the assembly that the valve is threaded into so that there is enough clear to remove the valve. Refer to step #3 in replacing the B-line Counterbalance Valve on page R15. a. 4. 3. One (1) piece of #6 O-ring face plug Lift Systems # C33 2. 5.Replacing the RV033 Safety Relief 1. Before the safety relief can be remove any pressure trapped in the cylinder will need to be relieved. Tighten the cartridge back down and turn the adjustment back out the same number of turns it was screwed in. 6” adjustable wrench b.

It maybe necessary to rotate the assembly counter clockwise at this joint in order to unthread the valve. Turn the assembly back to its original position. Bolt the reel down if it was unbolted. R18 . Thread the new valve on. 6. It may also be necessary to unbolt the hose reel and lift it up to get the valve off. 7. 8. Function test and check for leaks. Remove the valve from this fitting. 9. 10.

Use rags to wipe up the oil as it is coming out around the screws. plug the hose and cap the fitting on the cylinder with the #6 flat face o-ring cap and plug. Since there could be pressure built up inside the cylinder. Three (3) pieces of #6 O-ring face plug Lift Systems # C33. 3. Items required a. R19 . Take two wire ties and use them to tie the hose to the reel. loosen up the bled screws on the cylinder to help release the pressure. 4. Two (2) large wire ties. b. One (1) piece of #8 O-ring face cap Lift Systems # C30. Wrap wire ties around hose and the roller guides. Disconnect the hose at the top of the cylinder. Three (3) pieces of #6 O-ring face cap Lift Systems # C29.Replacing the HR011 hose reel 1. One (1) piece of #8 O-ring face plug Lift Systems # C34. 10” adjustable wrench 7/16” socket and ratchet (1/4” drive. i. e. Set of open end wrenches. c. g. 2. 5/16” socket and ratchet. h. d. f.

Disconnect the hoses here and plug hoses and cap fittings. Unwrap the hose from the reel. plug hose and cap fitting with #6 flat face o-ring cap and plug. 9. 10. R20 . 6. Hold on to the drum of the reel and let it slowly unwind until all the tension is off. Use 5/16” socket and ratchet and remove the hose reel mounting bolts. firmly grasp the hose and cut the wire ties and slowly let the reel take up the hose. Using a 13/16” wrench disconnect the hose from the reel. Put on a pair of work gloves. Push the hose down through the top of the lifting unit and then lift the reel out. Securely clamp the reel down on a work bench.Disconnect the hose here and plug hose and cap fitting. Disconnect the hoses. 5. 7. 8. When the end of the hose clears the rollers. there are a total of four.

Remove the fitting assembly from here. 12. It is easier if there is a wrench available to fit hex on the swivel to remove it and then put the swivel is a bench vise. 13. Using a 7/16” socket and ratchet remove the clamp. remove hose. R21 . Remove clamp. Disconnect hose and plug hose and cap fitting. It maybe necessary to slightly turn the assembly so that the safety relief will clear the reel. Remove fittings with a 7/8” wrench from the other side of the reel by unscrewing the entire assembly from the reel. This can be done with the swivel in the reel or out of the reel. Remove the fittings from the swivel.11.

The reel needs to be tight but if the reel stops before all the hose is ran out then it’s too tight. Install the clamp around the hose and tighten. Run the hose through the rollers leaving enough hose extended to go through the top plate of the lifting unit. With the hose wrapped on the reel and the tension set. Tie the hose off to the reel as was done with when removing the old reel. With the reel securely clamped to a bench. Set reel back into lifting unit and bolt it back into place. Clean the threads on the fitting and apply new pipe sealant to Teflon tape. Once the fittings are installed attach the hose to the swivel and tighten with 13/16” wrench. do not crush the hose when tightening the clamp.Swivel 14. it should be one or two turns from that point. 15. wrap all the hose around the reel. Wrap the remaining hose around the reel and pull it out again. 18. 20. With a firm grip pull the hose so the reel turns with it. 16. 17. The first time doing this the reel should stop before all the hose is taken up. R22 . 19. when the hose reaches the end let it slowly return. Assembly new fitting into new reel as they were in the old reel.

