Advance Lifts Dock Lifts 6000 Series Manual

							 
 
 
 
SECTION 11.  TROUBLESHOOTING (Continued) 
 
6.  Equipment in which the cylinders are field installed may have incorrect alignment of 
cylinders, causing binding. Measure and ascertain that the cylinders are in the 
correct alignment with the equipment and with each other. Binding cylinders will 
often cause a “shuddering” vibration when the equipment is operating. 
7.  Oil may be too thin for ambient temperatures. See A-12 
 
C.  Motor labors or heats excessively:  
1.  Voltage may be too low. See A-3. 
2.  Wiring may be incorrect. Check that one leg of the motor lines is not open or 
grounded. 
3.  Pump may be overheating from oil starvation that develops high internal heat, 
heating   both the motor and the   pump, eventually causing pump failure. See A-1 
through A-9. 
4.  Oil may be too thick for ambient temperature. See “ Fluid Recommendations”. 
Binding cylinders. See B-6. 
5.  Pump may be overheating due to insufficient lubrication caused by oil being too thin. 
See A-12. 
 
D. Operation is “spongy”: 
 
1.  Bleed the cylinders to release trapped air by lowering the equipment to the fully 
down position and hold the down button depressed for an additional 20 seconds.  
Raise lift and repeat this procedure several times.  Check that the oil completely fills 
the clear suction hose at all times.  If the level falls back to the reservoir oil level, 
check suction lines and fittings for an air leak. 
2.  Check for oil starvation.  See A, 1-9. 
3.  Do not confuse “spongy” operation with small surges caused by foreign material on 
equipment wheel roller plates. 
 
 E.  Equipment lowers too slowly: 
1.  Pressure filter in pipe outlet of power unit may require cleaning.  See “ Component 
Information” for proper procedure. 
2.  Check for pinched hose, tubing, or obstruction in piping lines. 
3.  Check “Fluid Recommendations” for your ambient temperature type. Oil may be too 
thick.  See also H-6. 
4.  Foreign material in flow control valve.  With equipment fully lowered, remove and 
flush out any foreign material.  Do not change flow control setting, as equipment 
could be damaged by high speeds.  See “ Component Information” for proper way to 
remove, clean, and install the flow control valve. 
5.  Equipment having two down solenoid valves and/or flow control valves may have 
one valve inoperative. 
6.  Binding cylinders.  See B-6. 
 
 
 
 
 
 
P 11-3  
						

							 
 
 
 
SECTION 11.  TROUBLESHOOTING (Continued) 
 
F. Equipment lowers too fast: 
 
CAUTION! This can develop into a dangerous condition, the equipment reaching 
destructive speed.  Find and correct this condition before allowing use of this 
equipment. 
 
1.  Check for leaking hoses, particularly cracked fittings or other damage caused by 
equipment motion near the equipment and power unit, over-tightening of fittings until 
they develop hairline cracks.  Check underground conduits for evidence of fluid 
leaks. 
2.  Inspect the check valve.  The combination of the flow rates of the down flow control 
valve and a check valve stuck open due to foreign material, could increase the 
lowering speed.  See G-2. 
3.  If the equipment lowers initially at a normal rate, then speeds up as the equipment 
lowers, check the flow control valve(s).  Foreign material could stick, not allowing the 
pressure compensated function of the control to operate normally. See “Component 
Information” for the method of removal and replacement. 
4.  Oil may be too thin.  See A-12. 
 
G.   Lift raises then lowers back down: 
 
1.  Down valves may be incorrectly wired or stuck open due to dirt in the system.  See  
A-10, a. & b.  
2.  Check valve may be stuck open due to dirt in the system.  See “Component 
Information” for removal, cleaning and installation.  If pump and motor turns 
backward while the lift is lowering back down, the check valve is certainly 
inoperative. 
3.  Cylinder packing may be leaking.  Check for oil leakage, see “ General Hydraulic 
Information” and section on “Cylinder Repair Procedures”. 
4.  Check for leaking hoses, fittings, or evidence of oil in underground conduit runs. 
 
