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READ THIS INSTRUCTION MANUAL THOROUGHLY BEFORE
INSTALLING, OPERATING, SERVICING OR MAINTAINING
309 EXCHANGE AVENUE, CONWAY, ARKANSAS, 72032
TEL: 501-450-1500 FAX: 501-450-1585
BAYSAVER II
BAYSAVER II
9000LB Models
9000LB Models
48109B / 48209B
48109B / 48209B
Flushmount Models
Flushmount Models
48109BFM / 48209BFM
48109BFM / 48209BFM
(144" W/B / 172" W/B)
(144" W/B / 172" W/B)
12000LB Model
12000LB Model
4812205AF 172" W/B
4812205AF 172" W/B
THE LIFT. SAVE THIS MANUAL.
INSTALLATION
and OPERATION
MANUAL
OCT 2008 REV.-
6-1269
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Table of Contents
Related Manuals for John Bean BAYSAVER II
Summary of Contents for John Bean BAYSAVER II
- Page 1 INSTALLATION and OPERATION MANUAL BAYSAVER II BAYSAVER II 9000LB Models 9000LB Models 48109B / 48209B 48109B / 48209B Flushmount Models Flushmount Models 48109BFM / 48209BFM 48109BFM / 48209BFM (144” W/B / 172” W/B) (144” W/B / 172” W/B) 12000LB Model 12000LB Model 4812205AF 172”...
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Page 2: Table Of Contents
TABLE OF CONTENTS PAGE SAFETY INSTRUCTIONS ....................3 SAFETY WARNING DECALS ..................5 SPECIFICATIONS......................6 CONTENTS..........................7 TOOLS REQUIRED FOR INSTALLATION ..............7 INSTALLATION INSTRUCTIONS .................8 BAY LAYOUT........................9 UNPACKING PROCEDURE ..................10 HYDRAULIC INSTALLATION ..................11 ELECTRICAL INSTALLATION ................13 BLEEDING PROCEDURE...................14 AIR LINE INSTALLATION ..................14 MECHANICAL SAFETY INSTALLATION: ............15 PNEUMATIC SYSTEMS INSTALLATION ..............17 LEVELING PROCEDURE...................18 6.10... -
Page 3: Safety Instructions
1. SAFETY INSTRUCTIONS When using this lift, basic safety precautions should always be followed, including the following: Read all instructions in this manual and on the lift. Inspect lift daily. Do not operate if it malfunctions or problems have been encountered. Never attempt to overload the lift. - Page 4 Installation shall be performed in accordance with ANSO/ALI ALIS, Safety Requirements for Installation and Service of Automotive Lifts. For additional safety instructions regarding lifting, lift types, warning labels, preparing to lift, vehicle spotting, vehicle lifting, maintaining load stability, emergency procedures, vehicle lowering, lift limitations, lift maintenance, good shop practices, installation, operator training and owner/employer responsibilities, please refer to “Lifting It Right”...
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Page 5: Safety Warning Decals
2. SAFETY WARNING DECALS Be sure the operator is aware and underastands all safety warning lables and follows them accordingly. 5 of 40... -
Page 6: Specifications
3. SPECIFICATIONS Maximum Capacity: 9000 lbs. 4100 kg 12000 lbs. 5450 kg Overall Width: 84” 2134 mm 92” 2337 mm Width Between Runways: 36” 914 mm 36” 914 mm Overall Length (144” W/B): 234” 5944mm Overall Length (172” W/B): 264” 6706 mm 264”... -
Page 7: Contents
4. CONTENTS The complete lift is contained in two (2) packages: 1. The main structural components are pre-assembled and packaged one on top of the other. 1. The remaining parts are packed in an accessory box. Refer to the packing slip inside the accessory box for a list contents. -
Page 8: Installation Instructions
6. INSTALLATION INSTRUCTIONS When the lift arrives on site, please read the owner’s manual completely. Check the contents to make sure no parts are missing before starting installation. Gather all the tools listed and make sure the installation instructions are fully understood before commencing with the installation. IMPORTANT: It is the user’s responsibility to provide a satisfactory installation area for the lift. -
Page 9: Bay Layout
6.1 BAY LAYOUT Figure 2 - Typical Bay Layout (Surface Mount) IMPORTANT: DO NOT UNBOLT SHIPPING CLAMPS HOLDING EACH MAIN FRAME ASSEMBLY TOGETHER UNTIL INSTRUCTED TO DO SO. NOTE: Leave any additional room for any desired aisle or work area. Recommended clearance around the lift is a minimum of three (3) feet. -
Page 10: Unpacking Procedure
recommended that the user provides additional overhead clearance or a shut off mechanism to stop the lift from raising the vehicle too high. 1. After selecting the location best suited for your lift, draw a line parallel to the front of the lift, approximately 72”... -
Page 11: Hydraulic Installation
6.3 HYDRAULIC INSTALLATION ATTENTION: The hydraulic pump system on this lift is not designed to be a load holding devise. Safety devises must be engaged before proceeding with any vehicle servicing or system maintenance NOTE: When working with hydraulics it is important to keep all components clean. All hydraulic connections are 37 ½°... - Page 12 Hydraulic Schematic 12 of 40...