24. 22.21. Pull the hose upward and attach it to the fitting. At the same time have someone check for leaks. Then fully extend and retract the cylinder to make sure the hose reel is working properly. Attach the hoses inside the lifting unit back on the reel and tighten with a wrench. R23 . but do not tighten it until the wire ties have been cut loose. attach it to the fitting at the top of the cylinder. Start power unit and move the control valve handle into the retract position and hold it until it comes up to full pressure. and then tighten the hose. doing this will let any twist in the hose relax out and the hose should remain straight. 23. firmly grasp the hose and have someone cut the wire ties. If there wasn’t enough hose left extended. If there was enough hose left extended. If leaks are found stop and repair the leaks and repeat until it comes up to full pressure.

Set the lifting unit on the track or plate. Check to see if all four corners of the lifting are making contact. Section of track or a flat steel plate at least 2” thick (With one side machined is best). 1-1/2 wrench or socket and ratchet b. form endto-end and side-to-side. e. The track or plate must be level in all directions. A solid plate that is at less 2” thick and has one side machined off so that it is flat works best. 3. 5. If one corner is not making contact then slip just enough shim under the wheels so that it is. If using track it must be level all the way around. Good high quality 24” level (A machinist level is preferable).) 1. Small porta-power cylinder that will fit under the lifting unit. Shims (type of shim depends on model of system) c. d. Set up a plate or track and level it from end to end and side to side. You may need to lift up the lifting unit slightly to slide in the shim. this is where a small portapower cylinder comes in handy. Use it to slightly lift the lifting unit. Items Required a. when the shim is in place lower the cylinder. 2.Lifting unit leveling (this only needs to be done if the wheel box shims were removed for some reason. The system is leveled at the factory. 4. R24 .

the wheel boxes will need to be shim. 6.Use a ports-power cylinder to slightly lift the unit to insert shims. If the unit is out of level. The level should show the unit as being level on all sides. all sides should be checked. R25 . 7. Use a level on the sides of the cylinder or boom to check level. Jack the unit up on the side or end that needs to be shim and slip the shim under the wheels and let the unit down on the shims. check it on all four sides. This saves time when leveling the unit. Place a level on the cylinder or the main boom section. Once it is level then the shims can be placed in between the wheel box and the unit.

Jack up one corner take the shim out from under the wheels. Then shim this side. tighten until the lock washers are compressed. Loosen and remove the 1” bolts holding the wheel box on with 1-1/2” wrench. lower the unit. Then shim this side.If the unit is leaning in this direction. If the unit is leaning in this direction. Reinstall the bolts. R26 . Slip the shims between the wheel box and its mounting plate. 8. When the unit is sitting level the shims can now be inserted between the wheel boxes and the mounting plate of the unit. and repeat with the other wheel boxes if required.

In addition. Use a thicker shim in place of two thinner shims if possible. when shimming it is easy to keep adding shims. With all the shims in place recheck the level and all four corners are making contact to ensure it is correct. try removing some shims if possible. R27 .With the unit slightly lifted and the wheel box bolts removed slip the shims in between the wheel box and its mounting plate. Wheel Box 9. The shims should not extend pass the edge of the unit Mounting plate. NOTE: When leveling and shimming try to keep the number of shim to a minimum.

Filter strap wrench to fit 5” diameter return filters. Items required a. Extend the cylinders to lower the oil level below the sight gauge. For loosen the filter element by turning it counter clockwise. On systems with return filters connect at least one lifting unit to the power unit and extend the cylinder to lower the oil. it maybe necessary to use a filter wrench to break it loose. 3. level in the power unit is below the sight gauge. 5. R28 . Catch pan 2. Place some sort of catch pan under the filter. b. Close off the ball valve.Replacing return filter elements 1. Close off the ball valve. 4.

