Advance Lifts Dock Lifts Pit Mounted Manual
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Fig. 4 Fig. 3 ALL MODELS Never use the safety maintenance bar when the platform has a load. Remove the load first, then brace for service or maintenance. Check that the safety bar is well seated and remains so during heavy wrenching or maintenance operations. CAUTION! Read the entire lift blocking procedure and all warnings before attempting to use the maintenance bar. SERIES 3000 Place the maintenance bar or leg near the center of the torque tube and on the base frame, then lower the equipment until it is totally supported by the bar or leg. (Fig. 3) SERIES 4000 Place the maintenance bar or leg near the center of the torque tubes, then lower the equipment until it is totally supported by the bar or leg. (Fig. 4) P 6-6 T-SERIES LIFTS CAUTION! Read the entire lift blocking procedure and all warnings before attempting to use the maintenance bar. SERIES 3000 Place the maintenance bar or leg near the center of the torque tube and on base frame, then lower the equipment until it is totally supported by the bar or leg. (Fig. 3) SERIES 4000 Place the maintenance bar or leg near the center of the torque tubes, then lower the equipment until totally supported by the bar or leg. (Fig. 4) T-SERIES LIFTS Place the maintenance bar into lower pocket on base frame. Hold bar vertical and fully lower the equipment until the platform is resting on the leg. (Fig. 5) ALL MODELS Never use the maintenance device when the platform has a load. Remove the load first, then brace for service or maintenance. Check that the maintenance bar is well seated and remains so during heavy wrenching or maintenance operations. ALL MODELS Every unit of the above models is supplied with a maintenance device. It is the only factory-approved method of blocking the lift open. If the bar is missing contact your distributor for re placement. MAINTENANCE DEVICE FOR: 3000 SERIES, 4000 SERIES AND T-SERIES P 6-6
SECTION 7: POWER UNIT ASSEMBLIES This section contains drawings and photos of completed power units to aid service personnel in identifying each component. Please be careful to match the correct voltage and horsepower as well as model number, when you are trying to identify the power unit for your lift. Advance Lifts uses several different brand name motors and pumps, so the ones shown in the pictures may not be the same exact brands as on your unit. More information about individual components may be available in the hydraulic or electrical sections of this manual. Also note that these illustrations may show options that were not included on your particular unit and the components used may be changed at any time without notice. Models 2000K & T-Series See Page 8-4 for Hydraulic Diagram and Pages 9-3 thru 9-5 for Electrical Diagram P 7-1 Single Phase Motor Pump-Motor Adapter Hydraulic Pump Down Solenoid Suction Line Reservoir Three Phase Motor Pressure Line to Cylinders Floor Mounting Flanges Reservoir Breather Cap Suction Filter in Reservoir Breather Filter System Return Line
Series 2000 and 3000 Power Units See Page 8-4 for Hydraulic Diagram and Pages 9-3 thru 9-5 for Electrical Diagram P 7-3 Single Phase Motor Pump-Motor Adapter Hydraulic Pump Reservoir Breather Ca pReservoir Drain Plug Suction Line Wall Mounting Bracke t Oil Identification Tag Suction Line Filter in Reservoi r Return Line to Reservoi r Suction Line Three-Phase Motor
Series 4000 Series 4100 Power Unit See Page 8-5 for Hydraulic Diagram and Pages 9-4 & 9-5 for Electrical Diagrams P 7-4 Three Phase Motor Hydraulic Pump Manifold Assembly (Detail on Page 8-6) Pressure Line Filters in Pipe Down Solenoid Junction Box Suction Line, (Filter in Reservoir) Three Phase Motor Down Solenoids Reservoir Drain Plug Reservoir Air Breather Cap and Fill Hole Wall Mounting Brackets Pressure Line to C ylinders
