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John Bean 48109B, Installation And Operation Manual

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John Bean 48109B Installation And Operation Manual Download Page 1

READ THIS INSTRUCTION MANUAL THOROUGHLY BEFORE 

INSTALLING, OPERATING, SERVICING OR MAINTAINING 

THE LIFT. SAVE THIS MANUAL.

OCT 2008 REV.-

INSTALLATION

and OPERATION

MANUAL

BAYSAVER II

9000LB Models

48109B /  48209B

Flushmount Models

48109BFM / 48209BFM

(144” W/B / 172” W/B)

12000LB Model

4812205AF 172” W/B

BAYSAVER II

9000LB Models

48109B /  48209B

Flushmount Models

48109BFM / 48209BFM

(144” W/B / 172” W/B)

12000LB Model

4812205AF 172” W/B

309 EXCHANGE AVENUE, CONWAY, ARKANSAS, 72032

TEL: 501-450-1500  FAX: 501-450-1585

6-1269

Summary of Contents for 48109B

Page 1: ...d OPERATION MANUAL BAYSAVER II 9000LB Models 48109B 48209B Flushmount Models 48109BFM 48209BFM 144 W B 172 W B 12000LB Model 4812205AF 172 W B BAYSAVER II 9000LB Models 48109B 48209B Flushmount Models 48109BFM 48209BFM 144 W B 172 W B 12000LB Model 4812205AF 172 W B 309 EXCHANGE AVENUE CONWAY ARKANSAS 72032 TEL 501 450 1500 FAX 501 450 1585 6 1269 ...

Page 2: ...OCEDURE 19 6 11 COVERS WHEEL STOPS AND APPROACH RAMPS 21 7 OPERATING INSTRUCTIONS 22 7 1 RAISING THE LIFT 22 7 2 LOWERING THE LIFT 23 8 FINAL CHECK OF ASSEMBLED LIFT 24 9 OPERATION TEST WITH VEHICLE 25 10 RECOMMENDED MAINTENANCE 26 11 PARTS MANUAL 28 11 1 BAYSAVER ASSEMBLY 28 11 2 BAYSAVER PART LIST 29 11 3 BAYSAVER HYDRAULICS 31 11 4 BAYSAVER HYDRAULICS PART LIST 32 11 5 BAYSAVER OPTIONS 33 11 6 ...

Page 3: ...orized personnel should operate the lift Do not allow customers or bystanders to operate the lift or be in the lift area 5 CAUTION Never work under the lift unless the mechanical safety locks are engaged 6 Always keep the lift area free of obstruction and debris Grease and oil spills should always be cleaned up immediately 7 Never raise vehicle with passengers inside 8 Before lowering check area f...

Page 4: ...es installation operator training and owner employer responsibilities please refer to Lifting It Right ALI SM and Safety Tips ALI ST For additional instruction on general requirements for lift operation please refer to Automotive Lift Safety Requirements For Operation Inspection and Maintenance ANSI ALI ALOIM ATTENTION This lift is intended for indoor installation only It is prohibited to install ...

Page 5: ...5 of 40 2 SAFETY WARNING DECALS Be sure the operator is aware and underastands all safety warning lables and follows them accordingly ...

Page 6: ...A Overall Length 172 W B 264 6706 mm 264 6706 mm Max Raised Height 72 1829 mm 72 1829 mm Min Lowered Height 8 3 4 222 mm 8 3 4 222 mm Lifting Time 60 Sec 60 Sec Power Requirements 230V 1Ph 60Hz 230V 1Ph 60Hz Air Requirements 90 120 psi shop air 90 120 psi shop air Shipping Weight 144 W B 3450 lbs 1565 kg N A N A Shipping Weight 172 W B 3560 lbs 1615 kg 4980 lbs 1615 kg Figure 1 Lift Dimensions ...

Page 7: ...bly Runway Scissors and Base Frame Note Hydraulic lines in base frames have been factory installed Other Structural Components 1pc Console and accessory box See accessory box list for contents 1pc Grout container 1pc Customer care kit including manuals 5 TOOLS REQUIRED FOR INSTALLATION Rotary Hammer Drill or Similar and Concrete Drill Bits 4 Level SAE Wrenches and Sockets Hammer Pry Bar Chalk Line...

