Advance Lifts Dock Lifts Pit Mounted Manual

							 
 
       
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
CAUTION! 
THIS MANUAL IS AN IMPORTANT DOCUMENT 
IT SHOULD BE KEPT WITH THE MACHINE OR 
LOCATED WHERE READILY AVAILABLE TO 
OPERATORS AND MAINTENANCE PERSONNEL 
FOR REFERENCE PURPOSES. 
Dock Lift Owners Manual  
						

							 
INSTALLATION, OPERATION AND MAINTENANCE MANUAL 
FOR THE FOLLOWING  DOCK LIFT MODEL NUMBERS 
 
Throughout this manual, units are refered to by series. Each series has special 
installation, maintenance and safety requirements.  
 
 
 
2000 Series Lifts 
(2010, 2020, 2030, 2040, 2050, 2060, 2070, 2080, 2090, 2400, 2500) 
 
2000K Series Lifts 
(2010K, 2500K) 
    
3000 Series Lifts 
(3200, 3210, 3220, 3230, 3240, 3250, 3260, 3270, 3280, 3300, 3310, 3320, 
3330, 3340, 3350, 3360, 3370, 3380) 
 
4000 Series Lifts (4100, 4120, 4130, 4140, 4150, 4160, 4170, 4180, 4200, 4210,4220,4230, 
4240, 4250, 4260, 4270, 4280, 4300, 4310, 4320, 4330, 4340, 4350, 4360, 
4370, 4380, 4400, 4410, 4420, 4430, 4440, 4450, 4460, 4470, 4480)
  
   
      
T-Series Lifts 
(T2-50608, T2-60608, T2-60609, T2-60610, T2-60708, T2-60709, T2-60710, 
T2-60808, T2-60809,
 T2-60810, T3-50608, T3-60608, T3-60609, T3-60610, 
T3-60708, T3-60709, T3-60710, T3-60808, T3-60809,
 T3-60810)    
  
   
      
OTHER______________________________________________________________________ 
  
  
   
  
  
   
  
                          
  
    
 
 
  
						

							 
Dock Lift Installation, Operation, and Maintenance Manual  
 
 
In any correspondence with your distributor or the factory you will need the following 
information: 
 
Model Number
________________________________ Serial Number______________________________ 
 
 
        Installation location: __________________________________ 
    
                                        __________________________________ 
 
                                        __________________________________ 
 
 
CAUTION! 
At Initial Installation, determine proper motor/pump rotation by starting the motor in very 
short intervals to prevent permanent pump damage. Running the pump backwards will 
damage it. See the Installation Instructions, Section 4, for proper procedure.  
 
 
     Distributor Information:
 ____________________________________________ 
 
                        _________________________________ 
 
                        _________________________________ 
 
                        _________________________________ 
 
 
 
Advance Lifts, Inc. 
701 S. Kirk Road 
St. Charles, IL 60174-3428 
Toll Free 1-800-843-3625 
Sales Fax 1-630-584-9405 
Parts and Service Fax 1-630-584-6837 
E-mail: [email protected] 
 
*Advance Lifts, Inc. furnishes one manual with each unit. Additional manuals are available at 
$25.00 each. 
 
 
P 1-1 
 
 
  
						

							 
SECTION 2: INDEX & INTRODUCTION 
 
 Identification …………………………………………………………………………   Section 1 
 Index & Introduction …………………………………………………………….…..  Section 2 
*Responsibilities of Owners/Users …………………………………………………. Section 3 
*Installation Instructions ……………………………………………….…………….. Section 4 
*Operating Instructions ………………………………………………...……………. Section 5 
*Maintenance Instructions …………………………………………………………    Section 6 
 Power Unit Assemblies ……...……………………………………………………… Section 7 
 Hydraulic Details …............................................................................................ Section 8  
   General hydraulic information 
  Schematics 
   Fluid recommendations & seal compatibility 
   Pressure information for hoses & pipes 
  Component information 
   Cylinder repair procedures 
Electrical Details …………………………………………………………………….. Section 9 
  Schematics 
  Controller specifications 
  Component information  
    Wire size charts 
Identification and Label Placement ………………………………………………..   Section 10 
Troubleshooting Hints ……………………………………………………………....   Section 11 
Warranty ………………………………………………………………………………  Section 12 
Optional Information…………………………………………………………………   Section 13 
 
INTRODUCTION 
 
Congratulations, the equipment that you have purchased is of the highest quality.  Your 
Advance Lift will provide you with many years of trouble free service in return for the 
minimal maintenance described in this manual. 
 