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Page 13: Electrical Installation
6.4 ELECTRICAL INSTALLATION IMPORTANT: ALL FINAL ELECTRICAL CONNECTIONS SHOULD BE MADE BY A QUALIFIED ELECTRICIAN. Please refer to Figure 4, the electrical diagram. Note: All electrical connections have been made and customer power supply can be connected using the 12” cable extending from the back of the console. -
Page 14: Bleeding Procedure
6.5 BLEEDING PROCEDURE 1. Once the main electrical power supply has been connected, turn the equalization adjustment fully clockwise. The equalization adjustment is located on the powerpack controller board, see Figure 4. 2. Press the up control button and raise the lift 10” (254mm) above the ground. If the LED does not illuminate, continue pressing the up button until the LED comes on. -
Page 15: Mechanical Safety Installation
Figure 5 – Air Line Connections 6.7 MECHANICAL SAFETY INSTALLATION: 1. At this point, run the lift up to full height and turn off the power supply to the power pack. 2. The safety release rods must be fed through the holes closest to the rear of each baseframe. NOTE: The rods should be installed so that the flat section in the middle of the rod is on top and pointing up toward the front of the deck when the slots on either end are parallel to the ground. - Page 16 Figure 6 - Safety release rod location. 3. Install the rectangular safety release tab using one (1); 1/4” - 20UNC x 3/4”lg. cap screws. The safety release tab screws to the surface of the safety release rod located under the mechanical safety locks.
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Page 17: Pneumatic Systems Installation
6.8 PNEUMATIC SYSTEMS INSTALLATION NOTE: A MECHANICAL SAFETY RELEASE CONTROL BUTTON ON THE CONTROL CONSOLE WILL RELEASE THE MECHANICAL SAFETY FOR LOWERING OPERATIONS. 1. Route the 30’ polytube next to the hydraulic hoses to the inlet of the lift, through the left baseframe assembly and into the 90°... -
Page 18: Leveling Procedure
6.9 LEVELING PROCEDURE 1. The highest point on the floor, noted from Section 6.1 step 6 is the point from which the base frame will be leveled from. Raise the lift to full height and, using a four (4) foot level across the base frames, verify again that this is the highest point. -
Page 19: Anchoring Procedure
Figure 8 - Leveling Procedure Example 6.10 ANCHORING PROCEDURE NOTE: Check operation of lift (up/down) and movement of jack beams before anchoring the lift CAUTION! WEAR SAFETY GOGGLES AND PRACTICE CAUTION WHILE DRILLING CONCRETE. Figure 9 - Anchoring 1. Lower the lift and measure the distance between the Jackbeam rails at front and rear of the lift. - Page 20 3. Using a rotary hammer drill and a 1/2” concrete bit, drill through the floor at each of the six (6) anchor bolt locations on each of the base frames. Make sure that the 1/2” concrete drill bit is in good condition. Refer to Figure 9. 4.
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Page 21: Covers, Wheel Stops And Approach Ramps
6.11 COVERS, WHEEL STOPS AND APPROACH RAMPS 1. Locate and install the center cover over the mechanical safety release connecting rod and center connecting hydraulic line. Install using the four (4) ¼" - 20 UNC x ¾" long hex head bolts, flat washers and lock washers. -
Page 22: Operating Instructions
7. OPERATING INSTRUCTIONS NOTE: In case of power failure, the manual override can be used to lower the lift. To operate the manual override, first remove red plastic tamper proof cap from each of the two solenoids connected to the hydraulic lines. Unscrew the center needle valves on each of these 2 solenoids simultaneously to the fully counterclockwise position. -
Page 23: Lowering The Lift
7.2 LOWERING THE LIFT 1. Check that there are no obstructions under the lift or vehicle. Be sure that the Sliding Jack Beams are fully lowered and positioned at the front or mid section of the lift. 2. Raise the lift by pressing the up button until the mechanical safety bars are off their stops, and the LED light illuminates. -
Page 24: Final Check Of Assembled Lift
8. FINAL CHECK OF ASSEMBLED LIFT 1. Final dimension check after anchoring. ____ 2. Check for hydraulic leaks. ____ 3. Re-check level of decks, front to rear, side to side. ____ 4. Check torque of anchor bolts. ____ 5. Check all fasteners, tighten if necessary. ____ 6. -
Page 25: Operation Test With Vehicle
9. OPERATION TEST WITH VEHICLE 1. Lower lift to ground. 2. Drive vehicle on to lift. 3. Raise lift to and lower onto 3-4 lock positions during full rise to ensure all locks are working correctly. 4. Check lowering speed and smooth decent rate. 5. -
Page 26: Recommended Maintenance
10. RECOMMENDED MAINTENANCE 1. The lift should be greased at least once every two months. There are six (6) points on each lift that will take grease: four (4) on the scissors hinges and one on each of the two (2) hydraulic cylinder rod eyelet’s. - Page 27 QUARTERLY REAR SLIP PLATE MAINTENANCE 1. Remove top Slip Plate covers by first removing the four (4) shoulder bolts on each cover. 2. Remove polyethylene bearing cages insuring that all the delrin bearings remain in the cages. Additional delrin bearings may be purchased if required. 3.
