42a manual with corded pendant

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SERVICE,

OPERATION AND

PARTS MANUAL

FOR 21A/42A

Date

1505 7 STE. Moline, IL 61244Phone (309) 764-9842Fax (309) 764-9848Email: [email protected]: www.lift-systems.com



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 & 62Pre-lift Planning check list……………………………..63 & 64

Parts……………………………………………………..P1-P12

Recommended Spare parts………………………….P13

Repair section………………………………………….R1-R55



SPECIFICATIONS

Model Number 21A/42A

Weight of each lifting unit: 3500lbsWeight 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



LIFT SYSTEMS

Introduction

The lift system consists of two or more bases. Standard equipment

consists of:

Hydraulic powers units Double-acting telescopic cylinder High capacity, 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, basicdirect manual hydraulic controls, and double-acting telescopic cylinders.

The operating condition of this hydraulic system depends upon your compliancewith the procedures and precautionary measures set forth in this safety &operations manual.

DO NOT operate this system if you are not familiar with its components and theprinciples upon which they operate.

NOTICE

Authorized personnel, trained to operate the equipment, must demonstrate acomplete 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 amalfunction occurs.

DESIGN

This lift system is designed for accurate, precise lifting and smooth movement of heavy loads. It is also designed to be very stable when used with proper and saferigging practices, performed by competent rigging and maintenance personnel.All procedures are based on the safe operation of the lift system in properoperating condition, and without deviation from its original intended use.



OPERATING CHARACTERISTICS & LIMITATIONS

Prior to operation, become familiar with the system and its limitations. DO NOTrely on past experience with similar types of lifting devices.

CAPACITIES & STABILIZATION

The lift system must be operated on a firm, level surface. All safety devices mustbe engaged prior to operation. The lift system must not be operated at capacitiesbeyond those specified by the manufacturer (see load chart on the power unit).

WARNINGS & CAUTIONS

Anyone authorized to operate and maintain the system must become completelyfamiliar with this manual.

Since the safety of personnel through the proper use of the system is paramount,

warnings and cautions have been used throughout this manual to emphasizethese areas of concern. They are defined as follows:

WARNINGS

If not followed could end in injury or death to personnel.

CAUTIONS

If not followed could end in damage or loss of the system.

MAINTENANCE RECORDS & EQUIPMENT UTILIZATIONLOGS

Accurate records on the usage and the maintenance of the system are highlyrecommended. Authorized personnel must update the records each time thesystem is in use or maintenance duties are performed.



IMPORTANT ALWAYS DO THE FOLLOWING:

* Understand all system operations, including the safety procedures, beforeaccepting any operating or maintenance responsibility.

* Perform complete pre-start inspection of the system before each use. Performrequired maintenance functions before beginning lifting or traveling.

* Be alert to any space problems and clearances required, including overheadcranes in the area, before starting any system movement. Plan your lift in advance.

* Check to make sure all lifting units are level and plumb at all points. Check oftenduring lifting and traveling to make sure that the system remains level and plumb. Useaccurate leveling measuring devices (tapes or level-lift systems) to determine whetherthe system is level and plumb.

* Check all rigging (shackles, chokers, etc.) to verify capability of handlingspecified load.

* Have all lifting beams and runway track approved by a qualified professionalengineer before the lift. Check for structural verification of the capacities based uponlifting points and load distribution. Check for stress level and deflection in both.

* Use runway track. Shim the runway track every three feet. Have a qualifiedprofessional engineer verify capacity to span lengths greater than three feet, or whenthe system will be traveling over pits or open areas in the floor.

* Use proper operating procedures. Verify that all safety devices are properlyconnected and engaged.

* Check the load chart before lifting the load to determine the exact pressure neededto lift the load. Use the load chart checklist provided.

* Use signalmen to alert the operator of hazards he cannot see from the operatorstation. Clear the work area of all personnel not essential to the safe operation of thelift system while lifting or traveling. Use a signaling device to alert personnel that a liftor traveling operation is beginning. Shut off power unit(s) when not in use.



* Keep all hydraulic hoses clear of travel area. Secure the twin-line hoses to the liftingunit(s) when traveling. Cover any hydraulic lines with fire retardant material if torchor welding work will be performed near the lift system.

CAUTION!NEVER DO THE FOLLOWING:

* Operate the system without performing all necessary inspections, preparation, andproper set-up beforehand.

* Allow unauthorized or inexperienced personnel to operate the system.

* Operate a malfunctioning system. Shut down and seek qualified assistance.

* Leave the system controls unattended with the engine running, or when a load issuspended.

* Lift more than the maximum capacity of the third stage, unless the third stage is fully

retracted.

* Take anyone's word for the weight of a load. Check the pressure readings againstyour load chart.

* Use sight method of determining whether the lift beam(s) or lifting units are level andplumb. Use accurate level measuring devices (tapes or level-lift system).

* Use runway track to traverse pits, basements, tunnels, or unsupported areas unlessa qualified professional engineer has verified the track capacity and the foundationloading capacity beforehand.

* Allow people to do any work under a suspended load unless safety cribs or standsare installed to support the load during the process.

* Allow anyone to override or bypass safety devices.

* Allow anyone to change or alter the plumbing, electrical, or fabricated assemblieswithout the expressed permission of the manufacturer.

* Underestimate the power of this system.



WARNING!Do Not adjust any factory-preset valves without the express permission and writtentechnical instructions from the manufacturer.

WARNING!Do Not weld on any part of the system. Never attach a welding ground to the liftingunits. Doing so could cause an electrical arc between the cylinder pistons and the bores

of the cylinders. This can cause damage that could score the bores causing internalbypass and the cylinder will no longer to be able to hold a load until it is repaired.

WARNING!Never set runway track up on snow or ice. By doing so it could be possible for the trackto slide out from under the system causing the loss of the load, which can causedamage, injury, or the loss of life.

WARNING!

Always make sure the ends of the header beam extend out over the edge of the headerplates. If they are not there is the chance that the lifting unit could be kicked out fromunder the header beam if it were to become unlevel.

WARNING! Never crib under the base of the lifting unit; Doing so will cause the lifting unit tobecome unstable. The lifting unit is designed to carrying the load with the wheels, notany other part of the unit.



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



PRE-START INSPECTION

The Pre-start inspection and maintenance must include checks for:A. Adequate fuel level*(Gas or diesel only)B. Proper engine oil level*(Gas or diesel only)C. Proper water level in radiator*(a) (Gas or diesel only)D. Proper hydraulic oil level**E. Any required lubricationF. No leaks or damage. Repair as requiredG. Lift/propel handles shifted to desired positionH. Thoroughly cleaned hydraulic connection pointsI. All safety devices engaged

* If diesel, gas, 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, even if otherpersonnel may have recently used the system.

OVERALL CLEANLINESS

Check all system surfaces to be sure they are free of oil, fuel, and any foreign objects(towels, papers, tools, etc.) which might interfere with operation or maintenance of thesystem. Clean all quick disconnection points in the hydraulic system before connectionoccurs. Check for signs of physical damage or wear. Repair or replace as required.

LUBRICATION

Consult the lubrication chart and maintenance record to see if lubrication is necessaryprior to operation of the system.

MAINTENANCE RECORDS

Update your maintenance records each time the system is operated or maintained. Thelife of the system will depend upon proper care and maintenance.

EQUIPMENT UTILIZATION RECORDSPersonnel authorized to operate the system must document usage of the system so thatit may be properly maintained.



POWER UNIT DESCRIPTION(Refer to drawings below)

Directional control valves: The control valves are a three positions, solenoid operated, spring centered, spool valvewith blocked working ports. Their function is to divert the hydraulic oil into the properhydraulic circuit by moving the spool electronically. The spool directs oil into the high-

pressure side of the circuit, and returns the low-pressure oil to the reservoir. The valvesare controlled by a pendent that the operator can carry around. However, pendent is notwireless, so the operator is limited by the length of the cord. It does allow some freedomof movement so the operator can get a better view of the lift.

Neutral Position:When the joysticks on the pendent are centered or neutral position the oil coming fromthe gear pump to return to the reservoir at low pressure. As a safety feature, the joysticks are automatically centered when they are released. In this position, the workports of the valve are blocked.

Lift mode/extend cylinders:In this position the joystick, send a signal to the valve which route high-pressure oil fromthe gear pump to extend the cylinder. Oil returning from the cylinder rod end at lowpressure is routed to the oil reservoir.

Propel mode/Forward t ravel: This position works the same as described above with the exception that the lift propelvalve handle on the lifting unit must be shifted to the propel position. Pulling the joystickwill then route oil to the hydraulic drive motor causing the lift unit to travel forward.

Lift mode/retract cylinder:

In this position the valves are routing high-pressure oil to the retract port of the cylinder.Oil returning from the piston end of the cylinder at low pressure is routed to the oilreservoir.

Propel mode/reverse travel: This position works as described above, with the exception that the lift propel/valvehandle on the lifting unit must be shifted to the propel position. Pushing the handle willthen route oil to the hydraulic drive motor, causing the lift unit to travel in reverse.

The pendent controlthe hydraulic control

valves.



Pressure Gauges:On all Lift Systems' power units there are hydraulic oil pressure gauges to provideinformation to the operator. The load distribution on the lifting units, and operatingcondition of the main hydraulic functions of the power unit, are monitored as describedbelow.

The individual lifting unit gauge will indicate pressure only when cylinders are extending. The operator monitors load distribution by comparing the amount of oil pressurerequired by each lift unit to raise the load. When one of the lift units has a higher-pressure reading, it means the unit is lifting more load. This problem must be correctedbefore the lift proceeds.

Hydraulic Oil Filter Dirt Indicator:All systems are equipped with some sort of hydraulic filter. Systems with a 200 gallonpower unit or less have a return filter with a dial type gauge. When the needle is into thered during operation, the filter element should be replaced. Larger systems have a high-pressure, 10-micron filter, and are also equipped with dirty filter indicators. The brands

of filters used have varied over the years, so the indicator also will vary. When theseindicators are showing red, the filter element must be replaced.

Lifting unitpressure gauge

Lifting unitpressure gauge.

When needle is in red Elementneeds to be replaced.



Shut-off valve: The shut-off valve, located in the suction line between the reservoir and the pump, mustbe open at all times. This shut-off valve is only to be used by a qualified servicetechnician when servicing the hydraulic system.