SECTION 8: HYDRAULIC DETAILS 1. General Hydraulic Information: A. All hydraulic cylinders will require the replacement of packing’s and seals after a period of time, depending on usage and environmental conditions. It is normal maintenance just like changing oil in an automotive engine. However, maintenance personnel should recognize the difference between leakage and weepage: B. Weepage is the normal accumulation of fluid that passes the seals in the course of operations, as the hydraulic fluid properly performs its lubrication function on cylinder walls and piston rods. It may be occasionally observed squirting from cylinder breathers, but should stop squirting after several cycles of full stroke when the small accumulation is cleared. C. Leakage is the fluid that leaks past worn or cut packing’s and seals. It too may be observed squirting but does not stop after several cycles and the lift will probably not hold position under load. D. See repacking under cylinder repair procedures. E. Always be careful when working around cylinders, not to nick the extended rod or dent the cylinder casing, as this may cause damage to cylinder seals or packing’s. F. If you elect to repaint or retouch part of the lift, cover exposed rods with plastic or soluble grease that can be removed after painting to insure that no paint sticks to the rods and damages packing’s or seals. 2. General precautions: A. Be sure that all pressure is relieved from the hydraulic system before disassembling any components. Continue to hold the down button for several seconds after fully lowering the unit on its mainenance support or the ground, before opening a line or component. B. Always be careful to avoid contamination entering the system. Be especially careful with the ends of hoses that may fall into oil dry or dirt. If you suspect contamination, flush the system and components. 3. Hydraulic fitting sealant and torque: A. Advance lifts may be equipped with either NPT fittings (tapered) or SAE fittings (with “O” ring seals, depending on age, know the difference! B. Be careful when tightening NPT fittings not to over tighten and crack them. Swivel fittings are especially vulnerable and should only be snug enough to stop leaking. C. If leakage persists after tightening the fittings fairly hard, inspect fittings for burrs on the mating edges or the possibility of a 37 degree SAE fitting being mixed with the standard 30 degree NPT fittings, or either one being mixed with SAE 45 degree fittings. D. When using Teflon tape on NPT fittings, be sure the tape is started 1-1/2 threads back from the leading edge and only use 2 wraps to be sure that tape does not break off and contaminate the system. You may substitute pipe sealant with Teflon paste from Pro Lock or Locktite, but again don’t over apply. Never use sealant or tapes on swivel fittings or SAE o-ring fittings. E. Never reuse old Teflon tape. Once a connection has been opened, remove all old tape and apply fresh tape. P 8-1
Oil Recommendations & Seal Compatibility Fluids: 1. As of 1/1/03 the current standard hydraulic fluid an ISO 46, (group II base) hydraulic fluid. This is the fluid normally supplied by the factory and is suitable for a temperature range of –10 to +100 degrees Fahrenheit. When replacing or adding fluid to an Advance Lift, use only ISO 46 hydraulic fluid that is manufactured with a group II base oil. ISO 46 hydraulic fluid can be identified by its purple color. 2. Caution! Do not use any fluid that has not been approved by the Advance Lifts engineering department. Brake fluids and other hydraulic fluids may attack the system’s seals or hoses. 3. A biodegradable or fire resistant fluid is also available, however you must contact the factory for its name, because it is also necessary to change some seals and/or hoses for total system compatibility, depending upon the specific model lift that you have. Seals: Generally, the seals in the unit are Buna-N-Nitrile and polyurethane. The hoses are composed of either PVC for suction lines or braided wire. Always call the factory about special fluids rather than make assumptions on your own. Options: 1. For extremely cold applications we recommend an oil immersion heater which simply fits in the drain coupling on most units, replacing the drain plug, these are available in appropriate sizes from the factory. NOTE: A separate 120V, 20 Amp circuit is required for all oil immersion heaters. 2. For extremely warm temperature ranges over +100 degrees Fahrenheit consult the factory. P 8-2
Pressure Chart for Hoses & Pipes
Hose SAE Working PSI Bursting PSI
¼” 100-R2A 5000 20000
3/8” 100-R2A 4000 16000
½” 100-R2A 3500 14000
¾” 100-12 4000 16000
Seamless Pipe Working PSI Bursting PSI
½” Schedule 80 4100 21000
¾” Schedule 80 3500 17600
1” Schedule 80 3500 15900
Caution: Never use any hose or piping that does not meet or exceed the ratings listed
above.
