twin busch TW 125 M, TW 125 F, TW 125 M Ultra Installation, Operation And Maintenance Manual

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INDEX

1. Notes and safety notes 4 - 6

1.1 Important note

1.2 Specialist

1.3 Safety notes

1.4 general notes

1.5 Warning notes

1.6 Loudness

1.7 Training

2. Overview 7 - 8

2.1 General description

2.2 Technical data

2.3 Construction of the lift

3. Mounting the Lift 9 - 12

3.1 set the Limit switch

3.2 Power supply

3.3 Oil connection

3.4 TW 125 F

3.5 Checkpoints after the Installation

4. Operating instructions 13

4.1 mechanical instructions

4.2 Electrical instructions

5. Operating 14 - 17

5.1 How to operate

6. Maintenance 18

6.1 Daily check

6.2 Monthly check

6.3 maintenance interval

6.4 Troubleshooting

6.5 General notes

7. Annex 19 - 38

7.1 Technical data sheet

7.2 Dimensions / TW 125 M Ultra flat

7.3 Dimensions / TW 125 F

7.4 Electrical diagram

7.5 Hydraulic diagram

7.6 24V- Electrical diagram

7.7 Spare parts

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1. Notes and Safety notes

1.1 important notes

Neither the manufacturer nor the seller will accept liability for improper installation, improper operation, overloading or unsuitable ground conditions. This model is specifically designed for lifting motor vehicles that do not exceed the approved maximum weight. If the lift is used for other purposes, neither the manufacturer nor the seller will be liable for any accidents or damage. Pay special attention to the permitted maximum weight. A sign with the approved maximum weight is attached to the lift. Never try to drive vehicles that exceed the approved maximum weight lift with the lift. Read the operating instructions carefully before operating the lift in order to avoid damage due to personal negligence.

1.2 Specialist

1.2.1 Only trained person are allowed to use the lift.

1.2.2 Electrical installation has to be done by an electrical specialist.

1.2.3 Costumer or other people are not allowed in the neat of the lift during operation.

1.3 Safety notes

1.3.1 Never move the lift when a vehicle is lifted up.

1.3.2 The engine has to be shot off during the operation.

1.3.3 The lift may only be put into operation if the vehicle is properly aligned. Only lift the vehicle in the place approved by the manufacturer and make sure that the transport mechanism is secured (release the pressure so that the lift rests firmly on the ground). Check the secure locking of the support arm lock and, if necessary, engage it in a renewed manner to ensure that the support arms can´t move.

1.3.4 It is forbidden to use the lifting arms of the lift as a storage area, especially for highly flammable or corrosive liquid.

1.3.5 Never use the Lift like a fork lifter.

1.3.6 All cables must be free of obstacles. Nothing should put pressure on the lines.

1.3.7 The area around the lift has to be free.

1.3.8 Do not use the lift in a washing bay.

1.3.9 It is prohibited to exceed the maximum stated lifting weight, (maximum lifting weight is 2500 kg) or lifting vehicles with more than 2900 mm wheelbase.

1.3.10 never stands on top of the lift or climb on it.

Attention! Any other use of the lift is improper and inappropriate. The manufacturer is not liable for any damage resulting from

using the machine for any purpose other than that stated in this manual.

1.3.11 to protect the operator, this lift is equipped with several safety devices in the electrical and mechanical system.

1.3.12 this lift is made only for lifting up vehicles.

1.3.13 The TW 125 M Ultra flat single-column lift is suitable for outdoor use (in dry weather only) as it is classified as a mobile hoist.

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Read the manual

Only trained person are allowed to use the lift

Repairs and maintenance only by qualified personnel never put safety equipment out of operation!

Keep the working area clear

Always keep escape routes clear!

The presence of persons (when lifting or lowering) under the lift is prohibited!

Watch your feeds

Climbing the lift is strictly prohibited!

Observe the pickup points of the vehicle manufacturer!

After a short lifting, check the vehicle for a secure fit!

1.4 General Description

Working place

TW 125 M Ultra: This lift can also be used outdoors on sunny, dry days with a suitable paved surface. However, it is expressly recommended by the manufacturer to use the lift in closed and dry rooms to protect the electric drives and controls.

Power supply

230 V (standard delivery), 400 V / 3 phases on request.

Working environment

You should ensure at least 1 m of free space around the lifted vehicle and around the lift, and have a ceiling height of at least 3.6 m.

1.5 Safety notes

All warnings are clearly visible on the lift to ensure that the user uses the device in a safe and secure manner. The warnings must be kept clean and replaced if they are damaged or missing. Please read the signs carefully and memorize their meaning for future operations.

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The specified load capacity

When installing or removing heavy parts, the vehicle can tip over! Support the vehicle!

Use only on level ground!

Do not maneuver with the vehicle raised!