WARNING!Operation of this system with this shut off valve in the closed position will causeirreparable damage to the pump. Immediate failure of the pump may result if theproper procedures are not followed.

Suction Strainers:Each power unit is equipped with a 125-micron suction strainer in the reservoir. Thisstrainer will allow the unit to run for a long period before the strainer becomes clogged,requiring replacement. Periodic inspection of the strainer is recommended.

Refer to the replacement parts section of this manual for suction strainer specificationsand instructions for replacement.

(Valve in closed position)

Quick Couplers: The couplers on the power unit connect to the twin line hoses. These must be routed tothe lifting unit with the corresponding number on it.

CAUTION! The quick couplers must be kept free from contamination at all times. Couplers must bewiped clean prior to use. If equipped with dust covers, covers should be used oncoupler halves any time the couplers are not connected. Failure to do so could allow dirtto get into the system causing premature wear on hydraulic components



Electrical Control Switches:Start Switch:

This switch starts the electric motor.

On Indicator Light: This light comes on when the start switch is pressed.

Stop Switch:

This switch turns off the electric motor.

Emergency Stop Switch: This switch is used in case of an emergency to kill all power to the electricalcircuits and motor controls.

Phase Reversing Switch: This switch is used when the phase is wrong and the motor will not run. Thereis a phase monitor in the system that prevents the motor from running in thewrong direction. The switch eliminates the need to have to switch wires to getthe motor to run in the proper direction,

Main Disconnect Switch Lever: This switch must be disengaged before the electrician may access the inside of the control box for wiring. It must be engaged with the door in the closedposition only, unless there is a service issue with the electrical components,and then a qualified person should only do it.

Main disconnect

Phase Reversing switch

Hour meter



POWER OPTIONS

Electric Motor Option:

Caution! A certified electrician should perform this task. Always confirm the

power is turned off and locked out before doing any work inside the enclosure.Failure to do so can be fatal.

Warning! Before connecting the power unit to a power source, make sure thatthe wire supplying the power is of adequate size. A certified electrician shouldconf irm this . Failure to do so can cause fire and/or personal injury.

There is no “standard” electric option. Most are built to the customer's specifications.However, some things are standard such as a phase monitor. This device checks thephase of the incoming power. If that phase is wrong, the unit will not run. This preventsimproper rotation of the hydraulic pump, which will cause pump failure. Once the unit isconnected to its power source, turn the disconnect to the “ON” position. Push the greenstart button on the gauge panel. If the unit does not start the incoming, phase maybe

incorrect. On the door of the enclosure, there is a forward/reverse switch. Turn theswitch to the other position and try to start the unit again. It should start, but if it fails toothen the problem lays somewhere else. There are circuit breakers inside the enclosurecheck to make sure one of them is not tripped.



Gasoline or diesel options:

Pre-heating and Starting the Diesel Engine

The engine starting procedure depends on the controls and safety shutdownequipment furnished by the manufacturer; follow their instructions for starting,operating, and stopping the engine and related equipment.

Warning! Use of ether as a starting aid may cause an explosion resulting in

severe personal injury and engine damage. Do not use ether as astarting aid as heat from compression or heat from glow plugs maycause a sudden igni tion of the ether vapor.

* Engines equipped with a glow plug will have a pre-heat indicator light. On mostdiesel options, the ignition switch is turned counter clockwise and held until thepreheat indicator light goes out indicating that the engine is ready for starting.Some options may have a push button that needs to be pressed and held untilthe light goes off, before the engine is started.

Caution! Limit pre-heating to recommended periods. Longer periods can ruin theheater element.

Caution! Do not engage the starter for periods longer than 30 seconds withoutallowing 2 minutes for the starter to cool.

* If the engine fails to start after 30 seconds, wait two minutes before re-cranking.Absence of blue/white exhaust smoke during cranking indicates no fuel is beingdelivered. If the engine does not start on the first attempt, check fuel supplysystem.

* Allow the engine to warm up before applying a load. Within seconds afterstarting the engine, oil pressure should exceed a minimum of 60 KPA (10 PSI).After engine has reached operating temperature, the oil pressure should be inthe range of 207 to 380 KPA (30 to 55 PSI) at full load RPM.

If it becomes necessary to use an additional source of power to start the engine,use a 12-volt battery connected in parallel.

Caution! Always let the engine run at idle speed without a load for at least twominutes before stopping. This lets the engine cool gradually and uniformly.

Operation Operation, including following pre-start, pre-heat, starting, and shut downinstructions, involves several checking and servicing procedures. Observingthese practices will help the user extend the life of the engine.



LIFTING UNITLAYOUT

ITEM # DESCRIPTION

1 Lift Quick Couplers

2 Shift Handle (Lift/Propel)3 Header Plate4 Spacer Block5 Clamp Block6 Propel Quick Couplers

1

2

3

4

5

6



LIFTING UNIT DESCRIPTION

Selector Valve for Lift /Propel: The lift/propel valve is used to select the mode in which the lifting unit is currentlyoperating. The upward handle position is for operating the travel. The downward handleposition is for operating the lifting and the lowering function.

Selector Valve for Propel/Freewheel: This feature is only found on system that have integral drives installed them. The valveis used to let lifting units freewheel, which allows them to center them selves with theload or to travel. When starting a lift or setting a load down these valves should alwaysbe in the Freewheel position. Failure to do so could put the lifting unit in a side-loadedcondition.

Quick couplers: The large couplers on the lifting units connect to the hoses from the power unit. Thesmall couplers connect propel devices to the lifting units.

CAUTION!The quick couplers must be kept free from contamination at all times. Couplersmust be wiped clean prior to use. Dust covers must be used when couplers aredisconnected. It is advisable to keep something such as brake cleaner at hand toclean the quick couplers before connecting them. Failure to do so could causecontamination of the hydraulic oil causing failure of pumps, valves and cylinders.

Retractable wheel boxes:Some models feature wheels, which are retractable to 48 inches, or the width of thelifting unit. When the wheel boxes are extended, the width is 60 inches. The standard

runway track is also retractable. To move the wheel boxes in, remove the two (2) or four(4) bolts on top and slide the wheel box over to the next set of holes. Replace bolts andtighten to between 45 to 50 foot/pounds torque. If the wheel boxes have been shimmed,the shims must remain with the same wheel box whether extended or retracted. Someunits do not have retractable wheel boxes. They may also have shims for leveling.

Wheel boxes and shims must be returned to their original place on each unit if removedfor any reason. The wheels are supplied with special anti-friction bearings to facilitateease of movement. The maximum rolling capacity is only achieved on firm, level tracksurfaces.

CAUTION!When retracting or extending wheel boxes, make certain that all shims remainwith the wheel box. Failure to do so will cause the lifting unit to be out of level,causing a side-loaded condition.



PRE-OPERATIONAL CHECKLIST

Before making every lift an inspection should be made of the system.Below is a checklist of items that should be inspected. Use the Pre-LiftCheck List on pages 61 & 62.

If gas or diesel powered, check the engine oil levels.

If water-cooled, check the water level.

Check fuel level.

If electric option, check to see if there is sufficient power at job site to operate thesystem.

Check for strange noises coming from electric motor when running.

Check power cords for proper gauge.

Check power cords for damage.

Check hydraulic oil level. (The lift cylinders must be fully retracted.)

Check oil for cloudy or milky appearance. (This means there could be water inthe oil, which causes loss of lubrication and component failure.)

Check twin line hoses for damage. (A damaged hose could burst underpressure.)

Check for leakage around tops of cylinders. (A little dampness over time isnormal; oil running down the cylinder is not new rod seals maybe required.)

Check hose reel hoses for damage. (A damaged hose could burst underpressure.)

Check all hoses that are exposed to sunlight for cracks. This would mainly be thepower unit hoses. Sunlight can cause the outer cover of the hoses to becomebrittle and crack over time.

Check the cylinder bolts; the lock washers should be fully compressed.(Retighten if needed.)

Check wheel box bolts for tightness.

Check pressure gauges, they should read zero when the system is not runningas well as when the pressure is dumped off by rocking the control valve handlesback and forth. (If the gauge will not go to zero then it is faulty.)

Do a visual check of all exterior welds for cracks on the lifting units.



Check for signs of oil leakage from lifting units.

Check for oil leakage around the mounting surface of the pumps on the powerunits. (If leakage is visible the shaft seal on the pump maybe leaking.)

With the power unit running check the indicator on the hydraulic filter to see if itreads dirty. (If it is, it should be changed.)

With the power unit running and the twin line hoses disconnected check theoperating pressure by pulling one of the control valve handles. The maximumoperating pressure will be the highest pressure shown on the load chart.

Check quick disconnects for leakage.

Check track bolts for tightness.

Check track for debris.



PREPARATION & SET UPIn addition to following the steps below, it is highly recommended that the practices inthe published by "Recommended Practices for Telescopic Hydraulic Gantry Systems"manual, by the S.C.R.A. are followed. This manual maybe purchased through theS.C.R.A. website http://www.scranet.org/store/. On pages, 63 and 64 of this manual isa Pre-Lift Planning checklist from the S.C.R.A. manual, which may be used for planninga lift. It is recommended that copies are made and the original in this manual remains inthe manual as a master.

1. Lay out the lift dimensions on paper

Do a dimensional layout of the lifting arrangement before doing any set-up. There are five critical dimension points which must be laid out before setting upto pick a load.A. The wheel boxes on each lifting unit must be extended, if possible, for

maximum stability.B. The lifting units must be kept as close to the load as possible to minimize

deflection in the lifting beams. Place runway track accordingly.C. 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.D. The lifting beam span needs to be as short as is possible to minimize

deflection.E. The loads on all lifting links needs to be as equal as possible to minimize the

chance of overload.

The layout of the lift must take these five critical points into consideration. If there is anyquestion about the load, center of gravity, or distribution of the load equally among thelifting units, contact a qualified engineer for verification of the layout.



2. Set runway track on the floor or support surface.

Bolt the sections together using the torque specification required. The runway trackmust be shimmed carefully to insure that the system remains level & plumb whiletraveling. The use of runway track is required.

Care must be taken to make certain that the supporting foundation for the track orcribbing is adequate to support the total load. If in doubt, the strength of the

supporting foundation should be verified by a qualified professional engineer.

Runway tracks should be parallel in the direction of travel. Alignment of the sectionsfrom end to end is critical when traveling any distance. Distance between theopposite track sections must be measured carefully and corrections must be madebefore proceeding further. Re-shim the sections if necessary after correctingalignment.

