INSTALLATION, OPERATION, AND SERVICE MANUAL TROJAN COIL CAR P.O. Box 1058 Item # 830CC • 1058 West Industrial Avenue Guthrie, • OK 73044-1058 • FAX: 405-282-8105 • www.autoquip.com 405-282-5200 • Version 1.
TABLE OF CONTENTS Identification and Inspection 3 Dangers, Warnings, and Cautions 4 Label Identification 8 Specifications 11 Lift Blocking Instructions 12 Installation Instructions 14 Operating Instructions 17 Routine Maintenance 19 General Maintenance 22 Replacement Parts List 31 Troubleshooting Analysis 32 IMPORTANT Please read and understand this manual prior to installation or operation of this unit. Failure to do so could lead to property damage and/or serious personal injury.
IDENTIFICATION & INSPECTION IDENTIFICATION When ordering parts or requesting information or service on this unit, PLEASE REFER TO THE MODEL AND SERIAL NUMBER. This information is on a nameplate attached to the leg assembly. Replacement parts are available from a local Autoquip distributor. INSPECTION Immediately upon receipt of the unit, a visual inspection should be made to determine that it has not been damaged in transit. Any damage found must be noted on the delivery receipt.
DANGERS, WARNINGS & CAUTIONS SAFETY ALERTS (Required Reading!) The following SAFETY ALERTS are intended to create awareness of owners, operators, and maintenance personnel of the potential safety hazards and the steps that must be taken to avoid accidents. These same alerts are inserted throughout this manual to identify specific hazards that may endanger uninformed personnel. Identification of every conceivable hazardous situation is impossible.
DANGERS, WARNINGS & CAUTIONS Read and understand this manual and all labels prior to operating or servicing the scissors lift. All labels are provided in accordance with ANSI Z535.4. DANGER! Do not work under lift without maintenance device! To avoid personal injury, NEVER go under the lift platform until the load is removed and the scissors mechanism is securely blocked in the open position. See the "Lift Blocking Instructions" section.
DANGERS, WARNINGS & CAUTIONS DANGER! Scissors lifts are designed individually for a specific load and application. To avoid personal injury, do not change the load or application from the original design. WARNING! NEVER stand, sit or ride on the lift! WARNING! All warning and information decals should be in place as outlined in the “Label Identification” section. If decals are missing or damaged, they should be replaced with new ones. Contact Autoquip for replacements.
DANGERS, WARNINGS & CAUTIONS CAUTION! Never run the pump for more than a couple of seconds without pumping oil. This applies to low oil conditions, improper motor rotation, running the pump against the relief pressure after the lift is fully raised against the physical stops, running overloaded beyond capacity, or running at reduced speed because of pinched or obstructed hydraulic lines. CAUTION! Do not operate the power unit on relief for more than a few seconds.
LABEL IDENTIFICATION 6 Figure 1 Label Placement Coil Car Item No. Qty Description 1 2 Caution! Familiarize Yourself With Operators Manual 36401487 2 4 Danger – Do Not Put Hands or Feet . . . 36430050 3 1 Autoquip Serial Number Nameplate 36401511 4 1 Fill with Recommended Oils Only 36400661 5 2 UP – STOP Valve (when applicable) 36401610 6 2 Capacity 36401586 8 Part No.
LABEL IDENTIFICATION Note: Labels shown here are not actual size.
LABEL IDENTIFICATION Figure 5 Label 36400661 Figure 6 Label 36401610 Figure 7 Label 36401586 10
SPECIFICATIONS LOAD CAPACITY The load capacity rating is stamped on a metal plate attached to one side of the lift. This figure is a net capacity rating for a lift furnished with the standard platform. The relief valve of the pumping unit has been set to raise the weight, plus a small amount for overload. Where gravity roll-sections, special tops, etc, are installed on the lift after leaving the plant, deduct the weight of these from the load rating to obtain the net capacity.
LIFT BLOCKING INSTRUCTIONS 1. Remove all load from the platform. Never block the lift when loaded. 2. Raise the platform sufficiently for the base rollers to rollback past the flip-over maintenance locks, located on the base frame of the lift. 3. Engage both maintenance locks by flipping them into the base frame (see Figure 8). 4. Lower the platform until the base rollers come into contact with and rest against the maintenance locks.
LIFT BLOCKING INSTRUCTIONS FLIP-OVER MAINTENANCE LOCKS, ON BOTHSIDES OF THE BASE FRAME.