11. Turn filter element clockwise to install. 8. When the filter makes contact with the o-ring give it. Most spin on filters of this type comes with two of o-rings. Open ball valve. 6. Use the O-ring that matches up with the old one. The o-ring sets in a groove that the outer edge of the filter goes into. Run the system and check for leaks. 7. Remove the o-ring. Smear a little grease on the o-ring this will help hold it in the groove plus it will act as a lubricate when installing the new filter. Spin the element off but use caution the element will be full of oil. Once the element is off the o-ring gasket will need to be replaced. 10. Install the new filter by screwing it on clockwise. 9. R29 . ½ turn.Turn filter element counter clockwise to remove.

Unscrew the elbow and pipe bushing if there is one from the strainer. Unscrew the ball valve from the 90-degree elbow. Pipe seal 9/16” wrench Silicone sealant Gasket material Caps and Plugs for the suction hose size will need to be determined. d. Pump with filters Large adjustable wrench or pipe wrench. R30 . Using a 9/16” wrench remove the lid of the power unit. It maybe necessary to pry the lid off since it is seal down with a silicone sealant Remove the bolts around holding the lid down. If the oil is highly contaminated and is being disposed of then it can be pumped into a waste oil tank or container. 2. g. Remove the suction hose and plug and the fitting. 6. 7.Replacing or cleaning suction strainer 1. b. Unscrew the strainer. 4. f. c. e. If it is only slightly contaminated and can be filtered and reused then pump it through a 10-micron filter in to clean containers. 3. 5. Items required a.

If the gasket needs replacing. 11. If the strainer is being reused. check the gasket. New gaskets may be cut out of gasket material. 14. Clean off and the threads of the fittings that were removed and apply new sealant and install.Remove Strainer. Apply sealant to the threads. Check for leaks around the ball valve. Remove ball valve from here. and then tighten. 8. Before putting the lid. apply a pipe sealant on the threads. clean it with a cleaning solvent and blow it off with compressed air. Remove elbow and bushing. screw the strainer in. This is recommended for new oil also. 15. and not damaged then clean it off and apply new silicone sealant. Reconnect the suction hose. back on. 12. cut them in one-inch strips. Pump oil through a 10-micron filter back into the power unit. 9. Remove hose. Clean off and the threads of the fittings that were removed and apply new sealant and install. and tighten. 16. If replacing the strainer. 10. 13. If it is fully attached to the lid. remove the old gasket and sealant from the lid and replace it with a new gasket and sealant. screw the strainer in. R31 .

1. The reading should be highest pressure stated on the load charts. 4. Start power unit. Standard Allen wrench set. Plug. It is possible over time because of age and wear it may need to be slightly adjusted. which could cause damage to the system. b. Read pressure on the gauges when the handles are fully stroked.Checking and Adjusting Operating Pressure Normally the operating pressure does not require any adjusting. In addition. Run engine speed up to full rpm’s if gas or diesel driven. doing so the system could be over loaded. Shut the power unit off 8. R32 . Relief valve cartridge. 5. Small adjustable wrench. Items require a. c. 3. Screwdriver (some components may require this instead of an Allen wrench) 2. Slowly pull control valve handles to the extend direction. If not use 5/16” Allen wrench to remove the plug on top of the main relief valve cartridge. and/or death to personal. Make sure all twin line hoses are disconnected. 6. 7. the pressure should never be adjusted higher that the highest pressure called out on the load charts. injury.

13. and recheck pressure. 10. On this type remove the hex cap from the adjustment. Control valve relief. Replace plug. Under the plug is the adjuster which requires ether a 7/32” or a 1/4” Allen wrench (sometimes they tend to vary). Repeat if the pressure still is not correct.9. underneath will it be a Allen head adjustment screw which R33 . This relief should always be set higher than the main relief. Insert the wrench and turn it clockwise to increase the setting and counter clockwise to decrease it. DO NOT do this when the system running. there is another relief valve located in the control valve that maybe set too low. on some control valves the relief maybe on the backside of the valve opposite of the handles. 11. 12. start the power unit. If the pressure cannot be increase to the proper setting.

