TW 125 M Ultra/ TW 125 F 1-post-lift

Transcription

1 TW 125 M Ultra/ TW 125 F 1-post-lift Lifting capacity: 2500 kg INSTALLATION, OPERATION AND MAINTENANCE MANUAL Read this entire manual carefully and completely before installation or operation of the lift. Follow the instructions strictly TWIN BUSCH GmbH Amperestr. 1 D Bensheim Tel.: Fax: info@twinbusch.de

2 INHALT 1. Structure Drawing Structure Drawing 1.2 Illustration 2. Main Technical Parameters Table 5 3. Overall Dimension Model TW 125 M Ultra / Overall Dimension 3.2 Model TW 125 F / Overall Dimension 4. Electrical Schematic Diagram 8 5. Hydraulik Schematic Diagram 9 6. Warning/Warning Signs Warning 6.2 Warning Signs 6.3 Safety Protection Devices 7. Installation and Commissioning Working Site 7.2 Installation 8. Operation Rules Operation Rules for Mechanical System 8.2 Operating Steps for Electrical Control System 8.3 Operation Flow Chart 8.4 Use of Lifting Arm 9. Maintenance and Troubleshooting Maintenance 9.2 Troubleshooting 10. Disposal at the end of working oil tank Disposal of waste oil tank 10.2 Disposal of material of machine 11. Exploded View Druckfehler, Irrtümer und technische Änderungen vorbehalten. 2

3 This single column vehicle lifter is classified as movable model and stable model. Movable single column vehicle lifter is special useful for indoor and outdoor grounds, and stable single column vehicle lifter is appropriate for relatively narrow and little site indoor. Both of them are the special equipments for lifting vehicles, such as cars, which park on ground, to a certain height for maintenance. 1. Structure Drawing Illustration 1. Vertical post 2. Load chain 3. Hydraulic cylinder 4. Electrical 5. Pressure bar 6. Hauling handle 7. Hydraulic movable wheel 8. Safety tongue 9. Trolley 10. Safety tongue handle 11. Main lifting arm 12. Locking wrench 13. Base 14. Truckle Druckfehler, Irrtümer und technische Änderungen vorbehalten. 3

4 15. Safety plate 16. Limit switch 17. Vertically movable telescopic arm 18. Horizontally movable telescopic arm 19. Swing supporting arm 20. Telescopic arm 21. Adjustment pallet Druckfehler, Irrtümer und technische Änderungen vorbehalten. 4

5 2. Main Technical Parameters Table Model Name TW 125 M Ultra (Movable) TW 125 F (Stable) Lifting capacity 2500 kg 2500 kg Oil pressure 11,5Mpa 11,5Mpa Max. lifting height 1950 mm 1950 mm Lifed vehicle width 1800 mm 1800 mm Lifting speed 40mm/s 40mm/s Motor power 2.2 kw 2.2 kw Voltage 380V/400V/415V/220V/230V Three-phase, single-phase 380V/400V/415V/220V/230V Three-phase, single-phase Frequency 50Hz/60 Hz 50Hz/60 Hz Oil pressure 115 bar 115 bar Approx. Single post mass 720 kg 720 kg Noise <60 db <60 db Overall dimension 2470x2030x2600 mm 2060x2030x2600 mm Insulation grade of electrical box IP 64 IP 64 Working environment temperature -5 C/+40 C -5 C/+40 C Working environment Both indoors and outdoors Indoors Druckfehler, Irrtümer und technische Änderungen vorbehalten. 5

6 3. Overall Dimension 3.1 Model TW 125 M Ultra / Overall Dimension Druckfehler, Irrtümer und technische Änderungen vorbehalten. 6

7 3.2 Model TW 125 F / Overall Dimension Druckfehler, Irrtümer und technische Änderungen vorbehalten. 7

8 4. Electrical Schematic Diagram 3-phase 1-phase Druckfehler, Irrtümer und technische Änderungen vorbehalten. 8