INSTALLATION INSTRUCTIONS INSTALLATION 1. Make sure installation area is clean before starting. 2. If the permanent electrical work is not complete, some means of temporary lines with an on-off device for the motor should be set up for testing purposes. 3. Place the lift in the installation area, typically on tracks or rails which are supplied and installed by the customer or installer. CAUTION! When moving the lift, do not attempt to pick it up by the platform; it is hinged and could be damaged.
INSTALLATION INSTRUCTIONS PROCEDURE FOR A LIFT ORDERED WITH AN ACCORDION SKIRT 1. Position the platform in the raised position. Install the maintenance locks (see “Lift Blocking Instructions” section). Position the accordion with the weight rod pocket at the bottom and the mounting collar at the top. The breathable material when provided must be positioned at the top of the skirt with the mounting collar. 2. Slip the skirt over the end of the platform.
INSTALLATION INSTRUCTIONS Figure 9 Skirt Installation 16
OPERATING INSTRUCTIONS Familiarize yourself with this operator’s manual before operating this equipment. CAUTION! Do not continue to depress the “UP” button on the controller if the lift is not raising or if the lift has reached the fully raised position. To do so may result in permanent damage to the motor or pump. Scissors lifts are designed primarily for in-plant applications and are furnished with constant pressure pushbutton and footswitch controls.
OPERATING INSTRUCTIONS To traverse the lift the operator simply depresses either the “FORWARD” or “REVERSE” button on the pushbutton control energizing the reversing motor starter in the control panel. The motor starter activates the motor in either direction, which then turns the gearbox reducer. The splined output shaft runs through the gearbox and drives the drive wheels mounted on each side of the lift.
ROUTINE MAINTENANCE Normally coil cars will require very little maintenance. However, a routine maintenance program could prevent costly replacement of parts and/or downtime. WARNING! To avoid personal injury, NEVER go under the lift platform or perform any maintenance on the lift until the load is removed and the scissors mechanism is securely blocked in the open position. See "Lift Blocking Instructions" section. MONTHLY INSPECTION 1.
ROUTINE MAINTENANCE Oil Viscosity Recommendations Environment (Ambient Temperatures) Recommended Oil Indoor location, variable temperatures (30 - 100° F) 10W30 or 10W40 Multiviscosity motor oil Indoor location, consistent Temperatures (70° F) SAE-20W motor oil Outdoor location, (-10 - 100° F) SAE 5W30 Multiviscosity motor oil Cold-storage warehouse (10 - 40° F) 5W30 Multiviscosity motor oil Freezer (-40° F to 0° F) Consult Factory GEARBOX LUBRICATION REQUIREMENTS Under normal operating condition
ROUTINE MAINTENANCE Oil Grades For ambient temperatures of approximately -10ºC to +50ºC (14º to 122ºF) a gear oil of ISO 220 at 40ºC with mild high-pressure additives should be used, DIN 51502 CLP 220, e.g. BP ENERGOL GR-XP 220, Esso Spartan EP 220, SHELL Omala Oel 220, Mobilgear 630, or Aral Degol BG 220. At high or lower ambient temperatures, the type of oil used should be adapted to the specific conditions. Contact the Autoquip Customer Assurance department.
GENERAL MAINTENANCE HYDRAULIC CYLINDER REPACKING 1. Raise the lift to its full height and block securely. See “Lift Blocking Instructions”. 2. Hold the “DOWN” control for several seconds to make sure pressure in the lines is bled down. 3. Disconnect the cylinder hose at the power unit end and insert into the oil-fill hole of the reservoir. 4.
GENERAL MAINTENANCE 15. Restore the oil level. 16. Loosen the bleeder plug at the top end of the ram casing and operate the pump to remove trapped air from the ram. When clear oil appears, tighten the plug and raise the lift slightly to remove the maintenance locks. 17. Lower the lift completely and hold the “DOWN” button for 30-40 seconds to allow air in the lines to bleed back into the tank. 18. Cycle the lift 10 – 15 times. 19. Check the oil level. 20. Clean the oil fill breather cap. 21.
GENERAL MAINTENANCE CYLINDER VELOCITY FUSE REPLACEMENT DANGER! Do not attempt to remove the velocity fuse until the lift is securely supported with the maintenance locking devices and all hydraulic pressure has been removed from the lifting cylinders and hydraulic hoses. Failure to follow these instructions could result in personal injury or death! Never attempt to take a velocity fuse apart and repair it. These are precision devices that are factory assembled under exacting conditions.