Please be sure that no individual is allowed to operate the lift until they have been fully 
familiarized with operating instructions in this manual.  Also insure that at least one person 
at the lift site is familiar with the maintenance section of this manual and is assigned 
responsibility for doing the maintenance on a regular basis. 
 
Please note that the lift has a metal nameplate attached to it that contains information 
such as the model number, capacities, and the serial number.  Do not remove the 
nameplate.  Be sure that no operator ever exceeds the capacities shown on the 
nameplate or they may cause damage to the lift or injure personnel. Also, be sure to have 
the serial number of the lift handy if you have to call the factory.  That serial number 
identifies your specific lift and will allow factory personnel to give you the most thorough 
and timely assistance possible. 
 
This manual is under constant review and we would appreciate any constructive 
suggestions that may enhance its usefulness.  Please send your suggestions to Advance 
Lifts, Inc Attn: Service Manager 
 
Thank you for purchasing our product. 
 
*Mandatory reading before attempting installation. 
 
 
P 2-1
  
						

							 
 
SECTION 3:  RESPONSIBILITIES OF OWNERS & USERS 
 
 
Inspection and Maintenance: The lift shall be inspected and maintained in proper 
working order in accordance with this manual and safe operating practice. 
 
Removal from Service: Any lift not in safe operating condition shall be removed from 
service until it is repaired to the original manufacturer’s standards. 
 
Repairs: Only authorized personnel shall make repairs. All repairs shall be in 
conformance with the manufacturer’s instructions.  
 
Operators: Only trained and authorized personnel shall be permitted to operate the lift. 
Operators must be alert to the safety hazards of lift operation. 
 
Before Operation: Before using the lift, the operator shall have: 
 
1. Read and/or have had explained and understood, the manufacture’s operating 
instructions and safety rules. 
 
2. Inspected the lift for proper operation and condition. Any suspect item shall be carefully 
examined and a determination made by a qualified person as to whether it constitutes 
a hazard. All items not in conformance with the manufacturer’s specification shall be 
corrected before further use of the lift. 
 
During Operation: The lift shall be used in accordance with its intended use and within 
the manufacturer’s limitations and safety rules. 
 
Safety rules: 
 
1. Do not overload lift. 
 
2. Insure that all safety devices are operational and in place. 
 
3. Insure that all personnel near an operating lift understand to stand so that no body 
parts can be pinched by the mechanism or platform and any items that may fall off the 
lift will not strike them. 
 
Modifications or Alterations: Modifications or alternations of industrial scissors lifts shall 
be made only with written permission of the original manufacturer, Advance Lifts. These 
changes shall be in conformance with all applicable provisions of this standard and shall 
be as safe as the equipment was before modification. These changes shall also satisfy all 
safety recommendations of the original equipment manufacturer of the particular 
application of the lift. 
 
 
 
 
P 3-1 
 
  
						

							 
SECTION 4:  INSTALLATION INSTRUCTIONS 
 
Series 2000, 2000K, T-Series, 3000, 4000 
 
 
 
Equipment and Supplies Required: 
 
1.  Equipment to maneuver the Advance Lift into position.  Nylon slings are preferred, but 
padded alloy chains through the guardrail socket holes will also work as rigging. 
 
2.  The appropriate gallons of oil and a funnel, for exact quantity see page P 8-3.  Note 
that the 2010K, 2500K & T-Series units only require 5 gallons. Series 3000 units 
require 10 gallons and series 4000 units require 15 gallons. 
 
3.  A ½”, extra heavy, double wire braid hose (SAE 100R2A) or extra heavy seamless 
piping from the power unit to the equipment with ½” JIC female fittings on the ends.  
Advance supplies a ½” JIC male flare connector on the outlet of the power unit and 
the end of the filter pipe on the lift.  4000 series lifts require two hoses because of their 
special piping needs.  If hose or piping length will exceed 35 feet, consult the pressure 
chart to insure proper sizing.  
Caution! Be sure all hydraulic fittings are rated for 
hydraulic systems that may peak out at 4000 PSI. Hardware store items can burst at 
150 PSI.  Only buy from reputable hydraulic outlets. 
 
4.  Material for shimming and grouting, and anchor bolts. We recommend “Rawl-Stud 
Wedge Anchors”, “Wej-It” or equivalent bolts in the 5/8” x 6” size.  The 3000 and 4000 
series will require the 1” x 9” size. The studs must be embedded at least 4 ½” into the 
concrete. 
 
5.  Electrical fused disconnect (if required), refer to local electrical codes. 
 
6.  Wire and electrical fittings for the branch circuit, pushbutton station, down solenoid, 
motor and any accessories. See branch and control circuit section of this manual.  
 