9 5. Hydraulik Schematic Diagram 1. Cylinder 2. Pressure relief valve 3. Electrical pump Druckfehler, Irrtümer und technische Änderungen vorbehalten. 9

10 6. Warning/Warning Signs Read this chapter carefully for safe operation, maintenance and repair to avoid accidents. 6.1 Warning 1. This lift must not be used out if doors if there is more than a very light wind, maximum 3km/hour windspeed. 2. Do not lift the vehicle with vertical posts moving! 3. Do not move vertical posts at random when the vehicle is lifted. 4. The lifter must only be operated after the vehicle turns off. 5. The lifter can only be started if the pallet on the supporting arm is placed stably onto the catch point under the vehicle base, there is no foreign substance under the bases of vertical post, and wheels in bases of the movable base have been in position (and been released with pressure). 6. Do not allow anyone to enter into working area during lifting. 7. Neither standing nor putting any other articles (including gasoline and acid base chemicals) on the supporting arm is allowed. 8. The lifter should not be used as a forklift. 9. All cables should be free of pressure from heavy objects, vertical posts or vehicles. 10. Electric cabinets and cables should be free from water to avoid serious accidents. 11. It is forbidden to lift vehicles with weight exceeding the specified Warning Signs! Attached on the fork. Standing on the forklift forbidden. No goods on it. Attached on the electric cabinet. High voltage! Take care! The manufacturer shall assume no responsibility for serious accidents and damages to persons or other equipment caused by using lifter for other purposes besides lifting specified vehicles. It is necessary to follow rules about use, maintenance and caution described in this manual. 6.3 Safety Protection Devices For the safety of operator and safe use, mechanical and electrical system is designed with consideration of safety protections: Electrical system 1. If the lifter is lifted over the limit, it shall stop automatically because of no upper limit switch; if lowered to the lowest position, cylinder shall reach the lowest position. 2. AC 220v power is applied to the electrical control circuit. Druckfehler, Irrtümer und technische Änderungen vorbehalten. 10

11 7. Installation and Commissioning 7.1 Working site The user should prepare the working site for the lifter before its arrival (movable lifters may be operated outdoors in a sunny day, but it is strongly recommended by the manufacturer to operate the machine indoors for the favorable performance of electrically driving units and electric control system) Power Source The working site must be equipped with three-phase power (220v, 380v, 400v, 415v). Install safe distribution box with a 4-hole socket around the operation position, which also is used for single-phase power Ground The lifter must be placed on flat and hard ground which is made of cement or bricks with the load of vertical post position of 3t/m Working Area There should be >about 1,000 mm space around the vehicle lifted, and the net height indoor is about 3600 mm. 7.2 Installation Because of the limitation of transportation, lifter shall be disassembled to pack. The users should assemble the lifter according to the following figures: Assemble movable single column lifter Overall assembly as follows: Druckfehler, Irrtümer und technische Änderungen vorbehalten. 11

12 7.2.2 Connect lines of limit switch Connect the two-wire outgoing line from limit switch inside of the post to clamp 2 and 3 in the control box, as shown in the following picture: Power supply lines to motor Clamp for limit switch Connect power line Replace the two red test wires against the two black power supply lines from the control box, and the connect the protective earth (PE) to the red marked ground (GND). Protective earth (PE) ye/gn Replace two red test wires against black power supply lines. Druckfehler, Irrtümer und technische Änderungen vorbehalten. 12

13 7.2.4 Connect oil pipe After the vertical post is installed on the electrical oil pump, align the oil pipe to the oil outlet hold of electrical oil pump and tighten the screw cap, as the following figure: Oil pipe Fill hydraulic oil (HLP 32) into the oil tank, 80% of 6 liters (1.6 US gal) Install stable single column lifter The ground for installation must be concrete pouring and level without concave or convexity or incline. The thick of concrete pouring shall more than 160mm, as the following figure: Place the base on the ground align the electric hammer with 16 drill bit to the hole on the base to drive into the ground 130m deep. Insert the expansion bolt into the hole and use the hammer to hit it completely and tighten the nut with min. 120 Nm (74 ft-lb). N16 expansion bolt 6 pieces Druckfehler, Irrtümer und technische Änderungen vorbehalten. 13

