OTC 1520 Manuel utilisateur

Sheet No.

Issue Date: Rev. G, October 31, 2013

Form No. 102778

Parts List &

Operating Instructions

for: 1520

655 Eisenhower Drive

Owatonna, MN 55060 USA

Phone: (507) 455-7000

Tech. Serv.: (800) 533-6127

Fax: (800) 955-8329

Order Entry: (800) 533-6127

Fax: (800) 283-8665

International Sales: (507) 455-7223

Fax: (507) 455-7063

Vehicle Lift System

Max. Capacity: 10 Tons (Pair) at 150 PSI

Specications

Max. capacity, each lift ............ 10,000 lbs.

Max. capacity, system ............ 20,000 lbs.

Max. air pressure ................... 150 psi

Min. wheel dia. . . . . . . . . . . . . . . . . . . . . . . . 19 in.

Max. tire to fender clearance .............8 in.

Weight, each lift ....................513 lbs.

Weight, system................... 1,080 lbs.

Width ..........................41-9/16 in.

Depth ...........................39-1/2 in.

Height, lowered....................53-1/4 in.

Height, raised .....................77-1/4 in.

1 of 6

Parts List & Operating Instructions Form No. 102778, Sheet 1 of 6, Back

1 — 2 Hex Nut (3/8-16 UNC, plated)

2 — 3 Split Lock Washer (3/8", not plated)

3 — 1 90° Street Elbow (1/4")

4 222899 1 Hose Assembly, single-wire reinforced

5 — 1 Back Cover

6 — 1 Hex Hd. Cap Screw (3/8-16 UNC x 1" lg., plated, Gr. 5)

7 515461 1 Wiper Ring, Piston & Cup Subassembly

9 — 1 Hex Hd. Cap Screw (5/8-11 UNC x 5" lg., plated)

10 — 3 Split Lock Washer (5/8", not plated)

11 — 3 Hex Nut (5/8-11 UNC, plated)

12 — 1 Quick Disconnect

13 — 1 Pin & Chain Subassembly

14 — 2 Cap Screw (5/8-11 UNC x 6-5/8" lg., not plated)

15 — 2 Palnut (1/4", washer cap, plated)

16 — 2 Extension Spring (.437 x 5" lg.)

17 — 1 Hex Hd. Bolt (1-8 UNC x 5-1/2" lg., not plated)

18 — 1 Hex Jam Nut (1-8 UNC, plated)

19 — 1 Cylindrical Bearing (1.500 OD x 1.030 ID)

20 — 2 Flanged Plain Bearing

(1-1/2" nominal ID x 1.625 OD x 1-1/2" lg.)

21 — 2 Hex Hd. Cap Screw (3/4-10 UNC x 1-1/2" lg., plated, Gr. 5)

22 — 2 Washer (1-1/2" OD x 49/64" ID x 1/16" thick)

23 545171 2 Compression Spring (2-1/4" OD x 5" lg.)

24 545172 2 Caster Extension

25 222903 2 Caster (4" dia.)

26 — 2 Compression Spring (1-3/4" OD)

27 — 2 Spring Guide Pin

28 — 2 Caster Pivot Arm

29 j2 Metallic Wheel (3" dia.)

30 j2 Axle

31 j4 External Retaining Ring (5/8" dia.)

32 — 1 Wheel & Grease Fitting Subassembly

33 — 2 Capscrew (3/4-10 UNC x 4-3/4" lg., plated, Gr. 5)

34 — 2 Self-Locking Hex Nut (3/4-10 UNC, plated)

35 — 1 Top Weldment

36 — 2 Downstop Release Handle

37 — 2 Stop Block

38 — 1 Base Weldment

39 547853 2 Phenolic Wear Pad

40 — 4 Rivet (1/4" dia. x 2-5/8" lg., plated)

41 — 4 Palnut (1/4", zinc plated)

42 — 2 Grip (.437 ID x 1-1/2" lg.)

43 — 2 Roll Pin (1/4" dia. x 1-3/8" lg.)

44 — 2 Pin Support Bracket

45 — 2 Hex Hd. Cap Screw (5/16-18 UNC x 1/2" lg., plated, Gr. 5)

46 — 2 Split Lock Washer (5/16" dia., not plated)

47 — 1 Hex Hd. Cap Screw

(1/2-13 UNC x 2-1/4" lg., plated, Gr. 5, full length thread)

48 — 1 Hex Nut (1/2-13 UNC, plated)

49 222904 1 Dual 3-way Valve

50 32 Handle Subassembly

51 34 Cap Screw (1/4-20 UNC x 1-1/2" lg.)

Item

No.