Do this until the proper setting is reached.requires a 5/32” Allen wrench. If unable to get the pressure set properly. Tighten the jam nut and replace the cap. 8. If the pressure rises above the operating pressure. 15. R34 . 14. Turn clockwise to increase and counter clockwise to decrease. this requires a 9/16” wrench or an adjustable wrench. 9. call the factory for assistance. stop at no more that 300psi above the operating pressure. there is also a jam nut that needs to be loosened before the adjustment can be made. slowly turn the adjustment clockwise to increase the pressure. Going back to the main relief valve and repeat steps 7. and 10. 16. With the power unit running at full rpm’s and the control valve handle in the extend position.

Replacing Typical Internal Gland Seals Replacement of the gland or rod seals on an open cylinder gantry can be accomplished with the cylinder still installed. Wrap two large wire ties around the hose and the roller guides here. But sure to wipe up any and all oil that may drain from the bleed screws. This is just a basic guide line and is not meant for any one model of cylinder. Have a bucket ready in case there is still some pressure in the cylinder. Disconnect the hose from the fitting at the top of the cylinder and place the bucket under the fitting to let all oil drain from the cylinder. 3. Make sure the cylinder is fully retracted. 1. It’s an absolute must to refer to the seal call out in the parts section of the manual. 5. Loosen the bleeder screws to let off any pressure that maybe trapped within the cylinder. R35 . wrap them around the hose and the roller guides on the hose reel to prevent the hose from being reeled up by the hose reel. Using two large wire ties. 4. Remove the header plate. 2.

11. If the gland will not slid off use a soft face dead blow hammer and rap on the bottom edge of the gland. 12. Therefore. Continue turning the gland putting some upward force on it at the same time. the factory can confirm this. Remove the bleed screws. Most internal glands are designed so they will past over the smaller ones. Remove the fittings at the top of the cylinder and plug the ports with a #8 SAE plug. the bleed screws will need to be removed. 10. This may help slid the gland upward and off the rod or sleeve. However. if the largest gland needs new seal it is not necessary to remove the smaller glands. Turn the desired gland counter clockwise. working the hammer around the full diameter of the gland. Using a heavy duty chain wrench such as the 36 inch Rigid Model C36. 9. if the small gland is being removed the ports will have to remain open until the small gland is removed. Due to the amount of press on the rod seals. once the threads are clear of each other the gland may not simply lift off. 7. There could be as much as 1-5/8” of thread depending on the model of cylinder. R36 .6. 8.

With the gland off remove old seals and thoroughly clean the gland with a cleaning solvent. Use a die grinder with a small wire wheel to clean off the rust. Rinse the gland off with cleaning solvent to remove all dust particles and dry it off with compressed air. 16. A rough spot in the threads could cause to gland to become stuck to the point it will have to be cut off. 13.Tap under here with a dead blow hammer to work the gland off. Install the outer seals. Inspect the gland for any rust that may have formed in the seal grooves and threads. if any rough spots are from use the wire wheel to smooth them out. 15. Do not let the ring roll or stretch it any more that necessary. starting with the backup ring. 14. R37 . 17. Then install the o-ring. Closely inspect the threads.

Then install the o-ring. Install the loader and the rod seal but use caution not to break the rod seal. R38 . 18. Install the backup ring first. take the portion that isn’t folded and put it into the groove and then gently let the rest of the seal fold back into position so it goes into the groove. Form it like show below so it will fit in the gland. Grasp seal here and gently pull inward so the seal will fit into the gland.

R39 . Before the wear band can be installed it will need to be cut to length. There should be 1/16” gap between the ends of the wear when is installed. Install the wiper.19. the loader goes in first with the rod seal on top of it. Poly pac seal make sure the flat side is up. Rod seal. 20. Install the poly pac seal making sure the flat surface of the poly is up towards the top of the gland. 21. Wear band. Wiper.

