Atlas PV-12PX Installation & Operation Manual

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Read this entire manual before operation begins.
Record below the following information which is located on the serial number data plate.
Serial No. Model No. Date of Installation
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Contents
Installation Requirements . . . . . . . 6
Installation Steps . . . . . . . . . . . 8
Exploded View . . . . . . . . . . . .34
Test Run . . . . . . . . . . . . . . .38
Operation Instructions. . . . . . . . .40
Maintenance Schedule. . . . . . . . .41
Trouble Shooting . . . . . . . . . . .42
Parts List For Model PV-12PX. . . . . .43
Warranty . . . . . . . . . . . . . . .49
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Speci cations
Clear-Floor Direct-Drive Model Features
Model PV-12PX Features
• Direct drive design, minimizes the lift wear parts and breakdown ratio
• Dual hydraulic cylinders designed and made on ANSI standards utilizing NOK oil seals in the cylinders
• Self lubricating UHMW Polyethylene sliders and bronze bushings
• Single point safety release with dual safety design
• Clear fl oor design provides unobstructed fl oor use
• Overhead safety shut off device prevents vehicle damage
• Standard adjustable heights accommodates variety ceiling heights
Specifications 4
Fig. 1
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PV-12PX Specifi cation Chart
Model Style
PV-
12PX
Clear-
Floor
Direct-
Drive
Lifting
Capacity
5.5 T
12,000
lbs
Lifting
Time
55S
Lifting Height Overall Height
1842-2071mm
72 1/2”–81 1/2”
3812/4192/4497mm
150”/165”/177”
Overall
Width
3829mm 150 3/4”
Between Columns
Arm Swings View For Model PV-12PX
58 in
Width
3137mm 123 1/2”
Minimum
Pad Height
for stackable
adapter
115mm
4 1/2”
Motor
2.0 HP
38 in
38 in
58 in
109-3/4 in
150-3/4 in
Fig. 2
Specifications 5
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Installation Requirements
Tools Required
Rotary Hammer Drill (3/4in bit) Carpenter’s Chalk
Hammer Screw Drivers
4 Foot Level Tape Measure (25ft)
Crescent Wrench (12”) Pliers
Ratchet & Socket (28mm) Allen Head Wrench (3mm, 5mm, 8mm)
Wrench set (mm)
(10#, 13#, 14#, 15#, 17#, 19#, 24#, 27#, 30#)
Vise Grips
Fig. 3
Installation Requirements 6
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Concrete Specifi cations
Concrete specifi cations must be followed accordingly. Failure to do so may result in lift and/or vehicle falling.
1. Concrete must be 6 inches minimum and must be totally cured before lift installation.
2. Concrete must be in good condition and must have a test strength 3,500psi minimum.
3. Floors must be level and no cracks.
36
6”
Concrete strength 3,500psi
6”
Fig. 4
Power Supply
220 volt single phase 30 amp breaker with minimum of 10 gauge wire. Voltage range 208v – 230V
Installation Requirements 7
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Installation Steps
A. Installation Location - Double check the installation site (concrete, layout, space size etc.) for the lift installation.
B. Use a carpenter’s chalk line to establish installation layout for the base plates.
Fig. 5
Installation Steps 8
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C. Check the parts before assembly.
1. Packaged lift, hydraulic power unit and parts box.
Fig. 6
2. Move the lift aside with a fork lift or hoist, and open the outer packing carefully.
Top Connection
Shipment
Assembly
Parts list
Fig. 7
3. Remove the top connection assembly.
Fig. 8
Nameplate
Installation Steps 9
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4. Lift the upper column with a fork lift or hoist. Loosen the bolts on the upper package stand. Remove off the upper outer column. Remove the parts in the inner column.
Fig. 9
5. Lift the lower column with a fork lift or hoist. Remove the package stand. Remove the lower column. Remove the parts in the inner column.
Installation Steps 10
Fig. 10
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6. Move aside the parts and check the parts according to the shipment parts list.
Fig. 11
7. Open the carton of parts and check the parts according to parts box list.
Fig. 12
Installation Steps 11
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8. Check the parts in parts bag 1# according to parts bag list.