Part

No.

Req'd

Description

To order items that

don’t have

part numbers, call

OTC Technical Services

at 1-800-533-6127.

j Included in Wheel Kit No. 525181.

3 Included in Handle Kit No. 525182.

Indicates

changes in

new revision.

Sheet No.

Issue Date: Rev. G, October 31, 2013

Parts List & Operating Instructions Form No. 102778

Air Control Unit

Air Inlet

Spool Port

Air Exhaust

Spool Port Air Inlet Port

(install customer-

supplied quick

coupler here)

6789

11, 12

10 14

Item

No.

Part

No.

Req'd Description

1 — 1 Valve Bracket

2 j 1 Valve Body

3 3 2 O-ring

4 j 4 Spool

5 — 1 Hex Hd. Cap Screw (5/16-18)

6 j 4 Plug

7 3 4 Spring

8 3 4 Cup

9 j 4 Brass Screw (6-32)

10 j 2 Lever

11 j 2 Nut (1/4" palnut)

12 j 1 Bar Round

(1/4" dia. x 3-15/16" lg.)

13 3 4 Seal (15/32" x 3/16" x 1/8")

14 — 2 Coupler Plug

15 — 2 90° Adapter

16 3 1 Screen

17 — 1 Hex Nut (5/16-18)

3 included in Repair Kit No. 222906

j included in Air Valve Assembly No. 222905

2 of 6

Valve Decal

Tire Placement

Decal

Downstop

Pawl Decal

Logo Decal

Made in USA

Decal

Warning Decal

Decal Placement

All the decals shown here are included in Decal Kit No. 222901. It is the lift owner’s responsibility to ensure

the decals are readable, and that every user has read (or in the case of illiterate or non-English speaking

users, “has been read to”) and understands all warnings, safety precautions, and instructions.

Parts List & Operating Instructions Form No. 102778, Sheet 2 of 6, Back

Safety Precautions

Do not raise / lower

one side of a vehicle.

Do not raise one

side of a vehicle.

Do not raise an

entire vehicle.

CAUTION: To reduce the risk of serious personal injury and / or property damage from falling loads,

read, understand, and follow all safety precautions. If the operator cannot read English, operating

instructions and safety precautions must be read and discussed in the operator’s native language.

Si el operador no puede leer inglés, las instrucciones de operación y las precau-

ciones de seguridad deberán leerse y comentarse en el idioma nativo del opera-

dor.

Si l’utilisateur ne peut lire l’anglais, les instructions et les consignes de sécurité

doivent lui être expliquées dans sa langue maternelle.

• Wear eye protection that meets ANSI Z87.1 and OSHA standards.

• The Vehicle Lift System is designed to lift over-the-road vehicles with rims of at

least 19 inches in diameter. Never use the lifts on vehicles with rims less than 19

inches in diameter.

• Maximum capacity is 10,000 lbs. per lift. Do not use the lift as a stand to raise or

support more than 10,000 lbs.

• The lifts are designed to operate on 150 psi shop air. Air pressure higher than 150

psi could result in failure of the vehicle lift system.

• Use the lifts only on a hard, level surface capable of sustaining the load.

• Do not use this lift with any other equipment used to raise a vehicle.

•Use the lifts in pairs, on opposite ends of the same axle.

• Do not use the lifts to raise a vehicle by the frame or structural member; the lift is

designed to be used only beneath the vehicle tires.

•To prevent tipping, never raise or lower only one side of a vehicle.

• Do not raise one end of a vehicle if the opposite end is supported by support stands.

•Do not raise an entire vehicle.

• Do not use blocks, non-factory supplied adapters, or cribbing devices with this equipment.

• Do not use this lift as a wheel dolly for the removal of tires.

•Stay out from underneath the vehicle until both lifts are pinned as stands.

Setup

The vehicle lift system consists of two lifts and one air control unit. Before unpacking the system, provide lifting

equipment capable of handling the weight of the units—each unit weighs approx. 513 lbs.

1. Remove banding and packaging material from each lift.

2. Remove the cable ties that hold the downstop release handle, load retention pin, and air hose.

3. Loosen the wire tie holding the cardboard box, and remove the box from the pallet.

4. Using a forklift, shop crane, or other suitable lifting device, carefully remove the lifts from the pallets. Place

the lifts on a hard, level surface.

Sheet No.

Issue Date: Rev. G, October 31, 2013

Parts List & Operating Instructions Form No. 102778

Assembly

Install handle

using 1/4-20

capscrews.