Rap around the top with a dead blow hammer to get gland started onto the sleeve.22. 25. Do not rap in just one or two locations. 27. Set the gland on to the top of the sleeve. 24. Once the gland is down on the sleeve and the seals are pass the end of the gland take the chain wrench and turn the gland and at the same time apply some downward pressure. 28. R40 . 26. The gland should slide down going into the sleeve it threads into. Apply a coat of oil to the outer o-rings. Coat the entire inner diameter of the gland with heavy oil. Make sure to rap around the full diameter of the gland. The gland will be a tight fit do to the amount of press on the seals. 23. Apply a thin coat of anti-seize to the threads of the gland. If the area where the gland threads into is full of oil it will be necessary to get some of the oil out ether by mopping it up with rags and some other means. Using a dead blow hammer rap on the top of the gland to get it start on to the sleeve.

Careful turn the gland until it starts to thread itself in. 30. R41 . Start the power and put the unit into retract and check for leaks. 31. 32. Slowly extend the cylinder and have some one open the bleed screws to remove any air in the cylinder. The gland and sleeve needs to make contact.29. Continue turning the gland until it is fully threaded down and the shoulders of the gland and sleeve make contact. Connect the unit to the power unit. fittings and reconnect the hose. When complete reinstall the bleed screws. 33.

This is just a basic guide line and is not meant for any one model of cylinder. 3. repairing and re-chroming.) 2. Securely clamp or chain the cylinder to the bench. Remove the cylinder from the lifting unit. This is just a guide line for replacing the seals only and does not include any instructions for honing. these types of repairs must be completely by a qualified repair facility. Remove port plugs in the rod and let the oil drain out. Remove plugs from ports. 4. 5. This task should only be attempted on a bench that is designed to securely hold the cylinder and is equipped with some sort of catch pans to catch the oil. Remove the counter balance cartridge. Remove the counter balance cartridge.Basic Guidelines for a Complete Cylinder Reseal It is not advisable to try to do a complete cylinder reseal in the field or at a jobsite due to the large amount of oil that will be lost during the disassembly. (See section on cylinder removal. R42 . 1. Lay cylinder down and sit it on the bench with the counter balance valve upward. Make sure one port is turned downward. If necessary turn the rod so one of the ports is pointed down.

Be sure to support the end of the rod to take the weight off the gland nut when turning it otherwise the gland could seize up. Due to the amount of press on the rod seals. Support this end to keep the rod level with the rest of the cylinder. 8. 11. Small cosmetic scratches that can not be felt are normal from wear. Before the rod is completely removed it is advised to catch the piston end ether by a sling or by placing something under it that is soft enough not to damage the piston. If the gland will not slid off use a soft face dead blow hammer and rap on the bottom edge of the gland. once the threads are clear of each other the gland may not simply slid off. An overhead crane or a jib work well for this. Starting with the barrel. 10. 9. working the hammer around the full diameter of the gland. 7. thoroughly clean the inside with something such as a cleaning solvent. With the small gland removed the rod can be pulled out. 13. Thoroughly inspect the inner diameter of the barrel for damage or scratches.6. 12. Make sure to place the rods and sleeves on something that will not scratch or damage them such as wood. Make sure to do this on all sections. Repeat steps 6. R43 . Catch the rod in this are here so that the piston does not get damaged. it will be necessary to support the end of the rod to keep it level with the rest of the cylinder. the barrel will need to be honed. 7 and 8 with the remaining sections. Any scratches that can be felt are found. Using a chain wrench turn the small gland nut counter clockwise to remove. However.

14. Check the threads for any roughness, if roughness is found use a die grinder with a wire wheel to smooth out the roughness.(Use wire wheels only) 15. Clean up all dust particles created by the wire wheel. 16. Cover the end of the barrel to prevent damage and to keep it clean. 17. Remove old seals from the sleeves and rod, one at a time. 18. Thoroughly clean the sleeves in side and out with a cleaning solvent. 19. When one is thoroughly cleaned, inspect the inner diameter for scratches as with the barrel. Check the condition of the threads as was done with the barrel. 20. Inspect outside for chrome damage. Check for pitting, flaking, dents and scratches. Cosmetic scratches are normal from wear and are acceptable. Any other damage and the item will need to be stripped, repaired and re-chromed. 21. Continue until all sleeves and rods are cleaned and inspected. 22. Remove the seals from the glands and thoroughly clean the glands with a cleaning solvent. 23. Inspect the glands for any rust that may have formed in the seal grooves and threads. Use a die grinder with a small wire wheel to clean off the rust. 24. Closely inspect the threads; if any rough spots are found use the wire wheel to smooth them out. A rough spot in the threads could cause to gland to become stuck so tightly it will have to be cut off. 25. Rinse the gland off with cleaning solvent to remove all dust particles and dry it off with compressed air.
R44