Warning!Make absolutely sure the track sections are bolted to each other end to endand never use the track without the cross members. Failure to do so couldcause the track to slip out from under the lifting units causing serious damage

to the load or equipment and, injury or death to personnel.

Make sure allbolts are tight.



All li ft ing units must be used on Li ft Systems' runway track, or track that hasbeen manufactured by an approved vendor using Lift Systems' design. Tracksections must be leveled as shown in the drawing above. Track must besupported at the proper intervals based upon the load being lifted. Consult thefactory for proper shimming & cribb ing information.

3. Set lifting units in position.Lifting units must be level and plumb after set-up and during all lifting andtraveling. Use accurate levels to check the cylinders for level. Perform any walkaround inspections or maintenance as required. Do not connect the lifting unit(s)to the track section with the propel cylinders, or drives, until after the load is liftedcompletely. The lifting unit will move slightly when lifting the load to find thecenter of the load on the beam.



4. If you are using lifting l inks.If lifting links are to be used, place links onto the lifting beam. Before setting thelifting beam on the header plate, position the links for lifting the load. Place thelifting beam on the header plates and clamp the safety clips in place. Tightensafety clip bolts. Make sure lift links and rigging are straight.

5. Setting up and making the proper connections When connecting the remote pendent and the control cables is important theyare connected in the proper order otherwise the system will not work. One powerunit will be the master the other is the slave. The masters will be power unitnumber one and number two and three and four will be the slaves.

Using a control cable supplied with the system take one end and plug it into theplug labeled OUT on the master unit (#1). Take the other end of the cable andplug it into the plug labeled IN on the unit labeled SLAVE (#3).

Now take the final cable and plug one end into the IN plug on the #1 MASTERand the other end into the pendent control. All the cables are the same and theyare keyed so they will only go in one way. If using only a 2-point system just

connect the pendent to the IN on the power unit.

Pendent

Control cable and allcables are the same.



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



6. Using the pendent contro lFrom the pendent, you can turn the lifting units on and off. You can operate thelifting units all at the same time using one joystick or separately. To operate theindividually turn the selector switch to the left, now each unit can be ranindividually. Turn the switch to the right and all units can be ran with just the righthand joystick.

7. Using Integral Drives To use the drives shift the selector valve handle on the jacks to the propel

position. Two units are equipped with drives so the selector switch must be set tosingle.

WARNING!Do not attempt to travel with the pendent set for ALL, it must be setfor single operation. Attempting to do so two legs will travel while theother two will be lifting or lowering. This is a very dangeroussituation, severe or death could occur.

8. Connecting twin-line hoses.Remove protective dust covers on the hydraulic quick disconnect couplers.Clean all the connectors properly before connecting. Connect the hydraulic linesbetween the power unit and the lifting units. After the quick couplers areconnected, grip the hydraulic line firmly just behind the coupler and pull hard toinsure that the couplers are connected together properly.

Start/stop buttons, turnsthe unit on and off.

J oysticks for operatingeach lifting unit.

Emergency stop must bpulled out before the un

will start.

This joystick will operate allunits when in ALL mode.

Power indicator light.

Indicator light for when inALL mode.

For selecting singleoperation or operating all

jacks with one lever.



9. Disconnecting twin line hosesBefore the twin line hoses can be disconnected, all the pressure in the lines mustbe dumped off the system. If the pressure is not dumped off, it will be extremelydifficult to reconnect the hoses. Turn the motors off but leave the power on,there should still be power to the pendent.

CAUTION!If the retract coupler is not connected properly, the pressure in the rod end

of the lift cylinder is then blocked from returning to the reservoir. If pressure builds high enough, it will relieve to the atmosphere through arelief valve, which is shown on the hydraulic schematic. If oil is squirtingfrom this relief valve, stop and check the couplers. Some newer units areequipped with a catch bottle. The relief valve protects the cylinder in theevent that return oil, when extending, is blocked from going back in thetank.

10. Selector valve handle.Shift the selector valve handles on the lifting unit(s) to the proper startingposition. The shift handle must be in the lift position. Start the power unit and

allow several minutes the motor or engine to warm up before operating thesystem.

11. Power unit starting.On electric power options, verify the electric motor direction prior to constantrunning, some system have phase monitors that prevents the motors from turnthe wrong direction. Failure to do so may result in damage to the hydraulic oilpump. Start the power unit and wait several minutes for the engine to warm up,or the electric motor to get up to speed, before operating the system. If anyunusual noises are heard, shut the system down. Reference the troubleshootingsection of this manual for possible problems and solutions.

12. Extend & retract test.Extend lifting units six inches, and then retract them to ensure all hoses areproperly connected and the system is working properly.

Warning!

Do not lift the load suddenly if the cylinders are miss-staging.Gently ease into the load so the cylinders can restage properlyusing the load to induce the right sequence hydraulically. If the

sections do not extend and/or retract in proper sequence with aload, consult the manufacturer immediately.



13. Traveling

The system lifting units must be level and plumb at all times during lifting andtraveling with loads. When traveling with loads, the track should be level andparallel to the direction of travel. Shim all low areas to insure that the lifting unitsremain level and plumb during travel.

WARNING!Do not attempt to travel with the pendent set for ALL, it must be setfor single operation. Attempting to do so, two legs will travel while theother two will be lifting or lowering. This is a very dangeroussituation, severe or death could occur.

Caution! The lifting units should always operate parallel to each other.Incorrect relationship between lifting units, such as allowing one sideto get ahead of the other while traveling, will create side loads in thecylinder stages causing them to miss-stage and leak.



Warning!If the wheels of the lifting units are to be in the same direction as thebeam length, then make sure beam deflection is at an absoluteminimum. Too much beam deflection may cause the lifting units toroll out from under the beam, causing the load and the lifting units tofall over.



WARNING! Failure to follow these safety procedures may result in severelyhazardous conditions and may cause serious damage to thecylinders.



Attaching and lifting the load. Attach the load to the lifting beams, or links, with rigging equipment rated properly forthe weight of the load being lifted. (Make sure all rigging equipment is adequate tohandle the load to include proper safety factors.)

How to Use the Control Valve and Pressure Gauges to Verify the Load

Using the Load Chart Check List .

Before the lift, fill out the load chart checklist with the pressure required at each liftingunit.

"Lift Load" Pressure:First, use the load chart provided to determine the amount of pressure needed to lift therequired load. Make sure the additional weight of any rigging or lifting beams used areincluded in the calculation of total load. Next, fill in the pressure required for each liftingunit in the "lift load" line on the form. Then, the operator will know when the lifting unit(s)reaches the pressure reading, which should be moving the load.

"Stop Limit" Pressure:Determine the smallest amount of safety factor available in lifting beams, track, andrigging in case of overload. Convert this to a load figure. This figure should be equal to,or greater than, the load you have calculated above. Use the load chart again to fill in"stop limit" pressure. The range of pressure between "lift load" and "stop load" must notbe more than 200 PSI. In the case of a maximum load for that stage, the pressure to liftor stop will be the same.

Before starting the lift, any and all propel or drive options should be unpinned or shiftedto freewheel. When beginning a lift, pull the valve handles gradually to insure accurate

readings on pressure gauges. As pressure increases to the predetermined lift pressure,watch for the load to begin moving. If the load begins moving before the pressure isreached, the load weighs less than calculated. Depending upon the weight of the load,further movement of the handles may result in faster movement of the load. A higher-pressure reading may occur due to increased resistance with increased flow and naturalfrictional losses in hoses, couplers, and valves.

Caution!

When the load starts to clear its supporting foundation, it may want to sway alittle so it can find its center with the lifting system. The lifting process should bestopped until the load has stopped swaying.

If the load has not moved when the "stop limit" pressure is reached the operatorshould….

STOP!!!If you continue to lift, you may overload and break chokers and shackles, or cause deflection in lifting beams, runway track, or the foundation support under the lifting units. Identify the problem and take whatever steps are required tosolve it, and then proceed with the lift.



Warning! If the pressure specified on the load chart is reached and the load is notlifting:

1. The load is actually heavier than calculated.

2. The load is tied or fastened down.

3. The lifting units are not level and plumb, causing side loads, with more pressureneeded to overcome the friction caused by the side load.

4. Faulty gauges.

5. Excessive beam deflection.

STOP!!!! Check the lifting units for level and plumb, the beams and track for deflection.If the setup is proper, the load is probably heavier than expected. Increasing the

pressure may overload the rigging equipment (chokers and shackles). Make sure therigging can handle the increased load before going to higher pressures.

Caution! Recheck for level and plumb in all directions after a substantial portion orthe entire load, is applied to the system.



LOAD CHART CHECKLIST

LIFTING UNIT #1 LIFTING UNIT #2

Approximate lifting weight ________ Approximate lifting weight ________

Approximate pressure Approximate pressure

Stage Lift load Stop Limit Stage Lift load Stop Limit#1 PSI PSI #1 PSI PSI#2 PSI PSI #2 PSI PSI#3 PSI PSI #3 PSI PSI

LIFTING UNIT #3 LIFTING UNIT #4

Approximate lifting weight ________ Approximate lifting weight ________

Approximate pressure Approximate pressure

Stage Lift load Stop Limit Stage Lift load Stop Limit#1 PSI PSI #1 PSI PSI#2 PSI PSI #2 PSI PSI#3 PSI PSI #3 PSI PSI



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



CAUTION!

The system is equipped with anti frict ion steel bearing wheels. It moves easilyeven under heavy load conditions. The system may move by itself if not heldback or blocked properly. The system must be level and plumb at all times.

Watch lifting beams constantly for deflection or signs of excessive loading.Excessive deflection of li fting beams causes severe side loading of cylinders andboom sections.

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 theseconditions.

Operator and crew should constantly monitor exact cylinder extensions.

Cylinder sections must extend in the following sequence: Large bottom section fi rst. Small section second.

Cylinder sections must be retracted in reverse sequence. Small section first . Large bottom section second.

If cylinder sections do not extend or retract in a proper sequence, contactmanufacturer immediately. Extending out of sequence may result in severedamage to the cylinder.



TRAVELING PROCEDURE

After load is lifted slightly, and is clear of supports, then the drives can be engaged fortraveling. See the option section for instructions on using the different drive options.Make sure that the connection from the front to the back lifting unit, traveling on thesame track, are tight. The connections must maintain equal distance between the liftingunits while traveling.