Fig. 13
9. Check the parts in parts bag 2# according to parts bag list.
Installation Steps 12
Fig. 14
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D. Install the hydraulic hose and lock release cable brackets on the extension columns.
Use M6 x 20 Hex Bolts with
M6 Nylock Nut & M6 Washer
Installation Steps 13
Fig. 15
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E. Install hydraulic cylinders
Connect the extended straight fi tting and 90° fi tting. Install the cylinders through the carriages.
Off side column
Power side column
Use Tefl on tape to seal pipe threads.
Do not use tefl on tape on hydraulic hose ends.
Installation Steps 14
Fitting towards the hole of the column
Fig. 16
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F. Install columns (Use M12 x 30 Hex Bolt,
Nylock Nut & Washer to install extensions)
Lay down the two columns on the installation site parallel of each other. Position the power side column according to the actual installation site. This lift is designed with 2 sectional columns. Adjust the height according to your ceiling height.
1. When the ceiling height is over 4500mm (177 1/8”), connect the outer columns to the lower holes.
Installation Steps 15
Fig. 17 High Setting
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2. When the ceiling height is over 4200mm (165 3/8”) but less than 4500mm (177 1/8”), connect the outer columns to the middle holes.
Installation Steps 16
Fig. 18 Low Setting
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3. When the ceiling height is less than 4200mm (165 3/8”), connect the outer columns to the upper holes. The cables are a special order option for the
extra low setting.
Installation Steps 17
Fig. 19 Special low Setting
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G. Position columns
1. Position the columns so the base plates line up with the chalk line. It is recommended to install the power side column on the passenger side of the vehicle. Meanwhile, assemble the overhead top beam. Spread the columns to approximately 122-5/8” from inside column to inside column. Install the overhead top beam.
2. Level and plumb the columns and shim where necessary.
3. Drill 3/4” holes. If the top of the anchor exceeds 2 inches above the oor grade, you DO NOT have enough embedment. Tighten the anchor bolts between 60 and 86 foot pounds.
Adjusting with
the shims
37
Width between
columns: 122-5/8”
Drilling
Installation Steps 18
Overall width: 150-3/4 in
Cleaning
Bolting
Fig. 20
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H. Install overhead top beam
1. With help of the hooks on the top beam, hang the top beam on top of the extension columns and connect the top beam to the extension columns with bolts, tighten the bolts.
Hook on to the
extension columns
Use M12 x 30 Hex
Bolts with M12 Nylock
Nuts and Washers
Tighten the bolts
Installation Steps 19
Fig. 21
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2. Assemble the over head top beam; tighten the anchor bolts.
Use M12 x 30 Hex Bolts with
M12 Nylock Nuts
and Washers
Fig. 22
Installation Steps 20
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I. Install the limit control bar and limit switch.
65
Use M12 x 30 Hex Bolts with
M12 Nylock Nuts and Washers
to install control bar brackets
Loosen Screw on Drive
Rod for adjustment,
Tighten the screw
after adjustment
Adjust Drive Rod
of Limit Switch
Fig. 23
Limit Switch
connected
with Cable
NC: Normal
contact
Installation Steps 21
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J. Install safety device.
145° Spring
Fig. 24 Power side safety device
Use M10 x 10
Allen Head
Set Screw
145° Spring
120° Spring
Use M10 x 20 Hex
Head Bolts to secure
Fig. 25 Offside safety device
the pulley bracket
Installation Steps 22
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K. Lift the carriages up by hand and lock them at the same level.
Installation Steps 23
Fig. 26
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L. Install cables
1. High setting cable connection, suitable for ceiling height over 4500mm (177 -1/8”).
1.1 Take out the carriages’ plastic covers, cable passes through from the bottom of the carriages and pulled out from the openings of the carriages, then screw the two cable nuts.
Cable
connecting
direction
Installation Steps 24
Fig. 27
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Cable
connecting
direction
Page 25
1.2 Connecting the cable for high setting.
High Setting
Cable 2
Cable 1
Cable 2
95 96
94
Fig. 28
Installation Steps 25
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2. Low setting cable connection, suitable for ceiling heights between 4200mm (165 3/8”) to 4500mm (177 1/8”).