Line Size Calculations
Formula: P= V x Q Where: P=PSI loss per foot
18,300 x DxDxDxD Q=GPM flow
V=SUS viscosity @
Operating temp.
D=Inside dia. Of pipe
in inches
Example: For a standard Series 2000 lift with a flow rate of approximately 3GPM, we
recommend ½” SAE 100R2A hose up to 35 feet and ¾” pipe or hose for distances
slightly beyond that. This keeps the line pressure loss at 40 PSI and allows for efficient
lowering speeds.
For each T or 90-degree elbow add 3 feet to length.
For each 45-degree elbow add 1 foot to length.
Target the pressure to below 50 PSI. The empty lift going down will see any excess
piping losses as restrictions and increase the time it takes the lift to lower.
Standard Oil Capacities of Listed Equipment
Series 2000 10 Gallons
Series 2000K, T 5 Gallons
Series 3000 10 Gallons
Series 4000 10 or 15 Gallons
P 8-3
P 8-4 MOTOR HYDRAULIC DIAGRAM FOR UNITS WITH INTERNALLY VALVED PUMPS RESERVOIR PRESSURE RELIEF VALVE. FACTORY SET, DO NOT ADJUST SUCTION LINE FILTER IN RESERVOIR CHECK VALVE INTERNAL FILTER PRESSURE COMPENSATED FLOW CONTROL VALVE DOWN SOLENOID ½’’ SAE 100R2 HYDRAULIC HOSE WITH ½” FEMALE JIC FITTINGS (SUPPLIED BY OTHERS) ½” MALE JIC FITTINGS SUPPLIED BY ADVANCE AT PUMP AND FILTER PIPE ON LIFT FLOW CONTROLS CYLINDERS HYDRAULIC DIAGRAM FOR THE FOLLOWING MODELS T-SERIES, 2000-SERIES, 2000K-SERIES, 3000-SERIES PUMP / VALVE ASSEMBLY (OPTIONAL) MANUAL DOWN VALVE 1/8” BREATHER LINE TO RESERVOIR (1/4” ON T-SERIES LIFTS)
P 8-5 MOTOR PUMP STANDARD HYDRAULIC DIAGRAM FOR ADVANCE 4000 SERIES LIFTS RELIEF VALVE PRESET AT ADVANCE, DO NOT ADJUST FLOW CONTROL VALVES (2) DOWN SOLENOID VALVES (2) CHECK VALVES (4) MANUAL DOWN VALVE PRESSURE LINE FILTERS (4) SUCTION FILTER (IN RESERVOIR) FLOW CONTROLS (4) RETURN LINE TO RESERVOIR MANIFOLD ASSEMBLY ½” MALE JIC FITTINGS SUPPLIED BY ADVANCE LIFTS FIELD INSTALLED ½” HOSE WITH ½” FEMALE JIC SWIVELS ON EACH END FIELD INSTALLED 1/8” HOSE RESERVOIR
Series 4000
Standard Valve Manifold
Reference Page 8-10 for Valve Cartridge Details
NOTE: Valve numbers coincide with those shown in the hydraulic diagram on
Page 8-5
Part Number Reference
Description Part Number
1-4. Check Valves 001-262
5,6. Down Flow Control Valves 001-303
7,8. Down Solenoid Valves 001-293
9. Manual Down Valve 001-277
10. Pressure Relief Valve 001-263
P 8-6
1. Check Valve 10. Pressure Relief
Valve (Do Not Adjust)
Pressure Line Inlet from
Pump 3. Check Valve
8. Down Solenoid
Valve
5. Down Flow
Control Valve
Pressure Line To
Cylinders. (Filter In
Pipe)
4. Check Valve 2. Check Valve
9. Manual Down Valve Pressure Line To
Cylinders. (Filter In
Pipe)
6. Down Flow
Control Valve 7. Down Solenoid
Valve