H. Equipment has raised but will not lower, or lowers partly: 
 
1.  Check both main and transformer secondary fuses. 
2.  Incorrect down solenoid wiring. 
3.  Stuck down solenoid valve.  See A-10b, however do not remove the down solenoid 
body, as the equipment will come down with nothing to hold it in place. 
4.  Faulty down solenoid coil. Coil can be removed safely for replacement.  As in step 3, 
do not remove valve body. 
5.  The maintenance device or other object blocking down travel. Do not pry out any 
object blocking down travel, because the hydraulic pressure has already been 
removed when the down button was pressed, and the equipment will fall at a 
dangerous speed.  Raise the equipment slightly using the up button, remove object, 
then press the down button. 
 
 
 
 
 
P 11-4 
  
						

							 
 
SECTION 11.  TROUBLESHOOTING (Continued) 
 
6.  Improper oil for ambient temperatures.  Oil may be too thick, causing improper 
operation of velocity fuses (if used).  See “Component Information’ on velocity fuses. 
Warm the cylinders by wrapping heat tape (of the type used for water pipes) around 
the cylinder. Later, after operation is normal, change to proper oil as per “Fluid 
Recommendations”. 
7.  Binding Cylinders. See B-6 
 
I.  Equipment raises slightly, then equipment stops and motor stalls: 
 
Check the suction line filter. Filter may be clogged, allowing slight movement until 
grime seals off filter.  Check the suction filter for buildup of “varnish”.  If necessary, 
remove the suction filter, hold the suction hose down into the oil, and try normal up 
operation of equipment.  If operation returns to normal either clean or replace the 
suction line filter.  See the “Component Information” section for procedure and 
proper placement of the suction hose. 
 
J.  Oil leaking or spraying out of the reservoir: 
 
1.  Reservoir may be mounted on its side.  The motor should sit on top of the reservoir, 
the mounting bracket positioned vertical for lagging the power unit to the wall. 
2.  Clogged air breather allowing reservoir to build up positive pressure, then spraying 
oil.  Try unit operation with air breather removed and clean or replace the air 
breather if this corrects the condition. 
 
K.  Equipment will not raise, motor will not run: 
 
1.  Control fuse has blown. 
2.  Motor starter overload has tripped.  Depress reset button on controller. 
3.  Line fuse blown, single phasing motor or motor starter overload tripping.  See #2 
above. 
4.  Initial installation: Line voltage 230V and transformer wired for 460V.  This will give 
12V-control voltage instead of 24V, and motor starter will not operate.  Check to 
make sure motor was not wired for 460V before trying operation.  The same 
situation applies to 115V control voltage.  Use a good AC voltmeter to check for 
proper control voltage. 
5.  Check transformer for loose screw terminals at the various connection points 
including jumpers and under the fuse clips. 
6.  Check push button station for proper operation and its wiring to the controller. 
 
L.  Down solenoid or Magnetic Starter Coil burns out routinely: 
 
1.  Transformer may be wired wrong.  As an example, a 460V line with the transformer 
and primary wired for 230V will give the control voltage of 48V instead of 24V.  
(Same doubling voltage applies to 115V control transformers.)  This will burnout 
coils ranging from immediately to several month intervals, depending on the stamina 
of the coil.  Correct the condition. P 10-5 
2.  The transformer may be defective.  Check control voltage with a good AC voltmeter. 
 
 
 
P 11-5 
  
						

							 
 
 
SECTION 11.  TROUBLESHOOTING (Continued) 
 
3.  Although very rare, high voltage spikes may be coming in on the power lines at 
random, burning out coils.  This cannot be detected with a power company recorder, 
A “Varistor” can be purchased and easily installed on control systems to protect the 
coils.  More severe cases on both 115V or 24V control systems may need a special “ 
High Insulation Transformer” in place of the standard control transformer. 
 
M.  Equipment does not lift rated load, or raises load about 1” then stops: 
1.  Check troubleshooting section (A), 2 through 11.  Check if platform roller wheels roll 
freely with no binding as lift raises and lowers. 
2.  Lift may be overloaded.  If a lift is listed as capable of fork truck loading, bear in mind 
that most “sit-down” rider fork trucks weigh at least 5,000 to 7,500 pound empty. 
3.  Platform may be shifted or damaged from transit or unintentional abuse. 
A.  Check if the inside edge of the bevel toe guard is rubbing against the base frame 
in the fully lowered position.  Look for scratch marks on the base frame.  Bend 
back bevel toe guards as required and see “b” below. 
B.  Check if the platform roller wheels are running straight on their platform members 
as the lift raises and lowers and legs or wheels are not rubbing on nearby 
platform members.  Consult Advance Lifts on how to straighten out a platform. 
C. Check that the platform roller wheels are actually rolling as unit rises.
 