Low Setting
Cable 2
Cable 1
Cable 2
Installation Steps 26
Fig. 29
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3. Special low setting cable connection, suitable for ceiling height less than 4200mm (165 3/8”), for this setting use with the optional short cable.
Special Low
Setting
Cable 2
Cable 1
Cable 2
96 99
94
Fig. 30
Installation Steps 27
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M. Install power unit.
Use M8 x 25 Hex Bolts
with M8 Nuts & Washers
Installation Steps 28
Fig. 31
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N. Install oil hoses.
1. At high setting and low setting oil hose connection.
2. Special low setting oil hose connection.
Limit switch
Oil hose
Oil hose passes
through the
retainer on top of
the overhead beam
Oil hose
connected
with 90°
tting
Installation Steps 29
Oil hose
connected with
90° fi tting
Fig. 32/33
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O. Install safety cable.
Install the safety cable from the off side safety assembly to the power side safety assembly.
Safety cable
Safety cable
passes through
small pulley
bracket
Install
safety cable
from offside
safety
assembly.
Safety cable
connected
with the
power
side safety
Fig. 34
assembly.
Installation Steps 30
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P. Install hose retainers.
Install oil hose retainers using M6 x 8 screws
Car in
direction
Fig. 35
Installation Steps 31
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Q. Install the lifting arms.
Lower the carriages down to the lowest position, then use the 8mm Allen head wrench to loosen the socket bolt (See Fig.37). Adjust arm lock as direction of arrow (See Fig.38). Adjust the moon gear and arm lock so they mesh, then tighten the Allen bolts on the arm lock (See Fig.39).
Loosen the Allen Bolt
Moon
Gear
Arm lock
Use the 8mm
Allen Head
Wrench to loosen the
Snap Ring
Allen Bolt
Fig. 36 Fig. 37
Tighten the bolts
Tighten the bolts
after the moon
gear and arm
lock engage
Fig. 38 Fig. 39
Installation Steps 32
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Install Electrical System
Connect the power source according to the data plate on the Power Unit.
Remove the short “Pig Tail” wire connected to the AC contactor terminals. This wire was used to test the motor after production.
ATLAS Single phase motor
Four Terminal Relay
1) Motor Lead a) M1 to “YELLOW” b) M2 to “BLUE”
2) Incoming Power a) One hot to L1 b) One hot to L2 c ) Ground to ground
3) Limit Switch a) Cut wire from terminal #5 to
the micro switch
b) With cut wire use both limit switch leads to make pigtails
Installation Steps 33
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Exploded View
Model PV-12PX
Exploded View 34
Fig. 48
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Cylinders
Exploded View 35
Fig. 49
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Atlas Manual Power Unit
220V/60HZ, Single Phase
Exploded View 36
Fig. 50
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Illustration Of Atlas Hydraulic Power Unit
ATLAS manual power unit, 220V/60HZ, Single phase
Fig. 51
Exploded View 37
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1. Adjust equalizing cables
Test Run
Use a wrench and hold the cable fi tting, meanwhile use a wrench to tighten the cable nut. Make sure the two cables have the same tension and the two carriages lift at the time. Replace the plastic cover on the lifting head.
2. Adjust safety lock cable
Lift the carriages and lock at the same height, pull the safety cable and then release a little, and then tighten the cable nuts. Make sure the safety locks click at the same time.
3. Bleeding the cylinders
Lift the carriages to about 12 inches and loosen the bleeding plugs, Lower the lift until hydraulic fl uid seeps from the tops of the cylinders, Tighten the plugs.
Fig. 53
Cable nut
Lock nut
Bleeding
plug
Test Run 38
Fig. 54
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4. Adjust the lower speed (Only for PEAK power unit) (Adjust with a
load on the lift)
You can adjust the lowering speed of the lift if necessary: Loosen the locking nut on the throttle valve, and then turn the throttle valve clockwise to decrease the lowering speed, or counterclockwise to increase the lowering speed. Do not forget to tighten the locking nut after the lower speed adjustment has been completed.