Begin travel of the lifting units by slowly engaging the control levers. Stop travel of thelifting units by slowly returning the control levers to the neutral position. DO NOT MOVELEVERS SUDDENLY! It will induce a surging movement to the load.

Selector valve handle

has to be in the upposition to travel. Downis for lift.

Travel speed canbe adjust with

these flow controls



TRAVELING CAUTIONS!

The system must be level and plumb at all times during lifting and traveling with loads.When traveling with loads, the track should be level, parallel to line of travel, andproperly shimmed for correct floor loading. The lifting units must operate parallel to eachother. Incorrect relationships between lifting units, such as one side getting ahead of theother while traveling, must be avoided. These conditions will create side loads in thecylinders, creating rapid packing wear and possible damage to the cylinder rods.

The foundation area supporting the track and lifting units must be firm enough tosupport the combined weight of the load, lifting units, lifting beams and track without anysettling or sinking. Any change in the support area under the runway track or liftingunits, during lifting or while traveling, is extremely dangerous and must be monitored bythe operating personnel at all times.

PROCEDURES FOR LOWERING THE LOAD

If the load is heavier on one side, it may come out of level rapidly when retracting thecylinders. Caution must be exercised. Use a level-lift system, or measuring tapes, tomonitor the load condition. Keep the load level!

1. The load increases the speed of the cylinders when retracting. Move the controllevers slowly. The more the control levers are moved, the faster the load moves.Lower the load slowly and cautiously.

NOTE: After shutting off the power unit, and prior to hose disconnection, gently rockthe directional control valve levers back and forth several times to relieveany trapped pressure in the lines.



OPTIONS

Level-Lift System

The unique design of the Level-Lift system puts accurateinformation instantly at the operator's fingertips. Thesensor(s) will transfer information on the horizontal levelof the load directly to the readout. Load corrections canbe made immediately, front to back, as well as side toside.

The Level-Lift system consists of two (2) main componentspackaged in a handsome carrying case for easy storage andmobility. The interior of the case is custom fit to the Level-Lift components giving durable and safe transport from job to job. All components are calibrated and tested at the factory.

For set-up, calibration, and use of the Level-Lift system,please refer to the instruction manual provided in eachcarrying case.

PropelsLift Systems offers three propel options; cylinder type,pin on hydrostatic drive, and integral. Follow the instructionsfor the specific propel option with which your lifting units areequipped.

Warning!! Never propel wi th a load that is raised higher than is

required for clearance. The higher the load the lessstable the system.

Using the Propels1) Cylinder type.

a) Pin the cylinder onto the two ears located just belowthe quick couplers using the 7/8" x 6-1/2 hitch pinsupplied.

b) Using the 7/8"x4 1/2" hitch pin connect the propelshoe to the rod of the cylinder. The runners of the shoe should sit on the center rail of the track.

c) Connect the hoses of the cylinder to the right handcouplers on the base.

d) To operate the cylinder, shift the valve handle on thebase to propel position. You can now extend and retractthe cylinders by moving the control valve handles on the



power unit. For Model 2020SC with the propel controlledfrom the remote pendant, move the Lift/Propel switch tothe Propel mode, then use the lift/lower switches tocontrol lifting unit movement of the lifting unit.

e) Now you can lift the load. However, make sure thecylinders are not pinned to the center rail. The lifting units must center themselves with the load.

f) If you want to pull the load, extend the cylinders to thefurthest hole on the center rail and pin the shoe to therail with 3/4" x 6- 1/4" hitch pin. Using the control valve,retract the cylinders until you reach the desired position.Make sure you keep the load even. If the cylinderscome to the end of their stroke, then unpin and extendthem, and re-pin them as before and repeat until thedesired position is achieved.

g) If you want to push the load, use the above procedure

starting with the cylinders retracted and extend to move theload.

h) When you are ready to lower the load, shift the valvehandle into the lift position and make sure the cylinders are not pinned to the track. The lifting units must center themselves with the load.

2) Pin on chain drives with ratchet jacks.

a) Pin the drive housing onto the tangs located just

above the wheel boxes.

b) Pin the ratchets to the tangs that are located on the top of the housings.

c) Extend the ratchet until you can pin the other endto the tangs located on the base.

d) Use the ratchets to raise the housing until the tires areno longer making contact. There is a small lever on theratchets to change their direction.

` 3) Integral drivesa) These are built into the lifting units. There is a valvehandle labeled propel/freewheel. When lifting or lowering aload, simply shift the valve handle to the freewheel position.When traveling, shift both the lift/propel and thepropel/freewheel handles to propel. You may now control thedrive from the power unit control valve.



Side Shifts

Lift Systems offers four types of side shifts or “Trolley”systems.

1) Cylinder type with slider pad dolly.

2) Cylinder type with wheeled dolly.3) Continuous hydrostatic drive with wheeled

dolly.4) Continuous chain drive with wheeled dolly.

If you order a side shift system, instructionsspecific to that system will be included at theend of this section.

Side shift or “Trolley” systems allow safemovement of the load latitudinally, or

perpendicular to the direction of movement of the lifting units. Due to stability and capacityfactors, the capacity of the system is de-ratedby a minimum of 40% when using side shiftsystems. As with all other phases of the liftplan, a professional engineer should beconsulted regarding the use of side shifts or“Trolleys”.

Warning! Always move slowly and smoothly whenusing side shift or “ Trolley” systems. Theinertia of a rapidly moving load may exceedthe stability of the lifting units causing lossof the load and possible injury or death topersonnel.

Warning!The header beam should never be more than ½” of level over a 20ft. span.



Date Operator Location Hours Utilized

Utilization Chart



42

MAINTENANCE SECTION SUMMARY

The preceding guidelines are intended for use with the hydraulic power units and liftingunits as supplied by Lift Systems.

DO NOT start or operate any hydraulic power unit without a complete understanding of allthe recommended operation and start-up procedures.

WHEEL LUBRICATION

The wheels on which this lift system moves are equipped with grease fittings located onthe hub of each wheel, and should be greased on a regular basis. Bearings should befilled with a good grade of EP (extreme pressure) grease.

To gain access to the grease fittings, the individual lifting units should be raised with a

forklift and blocked up to allow you to move, remove or service the wheels.

CAUTION!

Care should be taken not to change the proper placement of any shims when moving orremoving the wheel. Wheels must be shimmed snuggly in place.

OIL

Oil in a hydraulic system performs the dual function of lubrication and transmission of power. Careful selection of oil should be made with the assistance of a reputable

supplier, helping to ensure the satisfactory operation and life of this system and itscomponents.

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 proper viscosity to maintain adequate sealing and lubricating

qualities at the expected operating temperature of the hydraulic system.* The oil must have rust and oxidation inhibitors for satisfactory system

operation.

Manufacturer recommends the use of Mobil DTE 24 or equivalent. (Specifications for thisoil may be found in the maintenance section of this manual).



43

OIL LEVEL

Oil level must be checked when cylinders are fully retracted and prior to the operation of this system.

CAUTION!DO NOT OPERATE THIS UNIT WITHOUT OIL UNDER ANY CONDITION.

When it becomes necessary to add oil to this system, make sure that all oil added to thereservoir is strained through a 10-micron filter. An adequate filter can be purchased atyour local fluid power distributor or an industrial supply house.

OIL MAINTENANCE

Cleanliness! Hydraulic components are precision built. Cleanliness is imperative to the

long life and the good operating condition of this system.

The major cause of hydraulic system failure is dirt in the oil and related hydrauliccomponents. Keep all the quick couplers clean when on the job site, and covered withplugs and caps when not in use.

SUCTION STRAINER

To gain easy access to the strainer, pump the oil into drums for storage. Remove thecover on the reservoir. The strainer is screwed into the pipe coupler behind the shut off valve.

Remove the strainer, then clean it with solvent and blow it out with an air gun or replacethe strainer with a new one. Clean the reservoir out with solvent and wipe it completelydry with a lint free cloth. Apply a Teflon type sealant generously to the threaded area of the strainer. Screw the new suction strainer into the pipe coupler until the strainer issnug. Clean and install the shut off valve. Fill the reservoir with oil that has been filteredto 10 microns. The old oil can be reused only if it has been analyzed and has been foundto be acceptable. If it has not, it must be replaced.

We recommend that the reservoir lid be installed with new gasket material and siliconesealant. Then open the shutoff valve.



44

HYDRAULIC FILTER

The hydraulic filter used on heavy-duty machines is a high-pressure 10-micron filter thefilter unit has a built-in PSI bypass valve to show when the filter is clogged. To change thefilter. On older systems remove the top with a wrench; remove the spring, the spring

spacer, and the filter element(s). Then assemble in reverse. To change the filter on newersystems screw off the bowl of the filter, remove the element, clean the bowl and theninsert the new element and screw the bowl back on.

On the older systems the dirty filter indicator has a reset button that you push afterchanging the filter. The newer system only reads dirty when the system is running.

If there is a major failure of the pump, or other system components, all filter elementsshould be replaced. In addition, all of the oil in the system and inside the reservoir shouldbe cleaned or replaced.

* Pump the oil out of the reservoir into clean container(s) of suitable size.* Wipe out the inside of the reservoir to remove all dirt. Install a new suction

strainer.* Pump oil back into the reservoir, being sure to strain the oil through a 10-micron

filter.

In the event that the oil has been highly contaminated with something such as water,changing the filters or filtering the oil through a filter cart will not be enough. The oil willneed to be replaced, and all hydraulic lines and cylinders will need to be flushed out. Inthis event, it is best to send the system back to the factory to have the system cleanedand flushed.



45

SYSTEM MAINTENANCE

1. All hydraulic filters should be changed when the indicator shows the filter is dirty, oronce a year, whichever comes first.

2. Wheels and all bearings should be greased at least once a month with a good grade,high-pressure grease.

3. Have a hydraulic oil sample tested once a year for general wear, metal and watercontamination tests. If high water content is suspected (milky in color with lowlubricity) ask for a Carl Fischer method of water content tests.

4. Inspect hoses and gaskets for wear yearly and replace as needed.

5. Bleeding procedures for lifting units consult the factory for specific information.

6. Cylinder packing replacement procedures consult the factory for specific information.

7. For engine maintenance consult the engine manual supplied with the system.

For more detailed component data, refer to other sections of manual or contactmanufacturer. Details on components with replacement parts list and specifications onparts are available.