4. There may actually be no problem.  Many shipping tickets contain estimated weights 
much lower than the actual weight.  The lift may be seeing a load based on shipping 
tickets, well above lift capacity.  In this case the lift would not generally raise the 1” 
and stop, generally it will not lift at all from the full lowered position. 
 
N.  Breather lines do not stay connected. 
1.  Be certain that the lines are not pinched. 
2.  Check that there is no debris in the lines. 
3.  Once a line has been removed from the fitting, the hose must be cut back before 
reinstallation. 
4.  If lines are completely filled with oil, drain oil out and test cylinders for seal failures. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
P 11-6 
 
  
						

							 
 
 
SECTION 12. ADVANCE LIFTS INC. PARTS AND LABOR WARRANTY 
 
 
For a period of two years from date of shipment from the Company’s plant, the 
Company agrees to replace or repair, free of charge, any defective parts, material or 
workmanship on new equipment. This shall include electrical and hydraulic 
components. 
 
For a period of ten years from date of shipment from Company’s plant, the Company 
agrees to replace or repair any defective structure. 
 
Company authorization must be obtained prior to the commencement of any work. The 
Company reserves the right of choice between effecting repairs in the field or paying all 
freight charges and effecting the repairs at the Company’s plant. The Company further 
reserves the right of final determination in all warranty considerations. Evidence of 
overloading, abuse, or field modification of units without Company approval shall void 
this warranty. No contingent liabilities or freight damage will be accepted. 
 
 
  
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
P 12-1 
 
 
  
						

							 
 
6000 SERIES PARTS LIST 
 
 
GENERAL DESCRIPTION PART #
MECHANICAL: (COMMON TO ALL UNITS)
ROLLER WHEEL ASSEMBLY A-0074
ROLLER WHEEL PIN A-0075
WHEEL PIN SNAP RING 001-877
MAIN AXLE PIN A-0073
MAIN AXLE PIN SNAP RING 001-063
COMPLETE CYLINDER: 
1568 CYLINDER ASSEMBLY D-15751
CYLINDER PARTS:
1568 CYLINDER PACKING KIT 036-968
UPPER/LOWER CYLINDER PIN A-0548
CYLINDER PIN SNAP RING 001-876
MOTOR: SELECT BY VOLTAGE AND PHASE
115/208/230V 1PH 000-319
230/460V 3PH 5HP BALDOR MOTOR 003-373
PUMP: SELECT BY VOLTAGE AND PHASE
115/208/230V 1PH HALDEX HYDRAULIC PUMP #1003570 031-637
230/460V 3PH HALDEX HYDRAULIC PUMP 027-276
HYDRAULIC: COMMON TO ALL UNITS
BARNES 24V DOWN SOLENOID COIL 015-301
BARNES 115V DOWN SOLENOID COIL 001-741
BARNES 24V/115V DOWN SOLENOID VALVE 003-106
RELIEF VALVE 001-263
SUCTION LINE FILTER 001-280
TRANSFORMER: SELECT BY VOLTAGE AND OPTIONS
115/230V 3PH TRANSFORME
R029-921
230V/460V 3PH TRANSFORME
R029-919
CONTACTOR/MOTOR STARTER:
115V 1PH TESYS CONTACTO
R000-692
230V 1PH TESYS CONTACTO
R000-692
230V 3PH TESYS CONTACTO
R000-692
460V 3PH TESYS CONTACTOR000-692
OVERLOAD:
115V 1PH TESYS OVERLOAD 000-700
230V 1PH TESYS OVERLOAD 000-698
230V 3PH TESYS OVERLOAD 000-699
460V 3PH TESYS OVERLOAD 000-696
OPTIONS:
BLUE SPRAY PAINT 16oz 015-173
YELLOW SPRAY PAINT 16oz 015-174
PUSH BUTTON 000-802
REPLACEMENT NAME/SERIAL TAG 001-448
 
 
 
 
 
 
 
 
 
 
 
 
 
TO ORDER PARTS CALL 800-843-3625  
OR E-MAIL [email protected]