Throttle Valve
Lock Nut
Clockwise to
decrease the
down speed
Fig. 55
Counterclockwise
to increase the
down speed
5. Test with load
After fi nishing the above adjustment, test run the lift with a load. Run the lift in low position several times, make sure the carriages lift and lower at the same time, the safety lock device should click at the same time. Test run the lift to the top.
NOTE: If the lift vibrates while going up, lubricate all pulleys, pins and wear blocks. If the lift vibrates on the way down, bleed the cylinders.
Test Run 39
Fig. 56 Hydraulic System
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Operation Instructions
Please read the safety tips carefully before operating the lift To lift vehicle
1. Be sure there are no obstructions near the lift area;
2. Position lift arms to the lowest position;
3. Open lift arms;
4. Position vehicle between columns;
5. Move arms to the vehicle’s lifting point;
Note: The four lift arms must make contact at the same time on the vehicle’s lifting points and both axles must rise off of the ground at the same time.
6. Press the UP button until the lift pads contact underside of vehicle. Check to
make sure vehicle is secure;
7. Continue to raise the lift to the desired working height, ensuring the balance
of the vehicle;
8. Push lowering handle to lower lift onto the nearest safety lock. The vehicle is
ready to repair. Note: The lift must always be on the safety locks!!!!!
To lower vehicle
1. Be sure there are no obstructions near the lift area;
2. Press the button of UP to raise the vehicle slightly, and then release the
safety device, lower vehicle by pushing the lowering handle.
3. Open the arms and position them to the shortest length;
4. Drive the vehicle away.
Operation Instructions 40
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Maintenance Schedule
Monthly:
1. Re-torque the anchor bolts to 65-86 Ft Lbs;
2. Check all connectors, bolts, pulleys and pins;
3. Lubricate cable with lubricant;
4. Make a visual inspection of all hydraulic hoses/lines for possible wear or
leakage;
5. Check the condition of the safety lock device;
6. Lubricate all rollers and pins with 90wt. Gear oil or equivalent;
Note: All anchor bolts should take full torque. If any of the anchors do not tighten, DO NOT use the lift until the bolt has been replaced.
Every six months:
1. Make a visual inspection of all moving parts for possible wear, interference or
damage.
2. Check and adjust the equalization tension on the cables for level lifting.
3. Check the columns for plumb.
4. Check rubber pads and replace as necessary.
5. Check safety lock device and make sure they are in condition.
Maintenance Schedule 41
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Trouble Shooting
TROUBLE CAUSE REMEDY
Motor does not run
Motor runs but the lift is not raised
Lift does not stay up
1. Button does not work
2. Wiring connections are not in good condition
3. Motor burned out
4. Height limit switch is damaged
5. AC contactor burned out
1. Motor runs in reverse rotation
2. Gear pump out of operation
3. Release valve in damage
4. Relief valv e or check valve in damage
5. Low oil level
1. Release valve has debris in it
2. Relief valve or check valve leakage
3. Cylinder or fi ttings leak
1. Replace button
2.Repair all wiring connections
3. Repair or replace motor
4.Replace the limit switch
5. Replace AC contactor
1.Reverse the two power wires
2.Repair or replace
3. Repair or replace
4.Repair or replace
5.Fill tank
Repair or replace
1. Oil line is has an obstruction
2. Motor running on low voltage
Lift raises slowly
Lift can not lower
Trouble Shooting 42
3. Oil mixed with air
4. Gear pump leaks
5. Overload lifting
1. Safety lock device are activated
