This document describes the Tecalemit TEC4000 4-Post 4-Tonne Hoist, including installation, operation, and maintenance instructions.
Function Description
The Tecalemit TEC4000 is a 4-post, 4-tonne vehicle hoist designed for vehicle servicing and lubrication. It allows for lifting vehicles to a desired height for maintenance and repair, providing under-vehicle access. The hoist is available in a basic model and a "Wheels-Free" version (TEC4011), which includes additional beams for lifting the vehicle off its wheels, allowing for wheel and suspension work.
Important Technical Specifications
Hoist Capacity: 4 tonnes
Power Supply: 415V, 3-phase plus neutral, 50Hz. The wire (conductor) size must be a minimum 7-strand, 2.5 mm² cross-sectional area and copper.
Air Supply: 5.5 to 8 bar pressure (70 to 100 Psi), connected to a filter and lubricator.
Floor Requirements: Flat concrete floor of minimum thickness 100mm and minimum strength grade 28 Mpa. Masonry anchors (if used) must be a minimum of 16 mm diameter (thread size) and not installed within 150 mm of any edge, crack, or other fastener. If the floor is unsatisfactory, new concrete bases of minimum thickness 150mm and minimum strength grade 28 Mpa are required. Concrete must cure for a minimum of one month before using the hoist.
Hydraulic Oil: ISO viscosity Grade 32 (mineral oil based). Reservoir capacity is 8 litres.
Wire Rope Specification: 6 x 25 (12/6 +6F/1) independent wire rope core, right hand ordinary lay, grade 2070 Mpa, galvanised, 11 mm diameter.
Motor: 2.2 kW, 2750 rpm, 415V, 3 Phase, 50 Hz.
Motor Direction: Must be anti-clockwise when viewed from above.
Nyloc Nut Torque (Cylinder): 105 Nm (75-80 ft lbs).
Usage Features
Installation:
- Requires an undercover position with direct access for vehicles.
- Floor plan must be marked out as per FIG.A.
- Mains isolator switch and air supply filter/lubricator must be installed adjacent to the power column.
- Tracks are placed on supports, with the power track (containing the hydraulic cylinder and cables) on the power column side.
- Cables and hydraulic hose are fed through tracks and crossmembers.
- Crossmembers are fitted to the tracks, aligning bolt holes.
- For basic hoists, fixed wheel stops and drive-on ramps are bolted to the crossmember.
- For wheels-free hoists, extension U-brackets are fitted, and wheels-free crossmembers are placed into the U-brackets. Interlock pins are engaged to lock the crossmembers.
- Clutches and cable retainers are fitted, and cables are fed around pulleys.
- Clutch rods are fed through columns and clutches, then screwed into the base of the column and tensioned.
- Floor slope must be established, and columns packed to ensure vertical alignment, which is critical for accurate wheel alignment.
- Power pack is mounted, and the top limit switch is fitted and adjusted.
- Hydraulic hose is connected to the power pack and cylinder, ensuring no twists.
- 8 litres of hydraulic oil are poured into the reservoir (not filled completely initially).
- Air lines are connected, and column hooks are checked for operation and air leaks.
- Power supply is connected, and motor direction is checked (anti-clockwise).
- Hoist is raised to remove supports, and clutch actuator pulleys and clutches are checked. Cables are tightened if necessary.
- Slave columns are adjusted by packing until vertical and square. All hold-down bolts are installed and tightened.
- Cables are adjusted until crossmembers just start to lift off the column base plate.
- Clutch rods are checked for bowing, and wheels-free crossmembers are checked for rubbing or excessive gap.
- Hoist is raised until column hooks engage. Hooks must engage fully and simultaneously under spring pressure.
- Hoist is raised to full height, and oil is added if it slows down or gets noisy. Top limit switch operation is checked.
- Air trapped in the hydraulic system is expelled by lowering and raising the hoist several times. Oil level is topped up.
- SAE 140 oil is applied to clutch rods, cables, pulleys, ramp rollers, and hook pivots.
- Inner toeguards are bolted under the tracks. Hydraulic hose is attached.
- Outer toeguards are positioned and adjusted to be flat on the floor. For wheels-free hoists, they are bent towards the column base plates to create an 80 mm gap.
- Wheels-free support beams are placed between the tracks.
- The heaviest available vehicle (4 tonne maximum) is driven onto the hoist and raised to full height.
- For wheels-free hoists, interlock pins are engaged, and column hooks are checked for engagement at the same height. Cables are adjusted if needed.