Protect the lift from moisture! Electrical connections must be absolutely dry!

Avoid strong shaking on the vehicle!

1.6 Loudness

The emitted noise should not exceed 75 dB.

1.7 Training

Only qualified personnel may operate the lift. If necessary, we offer professional training for users.

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2. Overview

name

1

Vertical Colum

8

Safety components

2

chain

9

Lifting slet

3

Hydraulic cylinder

10

Safety components

4

Motor

11

Main arm

5

Discharge handle

12

Safety handle

6

Handle

13

Base frame

7

Hydraulic wheel

14

wheel

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name

15

Safety rack

19

Lifting arm

16

Limit switch

20

Extension arm

17

Extension arm

21

plate

18

Lifting arm

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3. Assembly

DIN 933 4.8 M10x30 Torque 12 Nm +/- 5 Nm

DIN 933 8.8 M16x40 Torque 200 Nm +/- 10 Nm

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Preparation of the assembly

The TW 125 M 1-post lift is delivered on a single pallet. In our case, 2 people build the 1-column lifting bales with the help of a motor crane. If you do not have a motor crane or another suitable lifting device available, we recommend that you use a sufficient number of strong people for the bodywork. First remove the box with the control unit.

Please read carefully the instructions in the box with the control unit before further assembly. Then remove the box with the motor unit. In this there is a bag with the mounting screws.

•

Now we can remove the outer packaging.

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Next we use the motor crane to put the column aside. To remove the pillar, it must be turned slightly on the ground. (Put something under it during draining so that the floor is not scratched) Now the column can be placed on rubber blocks or another suitable substructure.

Next we lift the support arm unit off the package. Place a sling as shown here around the support arm assembly. Now the arm unit can be put on the edge. We are also underlain here with rubber blocks, since next the sling for further transport must be moved further towards the center. Now the support arm unit can be moved aside. We only need them again at the very end of the construction. Again, we are inferior, so we can easily remove the strap and not scratch the floor.

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In the next step we put the pillar on the stand foot. Now we still have to cut the wire, to do this, the column is raised again to align with the engine crane. Align the column so that the holes will overlap each other after erecting the column. Again, we put something down. A thin piece of rubber is optimal.

For your safety, we recommend that you set up with at least three strong people. Make sure that the column can´t tip over accidentally and fix it immediately with the 10 supplied screws.

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Remove the control unit from the box and unscrew it. The screws for mounting the control unit are preassembled on the column.

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Please note that the following electrical installation may only be carried out by a qualified electrician!

Now the motor cable can be connected. To do this, we first open the box on the motor unit. There we open the two upper right terminals to which the red test leads are connected. Remove the red test leads from the box, but remember exactly where they were connected.

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Next, the oil hose is screwed on. First tighten the connection to the motor unit. To screw the oil hose, we hold the hose in position so that it runs straight down after tightening. Screw the hose tight.

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Let's fill up the oil tank (10 liters of hydraulic oil). However, by no means more than the MAX marks. Then we close the tank well again.

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Now we connect the lift to the power to lift the lift easily for further assembly. Press the button on the control unit until the lift is at the same height as the support arm unit. Should you drive too far, you can lower the lifting carriage via the release lever. Then the previously unscrewed screws are reinstalled.

These screws must be tightened with a torque of also 200 Newton meters crosswise. Thus, the assembly is almost complete.

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Wire from Motor

Limit switch

Let's go up the stage a bit to remove the remaining packaging. At the end we only need one more test run. Drive the stage all the way to the top and test the limit switch. After the limit switch has successfully stopped the stage automatically, they can use the drain lever on the motor unit to place the stage in the top safety catch. To deflate the stage must first be moved out of the safety catch a bit, and then by simultaneously pressing the release and release lever to be drained.

This completes the assembly of your single column lift.

3.1 Limit Switch

Connect the wire from the limit switch on point 2 and 3 like in the follow picture.

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3.2 Power supply

Replace two red test lines by black power lines.

(PE) Ye/gr

Fill up the tank (10 L) to 80 % (oil - HLP 32)

Oil hoses

Connect power lines from the control box in the junction box of the motor.

3.3 Connect the oil hoses

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3.4 TW 125 F Floor mounting

S/N

items

Y e s

No

1

Is the Floor aligning?

2

Are the screws closed? (90 Nm)

3

Are the oil hoses connected?

4

Are the Colum and the Base mounted? (200 Nm)

5 Are the arms mounted?

6

Is the electrical installation correct?

7

Are the safety components mounted?

8

Are all parts lubricated?

Align the base plate with a spirit level.