M RELIEF VALVE SUCTION LINE FILTER IS INTERNAL TO DELTATROL BLOCK UNLESS A SEPERATE FILTER IS SPECIFIED. SUCTION LINE FILTER P.F. CHECK VALVE RESERVOIR DOWN SPEED RESTRICTOR RETURN LINE FILTER LOWERING VALVE AND PRESSURE LINE FILTRATION. COMPENSATED FLOW CONTROL, SOLENOID DELTATROL VALVE PROVIDES COMPLETE, THE FUNCTION OF CHECK, RELIEF, PRESSURE PRESSURE LINE VELOCITY FUSES (1) VELOCITY FUSE PER CYLINDER. QUANTITY OF CYLINDERS AND VELOCITY FUSES DEPENDS ON MODEL OF LIFT USED.
GENERAL MAINTENANCE Figure 11 Hydraulic Schematic – Super Torque Motor 26
GENERAL MAINTENANCE WIRING AUTOQUIP "SUPER TORQUE' MOTORS Because Autoquip "Super-Torque" motors actually deliver substantially more horsepower than their nameplate rating, they must always be wired for heavier currentdraw than standard motors of the same nameplate rating. However, because of the starting efficiency and superior running characteristics of the "Super-Torque" motor, circuit components do not have to be as large as for standard motors of equal delivered horsepower.
GENERAL MAINTENANCE LIFT UP-STOP VALVE (when used) The up-stop valve is bolted to a mounting plate that is permanently welded near the end of the scissors leg on the clevis end of the lift. A mechanical plunger is located on the end of the valve which, when depressed, blocks the flow of oil until physically released. An adjustable striker bolt is mounted to a plate that is welded to the base frame, which is also at the clevis end of the lift.
GENERAL MAINTENANCE LEG UP-STOP VALVE MOUNTING PLATE UP-STOP VALVE PLUNGER OUTPUT PRESSURE HOSE (TO CYLINDERS) INPUT PRESSURE HOSE (FROM POWER UNIT) ADJUSTABLE STRIKER BOLT / BAR BASE CLEVIS UP-STOP VALVE BLOCK UP-STOP VALVE MOUNTING SCREW Figure 12 Up-Stop Valve System 29
GENERAL MAINTENANCE Figure 13 Electro-Hydraulic Schematic; Lift & Traverse Combination 30
REPLACEMENT PARTS LIST Specific part numbers vary from job to job, depending on the model and options chosen for the application. Call the Autoquip Service Department with the serial number of the specific equipment to order the appropriate parts.
TROUBLESHOOTING ANALYSIS DANGER! To avoid personal injury, NEVER go under the lift platform until the load is removed and the scissors mechanism is securely blocked in the open position. See "Lift Blocking Instructions" section. PROBLEM Lift raises, then lowers back slowly. POSSIBLE CAUSE AND SOLUTION • The "Down" solenoid may not be seating. Remove the solenoid coil and check again.
TROUBLESHOOTING ANALYSIS PROBLEM Lift does not raise. POSSIBLE CAUSE AND SOLUTION • The motor rotation for a 3-phase motor may be reversed. Reverse only two motor electrical leads. • Check for a line or hose leak. • Check for oil shortage in the reservoir. Add oil as necessary (See Oil Requirements in the “Routine Maintenance” section.) • The load may exceed the rating. (See the “Specifications” section.) Remove the excess load. • The suction screen may be clogged, starving the pump.
TROUBLESHOOTING ANALYSIS PROBLEM Lift won’t lower. POSSIBLE CAUSE AND SOLUTION • The solenoid coil may be incorrectly wired, burned out, not rated for the voltage, or the line voltage may be excessively low. Check voltage near the coil. • The velocity fuse may be locked. Do not attempt to remove the velocity fuse. The following steps should be followed: 1. Remove the load from the lift. Inspect all fittings, hoses, and other hydraulic components for leads or damage. 2.
TROUBLESHOOTING ANALYSIS PROBLEM Lift seems bouncy during operation. POSSIBLE CAUSE AND SOLUTION • Lower the lift to collapsed position and continue to hold “DOWN” button an additional 10-30 seconds to bleed air from the bleed screws. Do not confuse spongy or jerky operation with small surges that may occur when operating on rough or uneven floors WARNING! Do not remove the bleed screw! This could cause the lift to drop rapidly, resulting in damage to the lift or cause personal injury.
TROUBLESHOOTING ANALYSIS PROBLEM Lift won’t go forward or reverse POSSIBLE CAUSE AND SOLUTION • The traverse path may be blocked with debris or other obstacle. Look under the base and remove any obstacle that may impede travel. • The axle may be “high centered” on some obstacle, preventing the wheels from gaining enough traction. Inspect under the axles and remove any obstruction. • The non-rotation devise may have broken or vibrated loose. Reattach or replace bracket.