7.  Standard hand tools for electrical work and hydraulic maintenance. 
 
8.  A heavy pry bar for shifting the equipment and a drill for installing the lag down studs. 
 
9.  Maintenance device; This is supplied by Advance Lifts on all units. Check the 
maintenance section of this manual for proper usage of each style of maintenance leg. 
 
10.  Pit mounted units will require timbers to temporarily support the unit over the pit. 
 
 
 
 
 
 
 
 
 
 
 
 
P 4-1
 
  
						

							 
SECTION 4: (CONTINUED) INSTALLATION INSTRUCTIONS 
 
Installation Procedure: 
1.  Read the Installation, Operating, and Maintenance instructions completely before 
attempting installation.  You may also find it helpful to read the remaining sections of 
the manual for a better understanding of how the equipment works. 
 
2.  If you are installing a pit mounted unit, check the pit dimensions against the pit 
drawing for conformity (length, width, and depth including bridge recesses) and be 
sure to check the diagonal of the pit for square.  Also be sure whatever surface the 
base frame will sit on is flat and level or is shimmed to achieve that end.  (See p 4-6 
for a typical pit drawing).  
 
3.  Locate the power unit, check to insure that there is no water contamination in the 
reservoir. Fill the reservoir through the breather hole with the appropriate hydraulic 
fluid (see fluid recommendation section of this manual).  Ideally, you should mount the 
reservoir on a wall approximately 6 ½’ above the ground. This prevents people from 
standing on or placing objects on the power unit. It will free up floor space and 
because the reservoir is higher than the lift, it will allow any air in the system to 
naturally rise to the highest point and purge itself from the system. 
 
4.  Run the hydraulic and clear / blue breather lines from the power unit to the lift and 
flush the hydraulic lines with clean fluid before connecting them. If the lines must be 
pushed through chases or enclosures, be sure to cap the lines to prevent 
contaminates from entering the hose.  The breather line must not be pinched or 
restricted during installation. Cleanliness is the single most important factor in the 
maintenance of any hydraulic system.  CAUTION! Contamination will destroy 
cylinders, valves, and pumps! 
 
5.  Following the electrical diagrams in the electrical section of this manual, make the 
electrical connection to the motor and controls for the unit.  Be sure that you have
 
correct motor rotation!  Continued operation of a hydraulic pump in reverse rotation 
will destroy it!  You can detect the rotation by making short motor jogs and watching 
the clear suction line from the reservoir to the pump.  If the rotation is correct, the fluid 
will leap up the line into the pump.  If the rotation is reversed, there will be no fluid in 
the suction line.  You may change the rotation of a 3-phase motor by simply 
exchanging the positions of any two of the three power wire connections.  With single-
phase motors, rotation is set at the factory.  Remember to have the discharge end of 
the hosing secure and discharging into a container or someone may take an oil bath. 
 
Note: Some installers try to arrange all of the above work to be completed before they 
ever bring a lift to the job site.  This allows them to use the crane that is used to offload 
and position the lift for as short a time as possible. 
 
 
 
 
 
 
P 4-2 
						

							 
 
SECTION 4: (CONTINUED) INSTALLATION INSTRUCTIONS 
 
Installation Instructions: 
                                         
6.   Figure out the proper orientation of the lift. (Surface mounted units may simply be put 
into place).  Note: All dock lifts are built so that loads are transferred over the hinged 
(clevis) end of the platform when elevated to truck height and this is the end to which 
the hinged bridge is usually welded.  Occasionally, the bridges are side mounted.  
Surface mounted units are equipped with approach ramps for transitioning on and off 
the unit from the ground level.  The ramps are usually much larger than the bridge 
and located on the roller end of the platform and should never ever be used as a 
bridge to the truck!  
 
7.  For pit mounted units, place timbers diagonally across the corners of the pit and with 
shipping restraints still in place, but shipping blocks removed, place the lift on the 
timbers.  Then you may make temporary hose connections being careful not to over-
tighten and crack the hydraulic fittings.  Finally, you may remove the timber supports 
and lower the lift into the pit. 
 
9.  You may now break the shipping restraints (banding). Use the lifts power unit to 
open the lift a few feet and use your crane to raise the clevis end (hinged bridge 
end) of the lift by hooking the bevel toe guard or use a plate grab attached to the 
hinged bridge.  This will allow you to remove your chains or slings and the banding 
material from beneath the unit’s base frame.  The tipping may not be necessary if 
you hooked your lift chains through the guardrail sockets of the platform and the 
shipping bands slide out from under the lift.  DANGER! Do no allow anyone to get 
under the unit! 
 