2. Release valve has debris in it
3. Safety cable broken
4. Oil system has an obstruction
1. Clean the oil line
2. Check electrical system
3. Fill tank
4. Replace pump
5. Check load
1. Release the safeties
2. Repair or replace
3. Replace
4. Clean the oil system
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Parts List For Model PV-12PX
Item Part# Description Qty. Note
1 217001B Power side column 1 203 209002A Power unit 1 3 209003 Bolt 4 4 209033 Lock washer 4 5 209005 Self locking Nut 4 6 217003 Power side lock cover 1 7 217004 Main cam lock 1 8 217069 Hex Bolt 34 9 206006 Washer 35 10 206023 Self locking nut 34 11 420018 Self locking nut 8 12 217013 Hex Bolt 8 13 420045 Washer 30 14 61K074 Protective ring 2 15 217015B Right overhead bar 1 16 217016B Left overhead bar 1 17 420044 Pin stop 2 18 209149 Washer 4 19 420138 Socket Bolt 4 20 217019 Top pulley 4 21 217020 Bronze bush for pulley 6 22 217021 Top pulley spacer 4 23 217022 Pin 2 24 217023 Pin spacer 2 25 217024 Hose support 2 26 206009 Plastic small pulley 3 27 209056 Self locking nut 3
Parts List For Model PV-12PX 43
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Item Part# Description Qty. Note
28 209046 Hex Bolt 3 29 217026 Safety cable bracket 2 30 217027B Extension column 2 31 217028 Offside lock cover 1 32 217034B Offside column 1 33 209051B Adapter 1.5” 4 34 209052B Adapter 2.5” 4 35 209053B Adapter 5” 4 36 207045 Anchor bolt 12 37 620065 Shim 10 38 217114A Rubber pad assy. 4 38A 420138 Socket bolt 4 38B 209134 Rubber Pad 4 38C 680030B Rubber Pad frame 4 39 217036 Bottom pulley 2 40 217037 Bottom pin 2 41 209038 Hex Bolt 6 42 217047B Arm pin 4 42A 520023 43 209039 44 209022 45 206049
Snap ring Lock washer Washer Moon gear
4 18 18
4 46 217052C Lifting arm 4 46A 217120 Outer arm 4 46B 217121A Inner arm 4 47 206048 Socket bolt 12 48 206032 Snap clip 4 49 640109 Washer 8 50 206036 Roll pin 4 51 217044 Arm lock 4
Parts List For Model PV-12PX 44
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Item Part# Description Qty. Note
52 217045A Spring 4 53 217046C Left arm lock bar 2 54 217046B Right arm lock bar 2 55 209019 Flat head screw 12 56 217053 Rubber pad 2 57 209009 Cup head bolt 28 58 217054 Carriage plastic cover 2 59 217196 Carriage 2 60 217188 Slider block 16 61 217056A Cylinder 2 62 217173 Wire cable 1 63 206025A Foam Cushion 1 64 206129 Limit bar 1 65 201005 Split Pin 2 66 206025C Limit bar link 2 67 206013 Limit switch 1 68 206011 Cup head bolt 2 69 206042 Limit bar bracket 2 70 420026 Lock washer 1 71 206023A Hex Nut 1 72 217005 Plastic ball 1 73 217006 Lock handle 1 74 217007 Large spacer 2 75 217030 Main spring 2 76 217009 Main lock 2 77 217010 Hex Bolt 1 78 217011 Hex Nut 1 79 217012 Small spacer 2 80 217050 Main lock pin 2 81 217051 Socket bolt 2
Parts List For Model PV-12PX 45
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Item Part# Description Qty. Note
82 217066 Hex Bolt 2 83 217008 Torsion spring 1 84 217031 Cam lock 1 85 217033 Self locking nut 1 86 217032 Cable lock hold 1 87 217029 Small pulley bracket 1 88 217222 Oil hose 2 89 209060 90 for power unit 1 90 217223 Oil hose 1 91 207035 Extend straight fi tting 2 91A 217221 straight fi tting 2 92 420097 90 Fitting 2 93 217191 Retainer 12 94 420029 Cable nut washer 4 95 209066 Cable nut 8 96 217063B Cable with nut 2 97 217064B Safety cable 1 98 217068 Column connecting plate 2 101 201090 Shim 10 102 211016 T-fi tting 1 103 217501B Parts box 1
For optional short cable and hose
99 217112 Short cable 2
Parts For Hydraulic Cylinder
61-1 209069 O-Ring 2 61-2 209070 Bleeding Plug 2 61-3 209071 Support Ring 2 61-4 209072 Y-Ring 2 61-5 209073 O-Ring 2 61-6 209074 Piston 2
Parts List For Model PV-12PX 46