Page 8: ...hes or 130 mm Concrete must have a minimum strength of 4000 psi or 30 MPa and should be aged thirty 30 days prior to installation Please consult the architect contractor or engineer if doubt exists as to the strength and feasibility of the floor to enable proper lift installation and operation It is the user s responsibility to provide all wiring for electrical hook up prior to installation and to...

Page 9: ...E Leave any additional room for any desired aisle or work area Recommended clearance around the lift is a minimum of three 3 feet Ensure clearance conforms to local building and fire codes Recommended overhead clearance is a minimum of twelve 12 foot ceiling providing 6 feet for the maximum lift height and 6 feet for the supported vehicle For vehicles taller than 6 feet it is ...

Page 10: ...ssembly onto this line 144 3658mm W B 39 991mm back from the front of the lift 172 4369mm W B 49 1321mm back from the front of the lift 6 Check the floor in the outline for the highest point using a four 4 foot level Mark this location reference will be made to it later during the leveling procedure 6 2 UNPACKING PROCEDURE Cut and remove the metal banding straps that hold the accessory box and sli...

Page 11: ...the inlet ports located on the left side of the left main frame assembly Refer to Figure 3 4 Locate the two 2 21 6401mm long hydraulic hoses mounted from the back of the console Connect the hoses to the two inlet ports of the lift The inlet ports are located on the left side of the Left Main Frame Assembly Refer to Figure 3 5 Connect the 21 6401mm long 3 8 braided hose to the inlet on the left bas...

Page 12: ...12 of 40 Hydraulic Schematic ...

Page 13: ... 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 Figure 4 Electrical Schematic 220 Volt 1Ph ...

Page 14: ...ose and the powerpack be cleaned Place the fitting on a workbench and use an air gun to blow through the filter in the opposite direction to flow from the lift 6 Close the back cover of the Control Console making sure that all four hoses are routed through the slot located at the bottom of the back cover 6 6 AIR LINE INSTALLATION 1 Remove the air line fittings from the accessory box 2 Raise the li...

Page 15: ... 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 Refer to Figure 6 ...

Page 16: ...elease plate using the shoulder bolt supplied in the hardware kit Connect the safety release plate to the safety release rod using two 2 hex bolt and lockwashers 5 Assemble the breather and 90 elbow to the air cylinder as shown in Figure 7 Attach the air cylinder to the baseframe using the shoulder bolt provided 6 Install the safety release connecting rod between the safety bars using 20UNC x 1 lg...

Page 17: ...r supply line is higher than 120psi use optional part 6 0182 1 8 plug Check for leaks 3 Make sure there are no people tools or obstructions under the platforms before pressing the mechanical safety release button and then lower the lift by pressing down button on the control panel Stop lowering at approximately 3 feet from the floor Release the mechanical safety release button and lower the lift d...

Page 18: ... Now level the remaining outside half of the last base frame by placing the level across that unit and shimming as required 6 A quick check across along and between each base frame will ensure the leveling procedure was carried out successfully LEVELING EXAMPLE Assuming that the front right corner is the highest point level in the following order Shim along side A Shim across from side A to side B...

Page 19: ... 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 2 Raise the lift to full height and repeat the measurements and ensure there are no differences ...

Page 20: ...l anchor bolts to 55 ft lbs 7 Position the console in the final desired location Using a rotary hammer drill and a 1 4 concrete bit drill and anchor the console to the floor using the Nail in Anchors located in the hardware kit 8 Use the line covers to protect all cables hoses and wiring running to the lift Using a rotary hammer drill and a concrete bit drill and anchor the line covers using the n...

Page 21: ...od does not bind during operation 3 Locate and install protective line covers over all air and hydraulic supply lines 4 Using a rotary hammer drill and a concrete drill bit drill all line cover locations Using the nail in anchors supplied fasten the line covers to the floor 5 Locate and install the two 2 front wheel stops one 1 to the front of each of the runways using the six 6 1 2 13 UNC x 1 1 2...