Cylinder Packing Replacement Procedures

Lift system has used various cylinders from various suppliers over the years. This is atask that should not be attempted it at a job site. It is best to send the system back to thefactory where we are fully equipped to service the cylinders. In addition, we are alsoequipped to load test the system when the re-sealing is complete. If you choose to takethe cylinders to someone other that Lift Systems for resealing make sure, they areexperienced with this type o9f cylinder and are willing to stand behind their work in theevent there are problems.

If you choose to attempt this task yourself, you will first need to contact the factory for the

replacement seals and information on the seal locations and procedures. You will needthe system model number and serial number. You may be asked to provide the cylinderserial number.



46

Testing a Cylinder for Bypass There are two types of testing to check for cylinder bypass. The, first is theeasiest. In addition, someone who has knowledge of hydraulics and howcylinders work should do this test. Done incorrectly, damage to the cylinder

and injury may be possible.

LSI CYLINDER1. Extend the cylinder an inch or two.2. Disconnect the extend side of the twin line hose (this wil l be the male coupler on

the base or the female on the power unit) then cap and plug off and pilot linegoing to the counter balance valve located on the bottom of the cylinder.

3. Take a marker and make a mark on the chrome of the cylinder at the wiper.4. Try to retract the cylinder and hold it there for one minute.5. Watch the cylinder while it is in retract mode, if it extends even slightly there is oil

bypassing the piston seals. The cylinder will need servicing. (However, a very

small amount could acceptable so please consult factory to determine whatis acceptable. In addition, some brands of cylinders have cast iron pistonrings which will have some bypass and these require a different test. Seesection B. Please consult the factory to determine which type you have.)



47

Maintenance Chart

Date Hour Meter Reading Maintenance Performed Service Performed By



48

Troubleshooting

GENERAL TROUBLESHOOTING

1. Always check the basic things as listed below first. If the same problem exists in all of the lifting units, look for a problem in the power unit.

A. Is the pump working properly?B. Are the filters dirty?C. Is the hydraulic tank full of oil?D. Is the oil clean or contaminated?E. Are relief valves set to proper pressures?

2. Isolate the problem. If a lifting unit is not working properly, switch the hydraulic lines atthe power unit. If the power unit is for #1 and #2 take the lines for #1 and plug them

into #2 and #2 into #1.

A. If the problem no longer exists, the problem could be in the control valve orelsewhere in the power unit or couplers.

B. If the problem remains, then the problem is isolated to the lifting unit.

3. Look for simple solution first, as listed below.

A. Lift/propel lever may not be shifted properly.B. Dirty track can cause propel problemsC. The system may not be level or plumb.D. Load heavier than expected or held down in some way.E. All bolts may not have been removed.



49

TROUBLESHOOTING - PROPEL CYLINDERS

PROBLEM: Does not extend or does not retract:

CAUSES: SOLUTIONS:

A. Couplers not connected A. Connect couplers properlyB. Lift/propel lever shifted to lift B. Shift to propel positionC. Dirt or obstruction on track C. Clean trackD. System pressure set too low D. Adjust relief valvesE. Track is not level, uphill condition E. Level track

may existF. Track is not parallel; wheels are F. Align track properly

binding on guide bar.G. Load is still in contact with G. Check all clearances and be

surface or against an obstruction sure all tie down bolts areremoved

H. Ruptured hose in lifting unit H. Replace hose

I. Internal oil leakage in cylinder, could I. Use flow meter to check forbe worn piston seals bypass. Cylinders rebuild

maybe required.

TROUBLESHOOTING - PROPEL DRIVES

PROBLEM: Drives will not move the system

CAUSES: SOLUTIONS:A. Couplers not connected A. Connect couplers properlyB. Lift/propel lever shifted to lift B. Shift to propel positionC, Dirt or obstruction on track C. Clean trackD. System pressure set too low D. Adjust relief valvesE. Track is not level, uphill condition E. Level track

may existF. Track is not parallel; wheels are F. Align track properly

binding on guide bar.G. Load is still in contact with surface or

against obstruction. G. Check all clearances with thesurface, or against anobstruction, all tie down boltsare removed

H. Ruptured hose in lifting unit H. Replace hose

I. Freewheel/propel valve in freewheel I. shift valve to propel J . Ratchet style drives not making contact J . Ratchet drives down onto track.



50

K. Oil on track causing wheel to slip. K. Clean track.

L. Flow controls, if equipped, closed off L. Open flow controls.

TROUBLESHOOTING - LIFTING UNITS

PROBLEM: Li ft cylinder does not extend:

CAUSES SOLUTIONSA. Faulty hydraulic pump. A. Repair pump.B. Couplers not connected. B. Connect couplers properly.C. Lift/propel lever shifted to propel. C. Shift lever to lift position.D. Ruptured hose. D. Check for oil in base and

replace hose.

E. Load is too heavy. E. Verify weight. Change to largersystem.

F. Load is tied down. F. Remove bolts.

PROBLEM: Slow extension:

A. Couplers not fully connected A. Connect couplers properly.B. Load is heavy in area closest to B. Reposition rigging and the load.

that cylinder.C. Internal oil leakage in cylinder, C. Use flow meter to check for

could be worn piston seals. bypass. Cylinder rebuild may

be required.

PROBLEM: Leakage when extending:

A. Severe side loading A. Check for lifting units out of level, beam or runway trackdeflection.

B. Work packing. B. Replace packing

It is advisable, after a lif t is completed, and there has been some leakagearound the rods seals, to cycle the cylinders a few times to see if the leakage

stops. If it does, the leakage was probably due to s ide loading of thecylinder. If the leakage continues, the rod seals needs attention and thefactory should be contacted.



51

PROBLEM: Not staging properly:

A. Severe side loading. A. Check for lifting units out of level, beam or runway trackdeflection

WARNING! Operating with cylinders mis-staging can cause severe damage to cyl inders andhazardous lifting conditions due to cylinders restaging under the load. Consultfactory immediately.

PROBLEM: Deflection in cylinder stages:

A. WARNING! Severe side loading. A. Lower the load & reset properlyVERY DANGEROUS! Systemis out of level, runway track could besettling.

PROBLEM: Vibration in cylinder:A. Water in oil A. Drain and flush system.

Replace oilB. Bulged or deformed cylinder stage(s) B. Replace stage(s)

PROBLEM: Li ft cylinder does not retract:

A. System pressure set too low A. Adjust relief valvesB. No pressure to wedge lock control B. Check blocker valves in base.

cylinders.C. Couplers not connected C. Connect couplers properlyD. Lift/propel lever shifted to propel D. Shift lever to lift positionE. Ruptured hose E. Check for oil in base and

replace hoseF. Faulty coupler F. Change coupler on lifting unit

and try a different hoseG. Safety holding valve at base of G. Replace valve

cylinder is faultyH. Pilot line from retract line to safety H. Replace pilot line

holding valve is plugged or restricted



52

PROBLEM: Slow retraction:

A. System pressure too low A. Adjust relief valveB. Lift/propel lever shifted only B. Shift lever completely

part way to lift position

C. Air in upper cylinder area C. Bleed cylinderD. Contamination in system and D. Drain and flush system.Replacecylinder causing blockage or oilrestriction of oil flow.

E. Bulged or deformed cylinder E. Replace bulged or deformedcylinder section(s).

PROBLEM: Erratic extension or retraction:

A. Air in system A. Bleed systemB. Pump cavitations, tank low on oil B. Fill with oil and check pumpC. Contamination in system C. Drain and flush system.

Replace oil

PROBLEM: Slow extension and retraction on all l ifting units:

A. Hydraulic oil filters dirty A. Replace filtersB. Contaminated oil B. Drain and flush system.

Replace oilC. Worn pump C. Check with flow meter.

Replace pump if flow is too low



53



54



55



56



57



58



59



60



61

Pre-Lift Checklist

1. Lif t Plan

2. Secure AreaClose off with caution tape and other visible working signs or barriers necessary to prevent unauthorized entryinto work area.

Check for overhead crane operation. Shut down and lock out if telescopic hydraulic gantry system extendshigher than overhead crane.

Notify area foreman of impending operation.

Clear non-essential personnel from the area.

Check for hazards: electrical, wind, water, etc.

Do not allow other equipment or crews to work in the area that are not directly related to the lift.

Make sure there are clear access routes for the crew to use in case of an emergency.

Move heavy equipment clear of lift area.

3. Notify Owner Notify job site security/safety department of impending lift.

Notify job site engineer of impending lift and pre-lift meeting.

4. Pre-Lift Safety MeetingCheck area for debris.

Assign personnel to specific tasks.

Explain in detail how lift will be safely accomplished.

Very personnel understand their tasks.

Identify escape routes and other emergency procedures.

Confirm method(s) of communication to be used during the lift.

Explain what will be done under different emergency situations.

5. Pre-Lift Telescopic Hydraulic Gantry System Check.Fuel supply

Fluid levels.

Ensure quick disconnects are engaged.

Gantry legs for plumb.

Date Company Name____________________________

J ob# Location__________________________________



63

PROJECT DATAProject:Project Number:Client/Owner:Date of Lift:Location of Lift:

Description of Lift:Number of Gantry legs Used:

LIFT TYPEO 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 DATADescription:

Weight:How DeterminedDetermined by Whom

Load center of Gravity is: O Centered O Off-center

LIFTING COMPONENTS DATA

Size/ Capacity DeadweightLift Link Capacity ___________ __________ Header Beams ___________ __________ Sling Capacity ___________ __________ Shackle Capacity ___________ __________ Special Lift Devices ___________ __________

TOTAL CALCULATED LOAD

MAXIMUM CALCULATED LOADPER GANTRY LEG

Pre-Lift Planning Checklist



64

GANTRY DATAGantry Model:Serial Number:Manufacturer:Number of Stages:Gantry Weight:

Gantry is: O Externally P ropelled O Self-Propelled

GANTRY SUPPORT SURFACEO Concrete Floor on GradeO 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 CONFIGURATIONGantry 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 CALCULATEDLOAD PER GANTRY LEG ASPERCENT OF RATED CAPACITY

Prepared by: Date:

Lift Planner Signoff: Date:Project Manager Signoff: Date:



Part Section

P1

1. 101302 BREATHER

1



Part Section

P2

1. MG05 0-3000psi gauge

2. HF05 RETURN FILTERFE06 REPLACEMENT FILTER

3. MG09 DIRTY FILTER INDICATOR

1

2

3



Part Section

P3

1. F084 PIPE NIPPLE

C84 MALE COUPLERC81 DUST CAP

2. F084 PIPE NIPPLEC83 FEMALE COUPLERC82 DUST CAP

2

1



Part Section

P4

1. 112446 Control valve

2. 112656 Pump

1

2



Part Section

P5

1. 106287 Control cable

2. DV102 Lift/propel selector valve.

3. C84 ½” male coupler

4. C83 ½” Female

1

2

3

4



Part Section

P6

1. RV033 Safety relief valve

2. CBV04 counter balance valve

3. HR11 Hose Reel

1

2

3



Part Section

P7

1. RV003 Crossover relief

2. FCV12 Flow divider

1

2



Part Section

P8

1. 42HPA01 Header plate

2. 42HO05 Spacer block

3. 42HP06 Clamp block

4. 42HP14 Pin

5. CYL46 50-ton 2-stage cyl inder

6. HHCS004 Bolt(4total)

6

2

2

33

1

4

5



Part Section

P9

1. 05-011 Barrel

2. 30-013 Large sleeve

3. 50-011 Rod

4. 75-017 Large packing gland

5. 75-016 Small packing gland

1

2

5

4

3



Part Section

P10

Small piston seals

Large piston seals

1. W-020 Wear ring

2. 26-4610-35X Loader and 26-4610-35A Piston seal

3. W-027 Wear ring

4. 26-5004-13 Cast iron piston ring

5. 26-4610-36X Loader and 26-4610-36A Piston seal

1

2

1

5

4

4

3

3



Part Section

P11

Large packing gland

1. 26-4173-50A O-ring

2. 26-5044-2 Bronze backup ring

3. W-022 Wear ring4. 26-5043-9X Loader and 26-5040-9A Bronze buffer seal

5. 26-3980-83 Polypac

6. 26-3707-38 Wiper

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

4

3

2

1

5

6

7



Part Section

P12

Small packing gland

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 Polypac

6. 26-3707-32 Wiper

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

7

6

5

4

32

1



Part Section

P13

Recommended parts list

CBV11 Counter balance cartridge 2pcs

CBV04 Counter balance cartridge 2pcs

RV033 Safety relief 2pcs

C83 ½” Female coupler 2pcs

C84 ½” Male coupler 2pcs

C79 Male coupler 2pcs

C80 Female coupler 2pcs

THL50-1 Twinline hose 1pc

HHCS004 clamp block bolts 8pcs

42HO05 Spacer block 2pcs

42HP06 Clamp block 2pcs

FE06 Return filter elements 2pcs

101301 Breather 1pc

MG04 Pressure gauges 2pcs

55-996 Seal washers 6pcs

FS420-714 Bleed screws 6pcs

K272-0203 Cylinder seal kit 1pc

HA033T Hose reel hose 1pc

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

request.



R1

Repair Section

Steel wheel and bearing replacement

1. Items requireda. ¾” wrench or socket with ratchetb. Dead blow hammerc. Grease gun and multipurpose grease.

2. With ¾” wrench remove the two ½” hex head bolts holding thewheel box in place.

3. Using a fork lift, lift the lifting unit up off the wheel box.

½” hex head bolts.



R2

4. Roll the wheel box over on to it top and remove the ½” hexhead bolt with a ¾” wrench.

5. Tap on the end of the axle with a dead blow hammer until theend with the tab is out to where it can be grasped and then pullthe axle out while holding on to the wheel. But use caution andkeep a good grip on the wheel don’t let if drop down to where itcan pinch your fingers

6. Lift the wheel but take note there are spacers on each side of the wheel, keep track of where they go so that they can go backin the same locations when reinstalling the wheel.

Keep a good grip on thewheel when pulling theaxle out.

There will be spacerswith both bearings,make sure to keep trackwhere they go.



R3

7. If replacing just the bearings thoroughly clean the wheel andinspect the bearing race for damage. If it appears to be in goodcondition then there is no reason to replace it. If it is damaged itwill need to be replaced.

8. With the wheel lying on its side with the damaged race on thebottom side. Use a brass bar to tap the race out of the wheel. Itwill be necessary to tap around the entire diameter of thebearing; do not try tapping just in one location, this will onlycause the race to become jammed.

9. To install the new race the simplest way is to press it in with asmall hydraulic press. Use a piece of round stock that is slightlysmaller than the outer diameter of the race so that the taperedsurface is not damaged. Press the race in until it is seatedagainst the shoulder inside the wheel. If a press is not availablethe race can be tapped in with a soft faced hammer of somekind until it is flush with the hub of the wheel, at this point use apiece of brass to tap the race in until it is seated against theshoulder. Use caution not to damage the tapered surface.

The back side of bearing race. Tap hereto remove the race,making sure to goaround full diameter of

the race when doing so.

Tap here when tappingnew race into thewheel.



R4

10. Before inserting the new bearings make sure they have beenpacked with grease with a bearing packer or by hand. Makesure to leave a thick coat of grease on the outer portion of thebearings, this will help hold the bearings in place.

11. With the wheel box on its side take the wheel with thebearings and slid them in to the pocket. With the wheel in thepocket, lift so that the bottom spacers can be slid in.

12. Then slide the upper spacers into place.

Slid wheel and bearinginto pocket.

Lift the wheel enough toslide in the bottom spacers.

Slide upper spacers in.



R6

Cylinder removal

1. Items neededa. Two (2) Pieces of #8 SAE male plug, Lift Systems #F131

b. One (1) piece of #4 SAE male plug, Lift System #F129c. One (1) piece of #4 O-ring face cap Lift Systems #C51d. One (1) piece of #4 O-ring face -plug Lift Systems #C52e. One (1) piece of #6 O-ring face cap Lift Systems #C29f. One (1) piece of #6 O-ring face plug Lift Systems #C33g. Two (2) large wire tiesh. Two (2) 10” adjustable wrenchesi. External snap ring pliers for 1” pin j. One (1) 3/4” socket with ratchet.k. #3 Phillips screwdriver.l. 1-1/8”socket and ratchet.

2. Uses the external snap ring plies to remove one of the snaprings from the header plate pin, have the header platesupported with slings or hoist rings and slid the pin out and thenlift the header plate off.

Use snap ring pliers toremove 1” snap ring andslide pin out while headerplate is being supported.



R7

3. Since there could be pressure built up inside the cylinder,loosen up the bleed screws on the cylinder to help release thatpressure. Use a rag to wipe up the oil as it is comes out aroundthe screws.

4. Using two large wire ties, wrap them around the hose and theroller guide on the hose reel, this will keep the hose from being

unwound.

5. Slowly disconnect the hose from the top of the cylinder. Usecaution, there may still be pressure trapped in the cylinder.

Bleed screw- thereis one in each glandnut and the rod.

Wrap two large wire tiesaround the hose and theroller guide.

Slowly remove thehose, cap the fittingand plug the hose.



R8

6. Cap off the 45 degree fitting to which the hose was attached towith the #6 O-ring face cap. Plug the hose with the #6 O-ringface plugs.

7. Remove the fittings at the top of the cylinder and plug the portwith a #8 SAE male plug.

8. At the bottom of the cylinder disconnect the pilot line from theholding valve; cap the fitting with a #6 O-ring flat face cap andplug the hose with a #6 O-ring flat face plug. Then disconnectthe extend line and cap the hose with a #8 O-ring plug and capthe fitting with a #8 O-ring flat face cap.

9. Remove the small elbow fitting and plug the port with a #4 SAEmale plug, then remove the larger elbow and plug the port witha #8 SAE male plug.

10. Starting with the upper handrail clamp remove the two bolts

holding the hand rail clamp. Then remove the ¾” bolt holdingthe lower portion of the hand rail, remove the handrail.

Holding valve.

Pilot line.

Extend line.



R9

11. Loosen the lower bolts of the support arms on the end of thelifting unit that the handrail came off of. The arm that the upperbolt was removed can be folded back away from the cylinder.

Remove the boltsfrom here.

Remove the ¾” bolthere and remove thehandrail.

Loosen the lowerbolts but do notremove them.

Take this arm andfold it back.



R11

15. To reinstall just reverse the steps.

16. Torque the ¾” bolts to 165ftlbs. The upper clamp bolts should

be tightened so that the gap between the ears is equal on bothsides.

Torque these boltsand the lower onesto 165ftlbs.

Tighten these so thegap between theears is equal on bothsides.



R12

17. When the cylinder is fully installed it will need to be bled.

18. Put the cylinder into retract and loosen the bled screwsstarting with the top one. Leave the screw loose until there isoil coming out from around it. Then continue to the next onedown.

Bleed screws

Bleed screw, starthere and work down.



R14

5. Occasionally the o-rings on the cartridge may roll off thecartridge when removing, If this happens, make sure the o-ringsare not left in the valve body.

6. Insert new cartridge and turn it clockwise to tighten until thecartridge is seated, then torque the cartridge to 30-35ftlbs.

At times these o-ringswill roll off when

removing the cartridge.



R15

Replacing the B-line Counterbalance Valve

1. Items requireda. 9/16” wrenchb. 5/32” allen wrench

c. 1-1/8” wrench or 1-1/8” socket and ratchet.d. Foot pound torque wrench.

2. Using compressed air, blow any dirt or foreign particles outfrom around the counterbalance cartridge.

3. The valve may have pressure trapped in it. Use the following

steps to relieve the pressure:

a. Loosen the jam nut on the adjustment screw with the9/16” wrench.

b. Using the 5/32” allen wrench, turn the adjustment screwall the way in a clockwise direction.

c. Attach twin line hose to the lifting unit and the power unit.

B-line counterbalance valve.



R16

d. Do not start the power unit. Pull the control valve handleto the extend position to which the lifting unit isconnected. Have someone hold it in that position.

e. Very slowly, using the 1-1/8” wrench, turn the cartridgecounter-clockwise. If there is a lot of trapped pressure,the cartridge will be difficult to turn. As the pressure isreleased, the cartridge will become easier to turn.

4. Once the cartridge is removed, make sure the o-rings did notroll off and are not in the valve body.

5. Install the new cartridge and torque to 30-35ftlbs, it will benecessary to hold the valve body with another wrench toprevent the valve body from turning.

Ad ustment screw.



R17

Replacing the RV033 Safety Relief

1. Items requireda. 6” adjustable wrench

b. One (1) piece of #6 O-ring face plug Lift Systems #C33

2. Before the safety relief can be remove any pressure trapped inthe cylinder will need to be relieved.

a. Refer to step #3 in replacing the B-line Counterbalance Valveon page R15.