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Item Part# Description Qty. Note
61-7 209075 O-Ring 2 61-8 217089 Piston rod 2 61-9 217077 Piston rod fi tting 2 61-10 209078 Dust ring 2 61-11 209079A Head cap 2 61-12 217080A O-Ring 2 61-13 217090 Bore Weldment 2
Parts List For Model PV-12PX 47
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Parts For ATLAS Manual Power Unit, 220V/60Hz, Single phase
201-1 81400032 Motor 1 201-2 81400159 Protective Ring 1 201-3 81400063 Motor Connecting Shaft 1 201-4 81400031 Valve Body 1 201-5 81400160 Relief Valve 1 201-6 81400161 Lock Washer 4 201-7 81400162 Socket Bolt 4 201-8 81400121 Inlet Pipe 1 201-9 81400163 O-Ring 1 201-10 81400164 Filter 1 201-11 81400165 Hex bolt 4 201-12 81400093 Reservoir 1 201-13 81400166 Cross Bolt 2 201-14 81400167 Cover of Capacitor 1 201-15 81400087 Capacitor 1 201-16 81400168 Rubber Gasket 1 201-17 81400169 Hex bolt 1 201-18 81400062 Cover of Motor Terminal Box 1 201-19 81400028 Push Button 1 201-20 81400105 Release Valve 1 201-21 81400033 Handle For Release Valve 1 201-22 81400170 Washer 1 201-23 81400171 Hex Nut 1 201-24 81400043 Check Valve 1 201-25 81400133 Gear Pump 1 201-26 81400122 Oil Return Pipe 1 201-27 81400172 Filler Cap 1 203-27 209105A Check valve 1 203-28 440025 Gear pump 1 203-29 440026 Oil return pipe 1 203-30 440027 Filler cap 1
Parts List For Model PV-12PX 48
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Warranty
This item is warranted for ve (5) years on structural
components, two (2) years on hydraulic cylinders, and one (1) year on electric or air / hydraulic power units from invoice date. Wear items are covered by a 90 day warranty.
This LIMITED warranty policy does not include a labor warranty.
NOTE: ALL WARRANTY CLAIMS MUST BE PRE-APPROVED BY THE MANUFACTURER TO BE VALID.
The Manufacturer shall repair or replace at their option for this period those parts returned to the factory freight prepaid, which prove after inspection to be defective. This warranty will not apply unless the product is installed, used and maintained in accordance with the Manufacturers installation, operation and maintenance instructions.
This warranty applies to the ORIGINAL purchaser only, and is non-transferable. The warranty covers the products to be free of defects in material and workmanship but, does not cover normal maintenance or adjustments, damage or malfunction caused by: improper handling, installation, abuse, misuse, negligence, carelessness of operation or normal wear and tear. In addition, this warranty does not cover equipment when repairs or alterations have been made or attempted to the Manufacturer’s products.
THIS WARRANTY IS EXCLUSIVE AND IS LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OR MERCHANTABILITY OR ANY IMPLIED WARRANTY OF FITNESS FROM A PARTICULAR PURPOSE, AND ALL SUCH IMPLIED WARRANTIES ARE EXPRESSLY EXCLUDED.
THE REMEDIES DESCRIBED ARE EXCLUSIVE AND IN NO EVENT SHALL THE MANUFACTURER, NOR ANY SALES AGENT OR OTHER COMPANY AFFILIATED WITH IT OR THEM, BE LIABLE FOR SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGES FOR THE BREACH OF OR DELAY IN PERFORMANCE OF THIS WARRANTY. THIS INCLUDES, BUT IS NOT LIMITED TO, LOSS OF PROFIT, RENTAL OR SUBSTITUTE EQUIPMENT OR OTHER COMMERCIAL LOSS.
PRICES: Prices and specifi cations are subject to change without notice. All orders will be invoiced at prices prevailing at time of shipment. Prices do not include any local, state or federal taxes.
RETURNS: Products may not be returned without prior written approval from the Manufacturer. DUE TO THE COMPETITIVENESS OF THE SELLING PRICE OF THESE LIFTS, THIS WARRANTY POLICY
WILL BE STRICTLY ADMINISTERED AND ADHERED TO.
Warranty 49
PV-12P
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