Page 22: ...icle 3 Position the vehicle on the lift ensuring the resulting load on each deck is distributed as evenly as possible NOTE The vehicle is positioned correctly when the distance from the center of the tires to the inside edge of the runways is equal on both runways for the front and rear tires 4 Check that there are no obstructions above the lift that could damage the lift or vehicles 5 Raise the l...

Page 23: ...ety locking bars Continue to hold the button while depressing the down button on the control console 4 Continue lowering until the lift is approximately 34 864mm above the floor Then release the mechanical safety release button allowing the mechanical safety locking bars to be readied for their next use Continue to depress the down button until the lift is completely lowered and LED light goes off...

Page 24: ... if necessary ____ 6 Operate lift to full stroke then lower to ground while checking ____ for proper functionality 7 Ensure Customer Care Kit is complete and given to operator ____ a Operation Manual ____ b ANSI ALI Lift It Right Manual ____ c ANSI ALI Safety Tip Card ____ d ANSI ALI ALIS Safety Requirements for Installation ____ and Service of Automotive Lifts e ANSI ALI Quick Reference Guide ___...

Page 25: ...d 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 Lower lift to ground and drive vehicle off lift If any problems occur during the final checkout or operation of the lift please contact customer service at 1 800 268 7959 ...

Page 26: ...ic fluid 3 The roller tracks should always be kept clean and free of debris This area should be checked before any raising or lowering of the lift 4 Inspect the operation of the lift daily Raise and lower fully 5 Inspect electrical and mechanical operations of all switches electrical and mechanical 6 Lifts equipped with full floating rear slip plates and front radius turning plates require to be d...

Page 27: ...t to dry thoroughly 4 To obtain optimum performance the position of the slip plate bearing cage should be rotated every quarter to change the wear pattern With the first quarter maintenance flip the bearing cage over to the opposite side With the second quarter maintenance rotate the bearing cage end to end With the third quarter maintenance flip bearing cage over to the opposite side Fourth quart...

Page 28: ...28 of 40 11 PARTS MANUAL 11 1 BAYSAVER ASSEMBLY ...

Page 29: ...T 2 0112 14 2 FLAT SHIPPING BRACKET 2 0266 15 4 SPRING PIN 3 16 X 2 LG 6 0146 16 2 FLAT HD 20UNC x LG 6 1086 17 4 FULCRUM PIN 1 DIA 1 0106 18 8 BUSHING 1 I D 6 0085 19 8 END HINGE PIN 1 DIA 1 0107 20 4 CAM FOLLOWER 6 0637 21 4 JAM NUT 5 8 18UNF 6 0040 22 2 SAFETY BAR WELDMENT 2 1683 23 2 SAFETY PIN 1 0547 24 2 NEX NUT 20UNC 6 0032 25 2 SAFETY RELEASE TAB 1 2169 26 2 SAFETY RELEASE ROD 9K 2 2133 2 ...

Page 30: ...UNC x 3 8 LG SET SCREW 1 1245 50 1 ACTUATOR ARM WELDMENT 1 1246 51 1 SAFETY COVER 2 1055 52 2 SELF TAPPING SCREW 10 24UNC X 1 2 LG 6 0505 53 1 POLYTUBE 1 4 DIA 30 LG 6 1270 54 1 HYDRAULIC LEVELING DECAL 6 1405 55 2 T B BRACKET 12K FOR AIR KIT D S ONLY 1 0636 2 HEX BOLT 13UNC X 1 LG 6 0291 2 HEX NUT 13UNC 6 0035 4 PLAIN WASHER I D 6 0063 2 LOCK WASHER I D 6 0059 56 2 ADAPTER PLATE 12K 1 2319 6 HEX ...

Page 31: ...31 of 40 11 3 BAYSAVER HYDRAULICS ...