Air Hose

Load

Retention Pin

Downstop

Release

Handle

Lift Stop Bar

Lift Pads

This assembly requires:

• 7/16" box end wrench

• male quick disconnect

• wrench to ﬁt quick disconnect

• thread sealant

3 of 6

Figure 1

Attaching the Handles

Using two of the 1/4-20 cap screws per lift, attach a handle horizontally

across the back of each lift as shown in Figure 1.

Installing a Quick Disconnect

1. Install a user-supplied male quick disconnect (with thread sealant)

into the air inlet port on the underside of the air control unit.

Removing the Load Retention Pins

Use the following steps to remove the load retention pin and engage

the downstop on each lift.

1. Position yourself facing the lift. Hold the air control unit with the levers

pointing toward the lift and the quick couplers on the underside of

the unit.

2. Connect the air hose from the lift to a male quick coupler on the

bottom of the unit.

3. Connect shop air (150 psi) to the air inlet port of the unit (see Air

Control Unit illustration on Sheet No. 2 of 6).

4. Slowly raise the lift until the load retention pin can be removed.

5. Continue raising the lift until the downstop release handle (Figure 3)

can be pushed toward the lift, disengaging the downstop.

6. Place the load retention pin in its holder on the side of the lift.

7. Lower the lift by exhausting all the air from the cylinder.

8. Disconnect the air hose from the air control unit.

Note: The recommended clearance between the lift table bottom and

the oor is 1/8 inch minimum. If the clearance needs to be adjusted,

refer to the section titled Adjusting the Lift Table.

Shop Air

Hose from

Lift

Move lever UP to raise

lift; DOWN to lower lift.

Downstop

Release

Handle

Push the handle

toward the lift to

disengage the

downstop.

Figure 2

Figure 3

Parts List & Operating Instructions Form No. 102778 , Sheet 3 of 6, Back

Operating Instructions

Lift Table Tube

Figure 4

1. Park the vehicle on a hard, level surface, and set the parking brake.

2.Verifythevehicletiresareinatedtothecorrectpressure,tomaintain

the necessary tire diameter.

3. Position the lifts so the lift pads are cradling the tires AT OPPOSITE

ENDS OF THE SAME AXLE.

4. Push the lift pad under the tire until the lift table tube meets the tire.

See Figure 4.

5. Release the vehicle’s parking or air brake, and place the

transmission in neutral.

6. Uncoil the air hose from each lift, and route them to connect to

the air control unit at either the front or rear of the vehicle.

CAUTION: Keep hoses clear of pinch points, and do not

run them under the base of a lift because the base lowers

slightly as the vehicle is raised. Accidentally cutting off

the air supply can cause loss of load, resulting in personal

injury.

7. Position yourself at the front or rear of the vehicle so both lifts

are visible. Facing the vehicle, hold the air control unit with

the levers pointing toward the vehicle and the quick couplers

on the underside of the unit. See Figure 5.

8. Connect the air hose from the lift on your right to the right

side of the air control unit. Connect the air hose from the lift

on your left to the left side of the air control unit.

9. Connect shop air (150 psi maximum) to the air inlet port of

the air control unit.

Raising a Vehicle

1. Raise the vehicle by lifting UP on both air control levers at

the same speed, keeping the vehicle level.

2. Raise the vehicle until it is 2"–4" above the desired working

height. Note: The vehicle will lower by 2"–4" as the lift downstop

lugs engage.

3. Verify the downstop pawls will engage the downstop lugs AT

THE SAME HEIGHT on each lift. Use the air control unit to

adjust the level of the vehicle, if necessary. Figure 6.

Pinning the Lifts as Stands

1.Withthevehicle2"–4"abovethenalworkingheight,carefully

lower the lifts by pushing both air control levers DOWN at

the same time until the downstop pawls engage the closest

downstop lugs.

Verify the downstop pawls are securely engaged on the downstop

lugs of each lift and the raised axle is level. Fig. 6.

3. Remove the load retention pin from its holder on each lift.

Insert the pin through the oblong hole in the lift stop bar and

fully into the corresponding hole in the downstop lug. Fig. 7.

4. Exhaust the air from both cylinders by pushing both air control

levers DOWN at the same time.

5. Disconnect the hoses, and coil them on the hose holders on

the back of each lift. Figure 7

Load retention

pin in holder.

Insert load

retention pin

here to pin lift

as a stand.

Downstop

Release Handle

(controls pawl)

Downstop Lugs

Figure 6

Figure 5

Connect this

air line to lift

on left side of

vehicle.

Toward

Vehicle

Connect this air line to lift

on right side of vehicle.

Sheet No.