10.   Carefully lower the unit insuring that the platform edges clear the sides of the pit.  
The heavy pry bar may be used to reposition the unit with even clearance from all pit 
walls.  Note the lowered height in relation to the surrounding pit edges for later 
shimming adjustments. Caution! The lift shall be installed so that no part of the lift 
platform is more than ¼” above or below the surrounding surface. 
 
11.  Once the lift is properly positioned, (whether it is pit mounted or surface mounted), 
you may begin the lag down procedure. T-Series models have special lag down 
instructions located on page P 4-5. 
 
  12.    Raise the unit and position the maintenance leg or bar as shown in the maintenance 
section of this manual (pages 6-3 through 6-6).  Lower the unit onto the maintenance 
leg and press the down button for an extra 10 seconds to relieve all hydraulic 
pressure.  Drill the lag down holes and set the lag bolts.  Check the unit for side to 
side level and then shim or grout the base frame for continuous support. The 
shimming should enhance the match between the platform and the surrounding 
surfaces when fully lowered, but not at the expense of side to side levelness.  A 
slight slope from clevis end to roller end is not a problem, but side to side slope will 
cause premature wear on all the moving parts of the lift.  Tighten the lag bolts.  
  
 
 
 
 
 
P 4-3  
						

							 
 
 
 
SECTION 4: (CONTINUED) INSTALLATION INSTRUCTIONS 
 
 
 
13.  If a temporary hydraulic connection was made to lower the unit into the pit, now is 
the time to switch to your permanent hydraulic connection.  Note: on T-Series 
models the hose must run under the base frame, see page P 4-5 for pit details. 
Also, if there are any electrical options such as limit switches or electrical toe 
guards, now is the time to do that wiring. 
 
14.  Check that there are no tools or debris in the pit or beneath the unit, raise the unit 
and remove the maintenance leg, then fully lower the unit.  On pit mounted units, 
check that the bridges are flush with their curb angles and that they do not pivot 
when loads roll over them, shim any movement accordingly. 
 
15.  Operate the equipment through several cycles, holding the down button an extra 20 
seconds after the lift is fully lowered to bleed air from the cylinders.  Check the 
reservoir fluid level with the unit fully lowered and top off the fluid to 1” from the top 
of the reservoir on 5-gallon reservoirs and 2.5” from the top of 10-gallon reservoirs. 
 
16.  Adjust accessories such as limit switches and if the unit has electric toe guards or 
roller shades, fasten the hose in the pit so that it does not move and interfere with 
proper operation.  
 
17.  Raise the unit one final time, install the maintenance leg, and thoroughly clean the 
entire area.  Be sure all fluid spills are cleaned up so that they are not later 
misinterpreted as new fluid leaks. Check all hydraulic fittings for leaks. 
 
18.  Meet with the facility manager or maintenance foreman and turn over this 
maintenance manual with the reminder that no one should be allowed to operate 
the unit unless they are familiar with the operating instructions.  Show them the 
maintenance leg and any other maintenance devices. Point out the metal nametag 
on the unit with the serial number and capacity ratings. Make it clear that some 
specific person in their organization must be charged with responsibility for the 
maintenance of the unit and if they have no further questions, lower the unit and 
consider your job complete. 
 
 
 
 
 
 
 
 
 
 
 
P 4-4 
 
 
 
  
						

							 
SECTION 4.1: Special instructions for T - Series Only 
Ground Mounted Toe Guards (GMTG) 
 
1.  T-Series lifts not installed in pits require additional toe guard protection not outlined 
in the previous instructions. The toe guards are placed around the perimeter of the 
unit and are used to keep personnel a safe distance from the platform as the unit 
raises and lowers. All personnel shall stay to the outside of the toe guards when the 
lift is in operation. 
 
2.  Place the toe guards 3” from the lift platform’s beveled toe guards as illustrated in 
figure 1 below. Insure all four corners line up and lag the guards to the concrete 
through the holes provided using 3/8” concrete anchors as shown in figure 2.  
 
3.  Units with 8’ platforms require eight (8) concrete anchors and ten (10) anchors are 
needed for units over 8’ in length. 
 
4.  One of the guards has ¾” drilled mounting holes in it as opposed to the normal ½” 
mounting holes. This guard mounts to the base frame “lag-down angle” as illustrated 
in figure 3. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
                  P 4-5 
 
 
 
 
 
Concrete Pad Ground Mounted 
Toe Guard 
Lift Platform (Fig. 1) 
Concrete Pad 
(Fig. 2) 
Ground 
Mounted 
Toe Guard 
Lift Platform 
Concrete Anchor 
Ground 
Mounted 
Toe Guard 
Lift Platform 
(Fig. 3) 
Base frame 
Angle 
Concrete Pad 
3”