14 7.2.7 Overall assemble as follows Druckfehler, Irrtümer und technische Änderungen vorbehalten. 14

15 8. Operation Rules 8.1 Operation Rules for Mechanical System The movable single column lifter is provided with separate traveling mechanism. Shake the hauling handle of the steering rear wheel forwards and backwards to make the vertical column off the ground, then you can push or pull the lifter. On arriving the working site, press the valve handle to retract the wheel, then the vertical column lands on the ground steadily The lifter must only be pushed into the vehicle if in line with it. Insert the pallet under the vehicle beam and the pallet must be in line with the beam Retract the rear wheel of vertical post to land the vertical post steadily before the lifter lifts load, and make sure there is no foreign articles such as hand tools, bolts, screw caps, small stones. No lifting during moving! 8.2 Operating Steps for Electrical Control System New machine is operated for commissioning without load before its first use Switch on the power; press the button for 2 to 3 seconds and pay attention to the lifting arm. If it rises, the power phase sequence is correct. Otherwise, the phase sequence of power is not in accordance with that of power network. Adjust the phase sequence of the plug and press the button again, then the lifting arm should rise. 8.3 Operation Flow Chart 1. Vehicle in service position, engine off. 2. Turn the handle of wheel moved by oil pressure to lift the base of vertical post a bit. 3. Push the lifter into the underside of vehicle. 4. Make certain that there is no foreign articles and the ground is level. 5. Grasp the valve handle to make the base of vertical post lowered to the ground. 6. Align 4 pallets on the lifting arm to the supported position on the underside of vehicle. 7. Press the button to make the vehicle be lifted for centimeters. 8. Stop lifting and check for secure four top positions of pallet. 9. Check if the main lifting arm touches the vehicle base plate. In normal lifting, it should not touch the base plate. 10. Press the button to make the lifting arm unlocked. 11. To adjust pallet, turn it anticlockwise to make it rise (adjustment distance of 100mm). 12. Press the button again and pay attention to the lifting arm and the vehicle lifted until the lifting is safe and reliable. 13. Raise the lifter to the required height. 14. After the repair of vehicle is finished, press the button. 15. When the lifter is lowered to the ground, lock device of lifting arm is unlocked automatically (available for stable lifter). 16. Turn the handle of hydraulic pump and the lifter is off the ground, pull out the lifter. 17. Drive the vehicle away. Druckfehler, Irrtümer und technische Änderungen vorbehalten. 15

16 Valve handle Hauling handle The ramps Warning: When using of the ramps, we advise that the vehicle must be lifted as close to the column as possible for maximum strength. Movable lifter pushed into the underside of vehicle. Druckfehler, Irrtümer und technische Änderungen vorbehalten. 16

17 Vehicle driving onto the lifter Wrench for safety tongue Pressure relief handle Schematic diagram of lifter lowering. Druckfehler, Irrtümer und technische Änderungen vorbehalten. 17

18 8.4 Use of Lifting Arm Movable Lifter a. According the position under the vehicle chassis where the lifting arm is located, the supporting arm on the lifting arm (close to the vertical post) may be pushed and pulled up and down or to left and right, as the following figure: b. The supporting arm in the front of lifting arm may be turned or pushed or pulled inward or outward. To turn it, first hold the lock handle, and release it after it goes into the position. Supporting arm Lock handle c. By clockwise and anticlockwise turning, the height of pallet can be adjusted. Druckfehler, Irrtümer und technische Änderungen vorbehalten. 18