Page 32: ...007 1 13 1 RETAINING RING 6 0070 1 14 1 GREASE NIPPLE 6 0000 15 2 PIN 1 0029 16 4 RETAINING RING 6 0340 17 2 VELOCITY FUSE 6 0422 18 2 TUBE ASSEMBLY CYLINDER 1 0093 19 6 BULKHEAD CONNECTOR 3 8 JIC C W JAM NUT 6 0013 20 2 HOSE ASSEMBLY 2 2136 21 1 TUBE ASSEMBLY 2 0848 22 1 HYDRAULIC HOSE ASSEMBLY 2 2050 23 2 BULKHEAD 90 ELBOW 3 8 JIC M C W JAM NUT 6 0012 24 2 TUBE ASSEMBLY 2 0849 25 1 TUBE ASSEMBLY...

Page 33: ...33 of 40 11 5 BAYSAVER OPTIONS ...

Page 34: ...HOSE 22 LG C W FITTINGS 6 1345 13 3 STREET TEE 1 4 NPT 6 0014 14 2 STREET ELBOW 6 0015 15 2 POLYTUBE STRAIGHT ADAPTER 3 8 X 1 4 NPT 6 0710 16 1 HOSE 144 W B 1 0120 17 3 12 COILED HOSE 6 0337 18 2 REAR SLIP PLATE WELDMENT 3 0197 19 1 SET 225 BALL BEARING 1 4 DIA 6 0829 20 2 ROLL BACK RAMP WELDMENT 2 1958 21 2 FRONT BEARING CAGE 1 1070 22 4 TUBE CLAMP 6 0170 23 4 SELF TAP SCREW 10 X 3 8 LG 6 0169 24...

Page 35: ...35 of 40 11 7 BAYSAVER CONSOLE ...

Page 36: ...UBE TO 1 8 NPT M 6 0708 19 1 POLYTUBE 24 LG 6 1270 20 1 CONTACTOR BOARD 3PH 24V COIL 6 2172 1 CONTACTOR BOARD 1PH 24V COIL 6 2173 21 1 THERMAL OVERLOAD 1 8A 2 8A 575V 3PH ONLY 6 2174 THERMAL OVERLOAD 2 7A 4 2A 460V 3PH ONLY 6 2175 THERMAL OVERLOAD 6 0A 9 2A 220V 3PH ONLY 6 2176 22 1 PRINTED CIRCUIT BOARD 6 2125 23 1 DECAL SET 6 1344 24 2 FUSE 2A 600V 6 2178 25 2 STRAIN RELIEF 1 PHASE 6 1370 STRAIN...

Page 37: ...37 of 40 11 9 9000 LB BAYSAVER POWERPACK ...

Page 38: ... 1 PUMP INTAKE ASSEMBLY 6 2535 16 1 PUMP RETURN ASSEMBLY 6 2290 17 1 PRESS FIT FILLER BREATHER 6 3223 18 1 PRESSURE HOSE 6 3232 19 1 FLOW DIVIDER C W SOLENOIDS 6 2315 20 1 FILTER FITTING BSP 6 JIC C W BONDED SEAL 6 2553 21 2 PRESSURE SW C W COVER BONDED SEAL 6 2548 22 1 CARTRIDGE VALVE EQUALIZE VEI DT 6 1364 23 2 FILTER FITTING 3 8 BSP 6 JIC C W BONDED SEAL 6 2127 24 1 PRINTED CIRCUIT BOARD 6 2125...

Page 39: ...39 of 40 11 12 12 000 LB BAYSAVER POWER PACK PARTS LIST ...

Page 40: ...ETURN ASSEMBLY 6 2290 17 1 PRESS FIT FILLER BREATHER 6 3223 18 1 UNLOADING MANIFOLD ASSEMBLY 6 2555 19 1 PUMP INTAKE ASSEMBLY SHORT 6 2293 20 1 PRESSURE HOSE 6 3232 21 1 FLOW DIVIDER C W SOLENOIDS 6 2315 22 1 FILTER FITTING BSP 6 JIC C W BONDED SEAL 6 2553 23 2 PRESSURE SW C W COVER BONDED SEAL 6 2548 24 1 CARTRIDGE VALVE EQUALIZE VEI DT 6 1364 25 2 FILTER FITTING 3 8 BSP 6 JIC C W BONDED SEAL 6 2...

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