26. If there is no damage found and everything has been cleaned then the pistons and gland and be prepped for assembly. 27. Starting with the large sleeve install the cast iron piston ring that is the furthest away from the end of the piston. Make sure to refer to the cylinder seal callouts in the parts section of the operator’s manual. 28. Slip the ring onto the end of the piston as shown.

29. Using something such as four (4) pieces of banding material as shown in the pictures below. This allows the ring to be slid down to the groove without being caught in the other grooves. Banding material works well due to the thinness and it stiffness.

R45

30. Install the loader into the center groove; do not let the loader roll when installing it.

31. Before the piston buffer seal can be installed it must be heated in an oven at 450 degrees for 20 minutes, a pizza oven works well for this.

32. Working quickly while the seal is still hot, slip it over the piston and into the groove on top of the loader.

R46

Cut the wear ring material with a razor knife. The seal should be tight and it should not move or spin in the groove.33. make sure the ends of the piston rings are not inline with each other. To install the wear rings they must first be measured. Set the wear ring material in the groove and measure it as show in the picture below. 36. they should be 180 degrees from each other. Using a compressed air. R47 . this will cool and shrinking the seal into the groove. 34. Install the last cast iron piston ring. blow cool air on the seal working around the full diameter of the seal. 35.

Place the wear ring material in the groove and hold them in place by using zip ties. Make sure the ends of the wear rings are chamfered.37. The ends of the wear ring must be chamfered as shown. R48 . 39. Using Loctite 380 instant adhesive spread a thin coat over the wear ring groove as shown. there should be 1/16” gap between the ends. 38. Place the wear ring in the groove and check the length. It will take 30 to 60 minutes for the adhesive to dry.

Then install the o-ring. Form it as shown below so it will fit in the gland. starting with the backup ring. Install the outer seals. Do not let the ring roll or stretch it any more that necessary.40. 42. R49 . Once the pistons are complete then the glands can be prepped. take the portion that isn’t folded and put it into the groove and then gently let the rest of the seal fold back into position so it goes into the groove. Prep the remaining pistons by following the above steps. Install the backup ring first. Then install the o-ring. Install the loader and the rod seal but use caution not to break the rod seal. 41. 43.

Grasp seal here and gently pull inward so the seal will fit into the gland. the loader goes in first with the rod seal on top of it. There should be 1/16” gap between the ends of the wear when is installed. 45. Before the wear band can be installed it will need to be cut to length. 44. 46. R50 . Rod seal. Install the poly pac seal making sure the flat surface of the poly is up towards the top of the gland. Poly pac seal make sure the flat side is up. Install the wiper.

Prep the rest of the glands in the same fashion as above. 48. R51 . Take the large sleeve. remove the zip ties and coat the entire piston with heavy oil. Take the barrel and coat the first six inches of the inner diameter of the barrel with a heavy oil. 49.Wear band. Wiper 47.

This is to ensure the damage does not occur to the seals or to the threads of the mating part. The factory has special compression rings for compressing the seals so that the sleeve can be inserted into its mating part. R52 .50. It maybe necessary to come up with such a device. 51. Lift the sleeve making sure it is level with the barrel by using a level.

R53 . 52. Slowly and carefully push the sleeve into its mating part.Compression ring.

do not use steel. take the appropriate gland and coat the entire inside with heavy oil and to the outer diameter of the sleeve. tap the top of the gland to work it onto the sleeve. Using a dead blow hammer. 55. When the end of the sleeve makes contact with the first rod seal the gland will become tight. 56. Once the gland is past the end of the sleeve use a dead blow hammer and something such as a piece of nylon to drive the gland down the sleeve. 54.53. R54 . With sleeve install. Carefully slide the gland over the end of the sleeve. Do not use a steel hammer.