19 8.4.2 Stable Lifter a. The supporting arm on the lifting arm (close to the vertical post) may be turned as the following figure. To turn it, first pull the lock handle up and then release it when it goes into the position. It is locked. The lifting arm shall be unlocked automatically when reaching the lowest position. b. The supporting arm in the front of lifting arm moves in the same way as described in c. The height of pallet is as described in Druckfehler, Irrtümer und technische Änderungen vorbehalten. 19

20 9. Maintenance and Troubleshooting 9.1 Maintenance For daily maintenance and service of lifter, see operation steps and cautions described in previous page The working environment and the surface of this machine should be cleaned usually When this machine has been put into use for 6 months, clean hydraulic filter oil tank and replace the oil During the use of this machine, if any oil leakage is found, check the leakage source. If any oil coming out from the neck of cylinder is found, the o-ring installed on the piston has been worn and it must be replaced (its specification is UHS65) Troubleshooting If lifting is impossible: 1) check the power, 2) interchange any two wires of three-phase wire and try lifting again because the phase sequence of power does not conform to the adjusted phase sequence when motor and pump is operating If lifting is possible with no load but impossible with full load of 2.5T, adjust the pressure adjustment screw on the fluid valve as the figure. It is possible to press the Up button while turn the screw (clockwise) slowly (for ), until the lifting arm rises If lifting is still impossible after above actions have been taken, remove pressure relief valve and put it into diesel oil to wash. After that, install it again (N.B. remove it according to the corresponding sequence) If there is any abnormal noise from hydraulic system during lifting, the hydraulic system may inhale air or the oil screen is clogged. Check the oil level and add oil if necessary. Make the cylinder move up and down for several times. In addition, clean or replace oil screen. Druckfehler, Irrtümer und technische Änderungen vorbehalten. 20

21 10. Disposal at the end of working oil tank 10.1 Disposal of waste oil tank Note: Waste oil should be cleared daily. For environmental reasons, do not dump the oil into sewage channel or river. Use a dedicated bucket to collect waste oil and dispose of at professional authorities Disposal of material of machine Note: The mail material of machine is steel, when the machine is at end of it s working life, deal with the products obey the rules or law in local. Mention that oil must be drained and disposed of safely before the steel is scrapped. Druckfehler, Irrtümer und technische Änderungen vorbehalten. 21

22 11. Exploded View 1. Cover 8. Axle pin 2. Limit switch 9. Axle sleeve 3. Terminal box 10. Bar 4. Bolt 11. Bolt 5. Nut 12. Allen head screw 6. Electric pump 13. Shim 7. Hydraulic movable wheel 14. Vertical post Druckfehler, Irrtümer und technische Änderungen vorbehalten. 22

23 15. Roller 21. Leaf chain 27. Chain connector 16. Bearing 22. Chain connector 28. Shim 17. Round nut 23. Round pin 29. Spring washer 18. Wheel frame 24. Cotter pin 30. Nut 19. Pin 25. Nut 31. Hydraulic cylinder 20. Screw 26. Allen head screw Druckfehler, Irrtümer und technische Änderungen vorbehalten. 23

24 32. Loosen 39. Longitudinal arm 46. Pallet 33. Safety tongue 40. Inner telescopic arm 47. Main lifting arm 34. Round pin 41. Outer rotary arm 48. Bolt 35. Handle 42. Pin shaft 49. Gasket 36. Pulley 43. Tooth block 37. Slider 44. Spring 38. Transverse arm 45. Lock handle Druckfehler, Irrtümer und technische Änderungen vorbehalten. 24

25 50. Base 51. Pin shaft 52. Check ring 53. Axle sleeve 54. Bearing 55. Wheel Druckfehler, Irrtümer und technische Änderungen vorbehalten. 25

26 Cylinders Stop Collar O-rings Piston Rod Anti-explosion valve O-rings Cylinders Cover Piston Dustproot-ring Rider ring Cylinders Cover U-rings Rider ring Hexagon Nut Druckfehler, Irrtümer und technische Änderungen vorbehalten. 26

27 Druckfehler, Irrtümer und technische Änderungen vorbehalten. 27