- For wheels-free hoists, support beams are located under suitable pickup points, and adaptor pads/extensions are positioned.
- Hoist is raised slightly to unload interlock pins, which are then disengaged.
- Hoist platform is lowered until the vehicle is fully supported by wheels-free beams, checking safety at pickup points and column hooks.
- Hoist is raised to unload column hooks, adaptor pads are removed, and the floor area is cleared. Hooks are disengaged, and the hoist is lowered to the floor. Vehicle is removed.
Operation (To raise hoist):
- Park vehicle centrally, stop engine, apply parking brake.
- Place chocks in front of and behind wheels (manual chocks on at least one wheel).
- Ensure hoist area is clear of people and obstructions.
- Raise hoist to desired height.
- For wheels-free hoists, engage crossmember interlock pins.
- Lower hoist onto column hooks and visually check engagement.
- Turn main switch to horizontal "Off" position.
Operation (To lower hoist):
- Ensure floor area beneath hoist is clear.
- Raise hoist until column hooks are free.
- Disengage column hooks and lower hoist to the floor.
- Remove wheel chocks, check driveway, drive vehicle off.
Operation (Wheels-free system):
- Park vehicle centrally, stop engine, apply parking brake.
- Ensure hoist area is clear, raise hoist to desired height, turn main switch to "Off".
- Position longitudinal support beams under vehicle pickup points.
- Position adaptor pads under pickup points (adjust beams if necessary).
- Disengage interlock pins on both ends, check visually.
- Slowly lower hoist, visually verify all four column hooks are fully engaged in notches.
- Continue lowering until vehicle is supported by adaptor pads, check position and security.
- Lower hoist tracks to give access to vehicle, keeping them as close as practical for safety.
- Turn main switch to "Off".
To remove vehicle (Wheels-free system):
- Ensure hoist area is clear, raise hoist tracks until vehicle is supported by tracks and column hooks are free.
- Remove adaptor pads and extension pads, move beams to centre of tracks.
- Engage interlock pins at both ends.
- Ensure floor area beneath hoist is clear, disengage column hooks, lower hoist to floor.
- Check driveway, drive vehicle off.
Maintenance Features
Monthly Maintenance:
- Fully lower hoist, check oil level (top up with ISO viscosity Grade 32 hydraulic oil if low).
- Wipe cables clean with solvent-soaked cloth, check for frayed ends/damage. Lubricate with cable grease or SAE 140 oil. Adjust cables if necessary (tight enough to prevent clutches from operating when fully lowered, but not so tight as to prevent crossmembers resting on column base plates).
- Check safety clutches in crossmembers for damage and correct operation. Check column hooks for proper operation. Adjust if necessary.
- For wheels-free systems, clean U-brackets, check column hooks and crossmember interlock pins for proper operation. Adjust if necessary.
- Lubricate clutch rods, clutch actuator pulley axle and pivot, ramp rollers and pivots, column hook pivots, and wheels-free interlock pins with SAE 140 oil.
- Check airline lubricator is filled with oil and filter bowl is empty.
Yearly Maintenance:
- Thoroughly inspect cables over their full length as per wire rope inspection guidelines.
- Check all cable pulleys for true running and excessive wear.
- If hydraulic oil is discoloured, drain reservoir and refill with ISO viscosity Grade 32 hydraulic oil.
- Check all nuts and bolts for tightness.
Service and Repairs (Wire rope inspection):
- Inspect full length of each wire rope without removal. Look for crushing, deforming, kinking, corrosion, excess wear, or more than 15 broken wires in any 90 mm (3.5 in.) length.
- Clean and inspect cables at full lower, 1 meter raised, and full height positions.
- If any single wire rope needs replacing, the complete set should be replaced.
Service and Repairs (Wire rope replacement):
- Remove covers from crossmembers and columns.
- Raise hoist approximately 1.5 m, engage column hooks and interlock pins, lower hoist onto hooks.
- Switch off and lock isolator switch.
- Remove cable retainer nuts and adjusting nuts.
- Remove axles and pulleys from power track, supporting cylinder.
- Remove cable retaining plates and cables from cylinder anchor plate.
- Pull cables out of columns.
- Feed new cables through columns, around crossmember pulleys, and into power track.
- Refit cables to anchor plate and retaining plates.
- Refit track pulleys, spacers, thrust washers, and cylinder, nesting cables in grooves. Refit axles.