60.57. 65. Using the chain wrench slowly turn the gland clockwise and at the same time apply a small amount to towards the mating part until the threads are engaged. Put heavy oil on the outer seals of the gland and anti-seize on the threads. When the gland reaches its mating part stop before it makes any contact. 66. 64. 63. Careful tap the gland into its mating part but stop just before the threads of both parts make contact. R55 . Connect power unit and put cylinder into retract while at the same time open the bleed screw to remove as much air as possible. Repeat steps 48 through 60 with the remaining sleeves and rods. Reinstall cylinder. Check the level of the sleeve to ensure it is level with its mating part. 61. Continue slowly turning the gland until it is fully seated. 59. Replace counter balance valve and the bleed screws. The cylinder should always be load tested and checked for drift after a complete reseal before ever going on a job. The two parts have to be level to each other in order for the gland to be threaded in. 58. 62.

TITLE X DRAWN BY: RLM APPR BY: X SIZE = B .005" FRACTIONAL + - 1/16" DATE 8/25/11 100GPU DUAL PUMP ELECTRIC WITH REMOTE PENDENT CONTROL PART NUMBER X ANGULAR + - 1/2 . This drawing is furnished with the understanding that the contents hereof. contained in this drawing remains the sole property of Lift Systems and use thereof without the approval of Lift Systems is prohibited. either all or part. TOLERANCES (EXCEPT AS NOTED) TM LIFT SYSTEMS INC LIFT SYSTEMS INC 1505 7TH STREET E. both patented and proprietary. will not be revealed or released to other parties without the express written consent of the President of Lift Systems.C83 FEMALE COUPLER C84 MALE COUPLER C83 FEMALE COUPLER 112446 CONTROL VALVE C84 MALE COUPLER CYLINDER PRESSURE 122447 MANIFOLD CYLINDER PRESSURE 122447 MANIFOLD 112446 CONTROL VALVE MGO5 MGO5 100 GALLON RESERVOIR TANK EF06 ELEMENT HF05 P P T 112448 RELIEF T 112448 RELIEF 112656 PUMPS 112440 10HP MOTOR M CONFIDENTIAL LIFT SYSTEMS All Rights Reserved All interest in the basic design and/or invention. MOLINE. IL 61244 ISO 9001 R E G I S T E R E D DECIMAL + - SCALE: MAT. This drawing must be returned on request.

CYL A 9 11 8 6 12 5 C A 4 7 10 D B 3 1 2 ITEM 6 8 12 1 2 3 4 5 6 7 8 ITEM C83 C84 DV76 C79 C80 CBV11 CYL46 RV033 PART NO. 1/2" FEMALE QUICK DISCONNECT 1/2" MALE QUICK DISCONNECT LIFT / PROPEL VALVE 3/8" MALE QUICK DISCONNECT 3/8" FEMALE QUICK DISCONNECT COUNTERBALANCE CARTRIDGE CYLINDER RELIEF VALVE DESCRIPTION 9 10 11 12 13 14 15 16 ITEM NOTES SET AT 2000 PSI SET AT 1800 PSI SET AT 2000 PSI SINGLE LINE HOSE REEL GLAND SOFT SEAL KIT FOR CYL65 SEAL KIT FOR RV033 B-LINE COUNTERBALANCE CARTRIDGE FLOW CONTROL FLOW DIVIDER/COMBINER HR11 K272-0203 MVP108 CBV04 FCV01 FCV12 HM02 RV003 PART NO. DRIVE MOTORS CROSSOVER RELIEF DESCRIPTION LIFT SYSTEMS INC TM LIFT SYSTEMS INC 1505 7TH STREET E. IL 61244 ISO 9001 R E G I S T E R E D DRAWN BY: RLM DATE: 8/26/11 HYDRAULIC SCHEMATIC TITLE: FOR 50 TON BASE WITH DIRECT DRIVES DRAWING NUMBER: . MOLINE.