3. Once the cartridge can be easily turned by hand, then thepressure has been relieved.

4. Tighten the cartridge back down and turn the adjustment back

out the same number of turns it was screwed in.

5. Since the cartridge of the relief in pointed towards the hose reelit maybe necessary to turn the assembly that the valve isthreaded into so that there is enough clear to remove the valve.

Remove hose.



R18

6. It may also be necessary to unbolt the hose reel and lift it up toget the valve off.

7. Thread the new valve on.

8. Turn the assembly back to its original position.

9. Bolt the reel down if it was unbolted.

10. Function test and check for leaks.

It maybe necessaryto rotate the

assembly counterclockwise at this

joint in order tounthread the valve.

Remove the valvefrom this fitting.



R19

Replacing the HR011 hose reel

1. Items requireda. One (1) piece of #8 O-ring face cap Lift Systems #C30.b. One (1) piece of #8 O-ring face plug Lift Systems #C34.

c. Three (3) pieces of #6 O-ring face cap Lift Systems #C29.d. Three (3) pieces of #6 O-ring face plug Lift Systems #C33.e. Two (2) large wire ties.f. 5/16” socket and ratchet.g. 10” adjustable wrenchh. 7/16” socket and ratchet (1/4” drive.i. Set of open end wrenches.

2. Since there could be pressure built up inside the cylinder,loosen up the bled screws on the cylinder to help release thepressure. Use rags to wipe up the oil as it is coming out

around the screws.

3. Take two wire ties and use them to tie the hose to the reel.

4. Disconnect the hose at the top of the cylinder, plug the hoseand cap the fitting on the cylinder with the #6 flat face o-ringcap and plug.

Wrap wire ties around hoseand the roller guides.



R20

5. Disconnect the hoses.

6. Use 5/16” socket and ratchet and remove the hose reelmounting bolts, there are a total of four. Push the hose downthrough the top of the lifting unit and then lift the reel out.

7. Securely clamp the reel down on a work bench.

8. Put on a pair of work gloves, firmly grasp the hose and cutthe wire ties and slowly let the reel take up the hose. Whenthe end of the hose clears the rollers. Hold on to the drum of the reel and let it slowly unwind until all the tension is off.

9. Unwrap the hose from the reel.

10. Using a 13/16” wrench disconnect the hose from the reel,plug hose and cap fitting with #6 flat face o-ring cap andplug.

Disconnect the hose here andplug hose and cap fitting.

Disconnect the hoses here andplug hoses and cap fittings.



R22

14. Clean the threads on the fitting and apply new pipe sealantto Teflon tape. Assembly new fitting into new reel as theywere in the old reel.

15. Once the fittings are installed attach the hose to the swiveland tighten with 13/16” wrench.

16. Install the clamp around the hose and tighten, do not crushthe hose when tightening the clamp.

17. With the reel securely clamped to a bench, wrap all thehose around the reel.

18. With a firm grip pull the hose so the reel turns with it, whenthe hose reaches the end let it slowly return. The first timedoing this the reel should stop before all the hose is takenup. Wrap the remaining hose around the reel and pull it outagain. The reel needs to be tight but if the reel stops beforeall the hose is ran out then it’s too tight, it should be one ortwo turns from that point.

19. With the hose wrapped on the reel and the tension set. Runthe hose through the rollers leaving enough hose extendedto go through the top plate of the lifting unit. Tie the hose off to the reel as was done with when removing the old reel.

20. Set reel back into lifting unit and bolt it back into place.

Swivel



R23

21. Attach the hoses inside the lifting unit back on the reel andtighten with a wrench.

22. If there was enough hose left extended, attach it to thefitting at the top of the cylinder, but do not tighten it until thewire ties have been cut loose, doing this will let any twist inthe hose relax out and the hose should remain straight, andthen tighten the hose.

23. If there wasn’t enough hose left extended, firmly grasp thehose and have someone cut the wire ties. Pull the hoseupward and attach it to the fitting.

24. Start power unit and move the control valve handle into the

retract position and hold it until it comes up to full pressure.At the same time have someone check for leaks. If leaks arefound stop and repair the leaks and repeat until it comes upto full pressure. Then fully extend and retract the cylinder tomake sure the hose reel is working properly.



R24

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.)

1. Items Requireda. 1-1/2 wrench or socket and ratchet

b. Shims (type of shim depends on model of system)c. Section of track or a flat steel plate at least 2” thick (With one side

machined is best).d. Good high quality 24” level (A machinist level is preferable).e. Small porta-power cylinder that will fit under the lifting unit.

2. Set up a plate or track and level it from end to end and side toside. The track or plate must be level in all directions. A solidplate that is at less 2” thick and has one side machined off sothat it is flat works best.

3. Set the lifting unit on the track or plate.

4. Check to see if all four corners of the lifting are making contact.

5. If one corner is not making contact then slip just enough shimunder the wheels so that it is. You may need to lift up the liftingunit slightly to slide in the shim; this is where a small porta-power cylinder comes in handy. Use it to slightly lift the lifting

unit, when the shim is in place lower the cylinder.

If using track it must be levelall the way around, form end-

to-end and side-to-side.



R26

8. When the unit is sitting level the shims can now be insertedbetween the wheel boxes and the mounting plate of the unit.

J ack up one corner take the shim out from under the wheels.Loosen and remove the 1” bolts holding the wheel box on with1-1/2” wrench. Slip the shims between the wheel box and itsmounting plate. Reinstall the bolts, tighten until the lockwashers are compressed, lower the unit, and repeat with the

other wheel boxes if required.

If the unit is leaningin this direction.

Then shimthis side.

If the unit is leaningin this direction.

Then shimthis side.



R27

9. With all the shims in place recheck the level and all four cornersare making contact to ensure it is correct.

NOTE:

When leveling and shimming try to keep the number of shim to aminimum. Use a thicker shim in place of two thinner shims if possible.In addition, when shimming it is easy to keep adding shims, tryremoving some shims if possible.

With the unit slightly lifted and thewheel box bolts removed slip theshims in between the wheel boxand its mounting plate. The shimsshould not extend pass the edgeof the unit

Wheel Box

Mounting plate.



R28

Replacing return fil ter elements

1. Items requireda. Filter strap wrench to fit 5” diameter return filters.b. Catch pan

2. On systems with return filters connect at least one lifting unit tothe power unit and extend the cylinder to lower the oil, level inthe power unit is below the sight gauge.

3. Close off the ball valve.

4. Place some sort of catch pan under the filter.

5. For loosen the filter element by turning it counter clockwise, itmaybe necessary to use a filter wrench to break it loose.

Extend thecylinders to lowerthe oil level below

the sight gauge.

Close off the ball valve.



R30

Replacing or cleaning suction strainer

1. Items requireda. Pump with filtersb. Large adjustable wrench or pipe wrench.

c. Pipe seald. 9/16” wrenche. Silicone sealantf. Gasket materialg. Caps and Plugs for the suction hose size will need to be

determined.

2. Using a 9/16” wrench remove the lid of the power unit. It maybenecessary to pry the lid off since it is seal down with a siliconesealant

3. If the oil is highly contaminated and is being disposed of then itcan be pumped into a waste oil tank or container. If it is onlyslightly contaminated and can be filtered and reused then pumpit through a 10-micron filter in to clean containers.

4. Remove the suction hose and plug and the fitting.

5. Unscrew the ball valve from the 90-degree elbow.

6. Unscrew the elbow and pipe bushing if there is one from thestrainer.

7. Unscrew the strainer.

Remove the boltsaround holding thelid down.



R32

Checking and Adjusting Operating Pressure

Normally the operating pressure does not require any adjusting. It ispossible over time because of age and wear it may need to be slightlyadjusted. In addition, the pressure should never be adjusted higherthat the highest pressure called out on the load charts, doing so thesystem could be over loaded, which could cause damage to thesystem, injury, and/or death to personal.

1. Items requirea. Standard Allen wrench set.b. Small adjustable wrench.c. Screwdriver (some components may require this instead of an Allen wrench)

2. Make sure all twin line hoses are disconnected.

3. Start power unit.

4. Run engine speed up to full rpm’s if gas or diesel driven.

5. Slowly pull control valve handles to the extend direction.

6. Read pressure on the gauges when the handles are fullystroked. The reading should be highest pressure stated on the

load charts.

7. Shut the power unit off

8. If not use 5/16” Allen wrench to remove the plug on top of themain relief valve cartridge.

Plug. Relief valve cartrid e.



R33

9. Under the plug is the adjuster which requires ether a 7/32” or a1/4” Allen wrench (sometimes they tend to vary). Insert the wrenchand turn it clockwise to increase the setting and counterclockwise to decrease it. DO NOT do this when the systemrunning.

10. Replace plug, start the power unit, and recheck pressure.

11. Repeat if the pressure still is not correct.

12. If the pressure cannot be increase to the proper setting, there

is another relief valve located in the control valve that maybeset too low. This relief should always be set higher than themain relief.

13. On this type remove the hex cap from the adjustment,underneath will it be a Allen head adjustment screw which

Control valve relief, on somecontrol valves the relief maybeon the backside of the valveopposite of the handles.



R35

Replacing Typical Internal Gland Seals

Replacement of the gland or rod seals on an open cylinder gantry canbe accomplished with the cylinder still installed. This is just a basic

guide line and is not meant for any one model of cylinder. It’s anabsolute must to refer to the seal call out in the parts section of themanual.

1. Make sure the cylinder is fully retracted.

2. Remove the header plate.

3. Loosen the bleeder screws to let off any pressure that maybetrapped within the cylinder. But sure to wipe up any and all oil

that may drain from the bleed screws.

4. Using two large wire ties, wrap them around the hose and theroller guides on the hose reel to prevent the hose from beingreeled up by the hose reel.

5. Have a bucket ready in case there is still some pressure in thecylinder. Disconnect the hose from the fitting at the top of thecylinder and place the bucket under the fitting to let all oil drainfrom the cylinder.

Wrap two large wire tiesaround the hose and theroller guides here.



R36

6. Most internal glands are designed so they will past over thesmaller ones, the factory can confirm this. Therefore, if thelargest gland needs new seal it is not necessary to remove thesmaller glands. However, the bleed screws will need to beremoved.

7. Remove the fittings at the top of the cylinder and plug the portswith a #8 SAE plug, if the small gland is being removed theports will have to remain open until the small gland is removed.