Issue Date: Rev. G, October 31, 2013

Parts List & Operating Instructions Form No. 102778

Lowering a Vehicle to the Ground

1. Clear the area under the vehicle of all personnel, tools, and shop equipment.

2. Remove the load retention pins, and insert them in their holders.

3. Uncoil the air hose from each lift, and route them to connect to the air control unit at either the front or the

rear of the vehicle.

CAUTION: Keep hoses clear of pinch points, and do not run them under the base of a lift because

the base lowers slightly as the vehicle is raised. Accidentally cutting off the air supply can cause loss

of load, resulting in personal injury.

4. Position yourself at the front or rear of the vehicle so both lifts are visible. Facing the vehicle, hold the air

control unit with the levers pointing toward the vehicle and the quick couplers on the underside of the unit.

5. Connect the air hose from the lift on your right to the right side of the air control unit. Connect the air hose

from the lift on your left to the left side of the air control unit. See Figure 5.

6. Connect shop air (145 psi max.) to the air inlet port of the air control unit.

7. Raise both lifts slightly (about 1/2 inch) so the downstop pawls are raised above the downstop lugs.

8. At each lift, release the downstop pawl by pushing the downstop release

handle toward the lift. See Figure 8.

9. Lower the lifts by pushing both air control levers DOWN at the same

time, keeping the vehicle level. Lower the lifts to their lowest position so

the downstop pawls will automatically reset.

Note: If you decide to raise the vehicle again before it has been fully lowered,

you must reset the downstops. To manually reset the downstops, pull the

downstop release handle toward you on each of the lifts.

10. Place the vehicle transmission in gear (or park), and engage the brakes.

11. Disconnect the hoses, and coil them on each lift.

12. Move the lifts away from the work area.

Using the Wheel Lifts with Support Stands

Transferring a Load to Support Stands

After a vehicle has been raised, and the wheel lifts have been pinned as stands, you may transfer the vehicle

to support stands, and remove the wheel lifts.

1. Select support stands that are capable of supporting the weight of the vehicle and are of the same height.

2. Determine lift points an equal distance from the wheel lift on each side of the vehicle. (Use lift points

recommended by the vehicle manufacturer for supporting the vehicle.)

3. Clear the area under the vehicle of all personnel.

4. Position the support stands on each side of the vehicle.

5. Remove the load retention pins, and operate the air control unit to lower the vehicle onto the support stands,

keeping the vehicle level. Note: If the pins do not pull out easily, raise the vehicle just enough to free the

pins.

6. When the vehicle is securely supported by the support stands, lower the lifts to their lowest position so the

downstop pawls are automatically reset.

7. Disconnect the hoses, and coil them on the hose holders on the back of each lift. Pull the lifts away from

the work area.

Push handle

toward lift

to release

downstop pawl.

Figure 8

4 of 6

Parts List & Operating Instructions Form No. 102778, Sheet 4 of 6, Back

Removing Support Stands

1. Position the lifts at opposite ends of the axle to be lowered so the lift pads will cradle the tires when contact

is made.

2. Uncoil the air hose from each lift, and route them to connect to the air control unit at either the front or the

rear of the vehicle.

CAUTION: Keep hoses clear of pinch points, and do not run them under the base of a lift because

the base lowers slightly as the vehicle is raised. Accidentally cutting off the air supply can cause loss

of load, resulting in personal injury.

3. Position yourself at the front or rear of the vehicle so both lifts are visible. Facing the vehicle, hold the

air control unit with the levers pointing toward the vehicle and the quick couplers on the underside of the

unit.

4. Connect the air hose from the lift on your right to the right side of the air control unit. Connect the air hose

from the lift on your left to the left side of the air control unit. See Figure 2.

5. Connect shop air (150 psi maximum) to the air inlet port of the air control unit.

6. To raise the lifts, pull UP on both air control levers at the same time. Both lift pads should contact a tire at

the same time.

7. Verify both lift pads have securely engaged the tires, and that the lift table tube of each lift meets the side

of the tire.

8. Raise the vehicle off the support stands by lifting UP on both air control levers at the same time, keeping

the vehicle level.

9. Withthevehicle2"–4"abovethenalworkingheight,carefullylowertheliftsbypushingbothaircontrol

levers DOWN at the same time until the downstop pawls engage the closest downstop lugs.

10. Verify the downstop pawls are securely engaged on the downstop lugs of each lift, and the raised axle is

level. See Figure 6.

11. Remove the load retention pin from its holder on each lift. Insert the pin through the oblong hole in the lift

stop bar, and fully into the corresponding hole in the downstop lug.

12. Exhaust the air from both cylinders by pushing both air control levers DOWN at the same time.

13. Disconnect the hoses, and coil them on the hose holders on the back of each lift.

14. Remove the support stands from under the vehicle.

Sheet No.