- Fit cable adjusting nuts.
- Check cables are not twisted or crossed over and run in grooves.
- Switch on isolator, raise hoist to unload hooks, check clutches are not engaged. Tighten cables.
- Refit cable retainer nuts, button head cap screws, and shake proof washers.
- Lower hoist to floor, checking clutches do not engage.
- With down switch held on, adjust cables until crossmembers just start to lift off column base plate. Lock adjusting nuts.
- Place heaviest vehicle on hoist, raise and lower several times. Check hoist is level and clutches do not engage. Tension cables if necessary.
- Lubricate cables, clutch rods, and clutch actuator pulleys. Refit crossmember and column covers.
Service and Repairs (Cylinder removal):
- Required if oil leaks from breather or piston rod.
- Raise hoist to comfortable height, engage hooks and interlock pins, lower onto hooks.
- Switch off and lock isolator switch.
- Disconnect hydraulic hose, catch oil. Remove cable ties.
- Extend cylinder to drain oil. Slide anchor plate to expose spanner flats, remove Nyloc nut and anchor plate.
- Remove axle holding cylinder and pulleys. Support cylinder.
- Wrap cylinder rod thread with masking tape. Undo gland, slide off rod, extract rod carefully.
- Examine and renew defective seals. Check piston rod and cylinder walls for scoring/flaking. Clean all parts.
- Reassemble in reverse order, ensuring cleanliness. Lightly oil seals.
- Tighten Nyloc nut to 105 Nm. Check cables are not twisted.
- Switch on isolator, raise and lower hoist several times to expel air. Top up reservoir. Check for leaks.
Service and Repairs (Hydraulic pump removal):
- Pressure relief, check, and solenoid valves are accessible without removing reservoir.
- Lower hoist fully. Switch off and lock isolator switch.
- Undo four screws holding reservoir top to main body, remove reservoir.
- Pump is now accessible for cleaning/repair.
- Reassemble in reverse, ensuring cleanliness.
- Switch on isolator, raise and lower hoist several times to expel air and ensure proper operation. Check oil level.
Service and Repairs (Hydraulic hose replacement):
- Flow control valve at cylinder prevents hoist from falling if hose bursts.
- Option (a) (Urgent vehicle removal): Disengage column hooks, lower hoist to floor (if possible), catch oil. Remove vehicle. Jack hoist to access hose under power track. Place supports. Clean oil.
- Option (b) (No urgent vehicle removal): Engage column hooks and interlock pins, lower hoist onto hooks. Check engagement. Clean oil.
- With hoist securely supported, switch off and lock isolator switch.
- Disconnect hose at both ends by undoing swivel nuts. Cut cable ties, remove clamp bracket, hose, and plastic sleeve.
- Remove reducing bush, flow control valve, sleeve, and bracket from burst hose. Fit to new hose. Apply thread sealant to 1/4" BSP male end, fit and tighten reducing bush.
- Feed hose back into track.
- Connect column end of hose and tighten. Connect cylinder end, ensuring hose is not twisted.
- Check hose hangs straight down beside column and does not rub.
- Position plastic sleeve to protect hose from track edges. Refit cable ties and clamp bracket.
- Switch on isolator, raise hoist off supports. Raise and lower several times to expel air, top up reservoir.
Fault Diagnosis:
- Motor will not run: No power, thermal overload tripped, top limit switch damaged, loose wiring, contactor faulty, raise switch faulty, motor faulty.
- Motor runs but hoist will not lift: Lack of oil, hoist overloaded, wrong motor direction, solenoid valve stuck open, relief valve stuck open, burst hose, motor-pump coupling failure.
- Hoist squeaks when operating: Dry clutch rods/pulleys, failed cable pulley bearing.
- Hoist creeps down under load: Dirt under solenoid/check/relief valve seat, leaking cylinder seal, leak in pipework.
- Safety clutches operate when hoist is fully lowered to floor: Hoist on obstruction, cables stretched.
- Hoist motor will not stop at full height: Cables stretched, lack of oil, limit switch arm loose, limit switch faulty.
- Hoist will not lower: Burst hose, clutches engaged, failed cable, solenoid valve not opening, no power, solenoid faulty, lower switch faulty, loose wiring.
- Column hook will not engage freely: Pivot dry/corroded, spring broken, air cylinder seized.
- Column hooks will not disengage: No air pressure, air line leak, air line kinked, air cylinder seal leaking, air cylinder head seized.
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