8. Remove the bleed screws.

9. Using a heavy duty chain wrench such as the 36 inch RigidModel C36. Turn the desired gland counter clockwise. There

could be as much as 1-5/8” of thread depending on the modelof cylinder.

10. Due to the amount of press on the rod seals, once the threadsare clear of each other the gland may not simply lift off.

11. Continue turning the gland putting some upward force on it atthe same time. This may help slid the gland upward and off therod or sleeve.

12. If the gland will not slid off use a soft face dead blow hammerand rap on the bottom edge of the gland, working the hammeraround the full diameter of the gland.



R37

13. With the gland off remove old seals and thoroughly clean thegland with a cleaning solvent.

14. Inspect the gland for any rust that may have formed in theseal grooves and threads. Use a die grinder with a small wire

wheel to clean off the rust.

15. Closely inspect the threads, if any rough spots are from usethe wire wheel to smooth them out. A rough spot in the threadscould cause to gland to become stuck to the point it will have tobe cut off.

16. Rinse the gland off with cleaning solvent to remove all dustparticles and dry it off with compressed air.

17. Install the outer seals, starting with the backup ring. Do not letthe ring roll or stretch it any more that necessary. Then installthe o-ring.

Tap under here with adead blow hammer towork the gland off.



R38

18. Install the loader and the rod seal but use caution not to breakthe rod seal. Form it like show below so it will fit in the gland,take the portion that isn’t folded and put it into the groove andthen gently let the rest of the seal fold back into position so it

goes into the groove.

Install the backup ring first.

Then install the o-ring.

Grasp seal here and gentlypull inward so the seal willfit into the gland.



R39

19. Install the poly pac seal making sure the flat surface of thepoly is up towards the top of the gland.

20. Before the wear band can be installed it will need to be cut tolength. There should be 1/16” gap between the ends of thewear when is installed.

21. Install the wiper.

Poly pac seal make surethe flat side is up.

Rod seal, the loader goes infirst with the rod seal on topof it.

Wiper.

Wear band.



R41

29. Careful turn the gland until it starts to thread itself in. Continueturning the gland until it is fully threaded down and theshoulders of the gland and sleeve make contact.

30. When complete reinstall the bleed screws, fittings andreconnect the hose.

31. Connect the unit to the power unit.32. Start the power and put the unit into retract and check for

leaks.

33. Slowly extend the cylinder and have some one open the bleedscrews to remove any air in the cylinder.

The gland and slee

needs to make contac



R42

Basic Guidelines for a Complete Cylinder Reseal

It is not advisable to try to do a complete cylinder reseal in the field orat a jobsite due to the large amount of oil that will be lost during thedisassembly. This task should only be attempted on a bench that isdesigned to securely hold the cylinder and is equipped with some sortof catch pans to catch the oil. This is just a guide line for replacing theseals only and does not include any instructions for honing, repairingand re-chroming; these types of repairs must be completely by aqualified repair facility. This is just a basic guide line and is not meantfor any one model of cylinder.

1. Remove the cylinder from the lifting unit. (See section on cylinder

removal.)

2. Lay cylinder down and sit it on the bench with the counterbalance valve upward.

3. Securely clamp or chain the cylinder to the bench.

4. Remove port plugs in the rod and let the oil drain out. If necessary turn the rod so one of the ports is pointed down.

5. Remove the counter balance cartridge.

Remove plugs from ports.Make sure one port isturned downward.

Remove the counterbalance cartridge.



R43

6. Using a chain wrench turn the small gland nut counterclockwise to remove. Be sure to support the end of the rod totake the weight off the gland nut when turning it otherwise thegland could seize up. Make sure to do this on all sections.

7. Due to the amount of press on the rod seals, once the threadsare clear of each other the gland may not simply slid off.

8. If the gland will not slid off use a soft face dead blow hammerand rap on the bottom edge of the gland, working the hammeraround the full diameter of the gland.

9. With the small gland removed the rod can be pulled out.

However, it will be necessary to support the end of the rod tokeep it level with the rest of the cylinder. An overhead crane ora jib work well for this.

10. Before the rod is completely removed it is advised to catch thepiston end ether by a sling or by placing something under it thatis soft enough not to damage the piston.

11. Repeat steps 6, 7 and 8 with the remaining sections. Makesure to place the rods and sleeves on something that will notscratch or damage them such as wood.

12. Starting with the barrel, thoroughly clean the inside withsomething such as a cleaning solvent.

13. Thoroughly inspect the inner diameter of the barrel fordamage or scratches. Small cosmetic scratches that can not befelt are normal from wear. Any scratches that can be felt arefound, the barrel will need to be honed.

Support this end to keepthe rod level with therest of the cylinder.

Catch the rod in this are hereso that the piston does notget damaged.



R44

14. Check the threads for any roughness, if roughness is founduse a die grinder with a wire wheel to smooth out theroughness.(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 itclean.

17. Remove old seals from the sleeves and rod, one at a time.

18. Thoroughly clean the sleeves in side and out with a cleaningsolvent.

19. When one is thoroughly cleaned, inspect the inner diameterfor scratches as with the barrel. Check the condition of thethreads as was done with the barrel.

20. Inspect outside for chrome damage. Check for pitting, flaking,dents and scratches. Cosmetic scratches are normal from wearand are acceptable. Any other damage and the item will needto 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 theglands with a cleaning solvent.

23. Inspect the glands for any rust that may have formed in theseal grooves and threads. Use a die grinder with a small wirewheel to clean off the rust.

24. Closely inspect the threads; if any rough spots are found usethe wire wheel to smooth them out. A rough spot in the threadscould cause to gland to become stuck so tightly it will have tobe cut off.

25. Rinse the gland off with cleaning solvent to remove all dustparticles and dry it off with compressed air.



R45

26. If there is no damage found and everything has been cleanedthen the pistons and gland and be prepped for assembly.

27. Starting with the large sleeve install the cast iron piston ringthat is the furthest away from the end of the piston. Make sureto refer to the cylinder seal callouts in the parts section of theoperator’s manual.

28. Slip the ring onto the end of the piston as shown.

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



R47

33. Using a compressed air, blow cool air on the seal workingaround the full diameter of the seal, this will cool and shrinkingthe seal into the groove. The seal should be tight and it shouldnot move or spin in the groove.

34. Install the last cast iron piston ring, make sure the ends of thepiston rings are not inline with each other; they should be 180degrees from each other.

35. To install the wear rings they must first be measured. Set thewear ring material in the groove and measure it as show in thepicture below.

36. Cut the wear ring material with a razor knife.



R49

40. Prep the remaining pistons by following the above steps.

41. Once the pistons are complete then the glands can be

prepped.

42. Install the outer seals, starting with the backup ring. Do not letthe ring roll or stretch it any more that necessary. Then installthe o-ring.

43. Install the loader and the rod seal but use caution not to breakthe rod seal. Form it as shown below so it will fit in the gland,take the portion that isn’t folded and put it into the groove andthen gently let the rest of the seal fold back into position so itgoes into the groove.

Install the backup ring first. Then install the o-ring.



R50

44. Install the poly pac seal making sure the flat surface of thepoly is up towards the top of the gland.

45. 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 thewear when is installed.

46. Install the wiper.

Grasp seal here and gentlypull inward so the seal willfit into the gland.

Poly pac seal make surethe flat side is up.

Rod seal, the loader goes infirst with the rod seal on topof it.



R51

47. Prep the rest of the glands in the same fashion as above.

48. Take the barrel and coat the first six inches of the innerdiameter of the barrel with a heavy oil.

49. Take the large sleeve, remove the zip ties and coat the entirepiston with heavy oil.

Wiper

Wear band.



R52

50. Lift the sleeve making sure it is level with the barrel by using alevel.

51. The factory has special compression rings for compressingthe seals so that the sleeve can be inserted into its mating part.

This is to ensure the damage does not occur to the seals or to

the threads of the mating part. It maybe necessary to come upwith such a device.



R53

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

Compression ring.



R55

57. When the gland reaches its mating part stop before it makesany contact. Check the level of the sleeve to ensure it is levelwith its mating part. The two parts have to be level to eachother in order for the gland to be threaded in.

58. Put heavy oil on the outer seals of the gland and anti-seize onthe threads.

59. Careful tap the gland into its mating part but stop just beforethe threads of both parts make contact.

60. Using the chain wrench slowly turn the gland clockwise and atthe same time apply a small amount to towards the mating partuntil the threads are engaged.

61. Continue slowly turning the gland until it is fully seated.

62. Repeat steps 48 through 60 with the remaining sleeves androds.

63. Replace counter balance valve and the bleed screws.

64. Reinstall cylinder.

65. Connect power unit and put cylinder into retract while at thesame time open the bleed screw to remove as much air aspossible.

66. The cylinder should always be load tested and checked fordrift after a complete reseal before ever going on a job.



P

T

M

RESERVOIR TANK

100 GALLON

112656

PUMPS

112446

CONTROL VALVE122447

MANIFOLD

EF06 ELEMENTHF05

P

CYLINDERPRESSURE

T

CYLINDERPRESSURE

MGO5

1505 7TH STREETE. MOLINE, IL 61244 TM

LIFTSY STEMS INC

DATE

TITLE

PART NUMBER

TOLERANCES(EXCEPT AS NOTED)

DECIMAL

FRACTIONAL

ANGULAR

+-

+-

+-

SCALE: DRAWN BY:

MAT.

1/2

1/16"

.005"

APPR BY:

LIFT SYSTEMS INC

X

X

100GPU DUAL PUMP E LECTRICWITH REMOTE PENDENT CONTRO

8/25/11 X

All R ights R eserved

patented and proprietary, contained in this drawing

thereof without the approval of L ift Systems is

without the express written consent of the President of Lift Systems. This drawing must be returned on request.

prohibited. This drawing is furnished with the under-

All interest in the basic design and/or invention, both

CONFIDENTIALLIFT SYSTEMS

remains the sole property of Lift Systems and use

standing that the contents hereof, either all or part,will not be revealed or released to other parties

RLM

S

I

90REG

MGO5

112448

RELIEF

112446

CONTROL VALVE122447

MANIFOLD

11

RE

C83

FEMALE COUPLER

C84

MALE COUPLERC83

FEMALE COUPLER

C84

MALE COUPLER

112440

10HP MOTOR



CYL A

5

4

3

6

7

8

9

10

11

12 A

B

C

D

42a manual with corded pendant

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