Issue Date: Rev. G, October 31, 2013

Parts List & Operating Instructions Form No. 102778

Maintenance

DANGER: To prevent serious injury or death resulting from a falling vehicle,

•NEVER perform maintenance service or inspections while the Vehicle Lift System is

in operation. Remove the lifts from service, and position the lifts so you have clear

access to all sides of each lift for inspection or service.

• Do NOT wash the base post. Washing the base post may remove lubricating grease,

causing the lift to fail, and the load to tip as it is lowered.

• Never use a damaged lift until all damaged components have been correctly repaired or replaced.

Test the lift and verify correct operation before returning it to service.

•Replace damaged air hoses with single-wire reinforced air hoses only. The use of any other type

of air hose increases the risk of lift failure should the hose become pinched or damaged.

•Inspect a lift IMMEDIATELY after it has been subjected to an abnormal shock or an abnormal load.

Lubrication

Lubricate the areas shown in the

illustration EVERY MONTH.

Downstop Pivot Shaft

and Release Springs

(use heavy grade

machine oil)

Swivel Casters

(use general

purpose grease)

Base Post

(use EP-1 yellow grease)

Front Wheels

(use heavy grade

machine oil)

Roller Wheel

(use general purpose grease)

Inspecting the Vehicle Lift

1. Inspect the lifts WEEKLY for any cracks, chips, or signs of excessive wear. Pay special attention to the welds.

2. Inspect the load retention pins WEEKLY for deformities or excessive wear. Note: If the deformities or

wearing away of material are easily seen without close inspection, it is excessive.

A. Test the load retention pins by inserting them through the lift stop bar and into each downstop lug. If the

pin cannot be inserted fully through the lift stop bar and into each of the holes in the downstop lugs in

all positions, it is excessively deformed and must be replaced before the lift can be used again.

3. Inspect the holes for the load retention pins in the base post WEEKLY. If these holes show excessive

elongation or wear on the top or bottom surfaces, they must be repaired before the lift can be used again.

5 of 6

Parts List & Operating Instructions Form No. 102778, Sheet 5 of 6, Back

Maintenance contd.

Inspecting the Air Hose

1. Inspect the air hoses DAILY for any signs of cuts, abrasions, or excessive wear. Replace damaged air

hoses with single-wire reinforced air hoses only. The use of any other type of air hose increases the risk

of lift failure should the hose become pinched or damaged.

2.InspectairttingsDAILYforcracksordamagedparts.Replacedamagedttingsbeforeusingthelift.

Adjusting the Lift Table

The lift has a 1/2-13 hex hd. cap screw mounted inside the top weldment to allow the lift table to be raised or

lowered slightly. The cap screw has been preset at the factory to provide 1/4" to 5/16" clearance between the

bottomoftheliftpadsandtheoor.Toadjusttheheightofthelifttable:

1.Placetheliftonaleveloorinanopenarea.

2. Raise the lift to its lowest downstop.

3. Loosen the jam nut, and turn the cap screw a few turns

clockwise to raise the lift table, or counterclockwise to

lower it.

4. Tighten the jam nut.

5. Lower the lift to its lowest position, and check the lift table

heightabovetheoor.

6. Follow steps 1–5 for the other lift. Each lift must have a

minimum of 1/8" clearance between the lift table bottom

andtheoor.

Cleaning the Air Control Valve

Rust, scale, or dirt from the air lines may become lodged under the rubber seals of the air control module,

causing minor air leakage. This leakage could cause the lift to slowly raise or lower even though the air control

levers have not been actuated. Use the following procedure to clean the air control module.

1. Disconnect the three air hoses attached to the air control

module.

2. Remove the valve bracket.

3. Remove the plug or plugs.

4. Use a stiff wire or pin punch to push the spool out of the

valve body.

5. If there is any dirt or foreign material embedded in the

rubber seal, remove the screw and cup from the end of

the spool, and remove and clean the rubber seal.

6. Turn the seal over, and assemble it into the cup.

7. Use the screw to secure the cup on the end of the

spool.

8. Lubricate the spool with a light chassis grease.

9. Insert the spool (with o-ring) into the air inlet spool port; insert the spool (without o-ring) into the air exhaust

spool port.

10. Insert the spring(s).

11. Apply thread sealant to the plug(s), and install the plugs into the valve body. Do not overtighten the plugs

because the threads are easily damaged.

Capscrew

Jam Nut

Lift Pad

Valve

Bracket

Valve Body

O-ring

Spool

Plug

Seal

Screw

Cup

Spring

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