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Page 28: Parts Manual
11. PARTS MANUAL 11.1 BAYSAVER ASSEMBLY 28 of 40... -
Page 29: Baysaver - Part List
11.2 BAYSAVER - PART LIST ITEM QTY. DESCRIPTION PART # BASE FRAME WELDMENT, 9K 4-0160 BASE FRAME WELDMENT, 12K 4-0160 SCISSOR WELDMENT 4-0153 9K ALIGNMENT DECK, LEFT SIDE (144”W/B) 4-0379 9K ALIGNMENT DECK, LEFT SIDE (172”W/B) 4-0415 12K ALIGNMENT DECK, LEFT SIDE (172”W/B) 4-0158 9K ALIGNMENT DECK, RIGHT SIDE (144”W/B) 4-0380... - Page 30 ITEM QTY. DESCRIPTION PART # COTTER PIN, 1/8” X 2”LG. 6-0115 BUSHING, 1 ¼” ID 6-0084 9K WEDGE ANCHOR, ½” X 4 ½”LG. 6-0140 12K WEDGE ANCHOR, ½” X 4 ½”LG. 6-0140 1/8” NPT BREATHER 6-0183 ELBOW 90°, 1/8”NPT TO 1/4” POLYTUBE 6-0709 AIR CYLINDER 6-1232...
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Page 31: Baysaver Hydraulics
11.3 BAYSAVER HYDRAULICS 31 of 40... -
Page 32: Baysaver - Hydraulics Part List
11.4 BAYSAVER - HYDRAULICS PART LIST ITEM QTY. DESCRIPTION PART # HYDRAULIC CYLINDER 3-0000 TUBE WELDMENT 2-0000 NUT GLAND 1-0011 GLAND 1-0008 ROD WELDMENT 2-0001 1-6* WIPER RING 6-0001 1-7* ‘O’ RING 6-0002 PISTON 1-0007 1-9* SEAL RING 6-0003 1-10* WEAR RING 6-0004 1-11... -
Page 33: Baysaver Options
11.5 BAYSAVER OPTIONS 33 of 40... -
Page 34: Baysaver - Options Part List
11.6 BAYSAVER - OPTIONS PART LIST ITEM QTY. DESCRIPTION PART # FRAME CLIP 6-0500 TERMINAL BOLT, 3/4”-16m W/1/4 NPT F 6-0167 FLAT WASHER 6-0426 SHOULDER BOLT, 3/8” X 5/8”LG. 6-0069 LOCKING PIN ASSEMBLY 2-2184 SELF TAP SCREW #10 X 1/2”LG. 6-0505 BULKHEAD, CONNECTOR 3/8”JIC C/W JAM NUT 6-0013... -
Page 35: Baysaver Console
11.7 BAYSAVER CONSOLE 35 of 40... -
Page 36: Baysaver Console Part List
11.8 BAYSAVER CONSOLE PART LIST ITEM DESCRIPTION PART # CONSOLE TOP COVER 2-2128 PUSHBUTTON CONTACTS 6-1248 EMERGENCY PUSHBUTTON CONTACT 6-2922 PUSHBUTTON 6-1247 ELECTRICAL BACK PANEL 3-0900 GREEN LED 6-3580 PUSHBUTTON PLATE (UP/DOWN ARROW) 6-1251 EMERGENCY STOP PUSHBUTTON W/ RESET 6-2921 FRONT COVER 2-2126 MANUAL SAFETY RELEASE VALVE... -
Page 37: 9000 Lb Baysaver Powerpack
11.9 9000 LB BAYSAVER POWERPACK 37 of 40... -
Page 38: 9,000 Lb Baysaver Powerpack Parts List
11.10 9,000 LB BAYSAVER POWERPACK PARTS LIST ITEM NO. QTY. DESCRIPTION PART NO. COMPLETE PUMP ASSEMBLY 6-2229 MOTOR, 220V (1 PHASE) 6-0087 MOTOR, 220V (3 PHASE) 6-0446 MOTOR, 575V (3 PHASE) 6-0447 PUMP TANK SKIRT 6-3226 TANK 10L PLASTIC 6-3224 RELIEF VALVE (4100 PSI) 6-3228 FITTING ¼... -
Page 39: 12,000 Lb Baysaver Power Pack - Parts List
11.12 12,000 LB BAYSAVER POWER PACK - PARTS LIST 39 of 40... - Page 40 ITEM NO. QTY. DESCRIPTION PART NO. COMPLETE PUMP ASSEMBLY 6-3234 MOTOR, 220V (1 PHASE) 6-0087 MOTOR, 220V (3 PHASE) 6-0446 MOTOR, 575V (3 PHASE) 6-0447 PUMP TANK SKIRT 6-3226 TANK 10L PLASTIC 6-3224 RELIEF VALVE (5400 PSI) 6-3238 6-3227 FITTING ¼ BSP- #6 JIC W/ BONDED SEAL PLUG ¾-16 C/W O-RING 6-3230 CHECK VALVE...