1. Drill the holes.

2. Clean the holes with a vacuum cleaner.

3.5 Checkpoints after the installing

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4. Operation instruction

4.1 Operating instructions for the mechanical operation

This mobile lift is equipped with a separate transport mechanism that works like a lift truck. Move the steering handle up and down several times until the lift is far enough away from the ground has to move around you freely. When you have reached your desired location, release the lift using the pressure release handle.

Before pushing the lift under a motor vehicle, make sure that both arms are aligned and without obstacles. Lift the vehicle only at the points approved by the manufacturer. The transport wheel on the column is retracted, make sure that no tools, screws, small stones or other lying under the lift. It is strictly forbidden to start the lifting process before the lift sits on the floor.

4.2 Operating the lift switch / operating test

Under no circumstances should you try to operate the lift before you have tested it. This step is very important and necessary to ensure that all hoses are properly fastened and that there is no danger from any leaking pipe. Turn on the power at the rotary switch. Press the button / lift switch (under the on / off rotary switch) for about 2-3 seconds. The lifting arms should now be raised, if this is not the case you must make sure that the power supply is correctly connected. Connect them correctly so that the direction of rotation of the motor is correct (400 V version).

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5.

Operation (using the mobile lift with manual unlocking as an example)

1. Position the vehicle to be serviced and switch off the engine.

2. Lift the lift by moving it up and down (lift truck principle) of the swiveling handle

(Steering arm) light on.

3. Slide the lift under the vehicle. (Alternatively, you can drive onto the lift,

if it was previously drained and sits firmly on the ground).

4. Make sure that the floor meets the requirements, is level and no obstacles

located on the ground.

5. Operate the pressure release handle on the swivel handle to release the lift.

The lift must be firmly on the ground.

6. Align the lift so that the lifting points on the vehicle and the lift coincide.

7. Press and hold the lift button (under the on / off switch) until the car is raised about 10-15 cm.

8. Now stop the lifting process and make sure that the car is correctly and safely aligned.

9. Lift the vehicle only at the points approved by the manufacturer.

10. If you wish to release the lift for corrective action, press and hold the unlocking lever (release the safety catch)

while pressing the release lever at the lift.

11. To change the height of the mounting plates, turn them.

12. After final alignment and check on firm seat, press the lift button again

(under the on / off switch) and hold it to the desired height.

13. Never let the car out of sight during the lifting and lowering process.

14. To deflate, as described above, press and hold the release lever (release the safety catch) and at the same

time press the release lever on the lift.

15. Move the swiveling handle (steering lever) up and down several times until the lift is clear of the ground

and pull out the lift under the car. Alternatively, you may also drive away the car, but in this case the lift must still rest firmly on the ground and must not be loosened!

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Unlock

Discharge valve (lowering lever)

Handle

5.1 Operation

.

Put the mobile 1 Colum lift under the vehicle

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Safety device

Arm

Pull the safety bolts, you can now adjust the support arms,

or drive the vehicle on the lift.

.

You can adjust the support arms as follows:

Release the safety latches to lock the support arm.

Turn the Plates to set the high.

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6. Maintenance and troubleshooting

6.1 Daily check

A daily check of the safety functions before putting the lift into operation is very important. Discovering a device failure before use saves you time, greater damage or even injury.

- Check all hydraulic connections.

- Check all cables and switch connections.

- Check all bolts and screws, if loose, please tighten.

- The working environment should be cleaned regularly.

6.2 Monthly check

-Check the mobility of the flexible parts.

- The entire construction should be inspected for any signs of wear, if any damage has been discovered, it should be repaired or,

if necessary, replaced with original spare parts.

- If you detect a leak on the cylinder neck, this is probably due to wear of the seal ring on the piston.

He needs to be renewed.

6.3 Maintenance interval

- After 12 month should be renew the oil and the filter.

6.4 Troubleshooting

No power

- Check the power supply

- The electrical connection is wrong

The lift rises, but not to the maximum load of 2500 kg.

- Set the necessary pressure.

- If you are still experiencing lifting problems, remove the pressure relief valve and clean it.

If you hear unusual noises during the lifting process from the hydraulic system, it may be that air is being drawn in. Check the oil level and clean or replace the filter.

6.5 General note

- Maintenance work may only be carried out by qualified personnel.

- Turn off the power before starting maintenance.

- Work on the circuit must only be carried out by a qualified electrician.

- Never use high-pressure cleaner or corrosive cleaning agents.

- Manipulating the safety devices is strictly prohibited.

- In case of disturbances, such as jerky movements or bending of load-bearing parts, leave the lift shut down the power supply immediately and contact your supplier.

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7. Annex

Tech. Data

TW 125 M Ultra

(Mobil)

TW 125 F

(fixed)

Capacity

2500 kg / 5511 Lb

Max. Wheelbase

2900 mm / 114 In

Max. high

1800-2000 mm / 70-78 In

Vehicle width

≤1800 mm/ 70 In

≤1800 mm / 70 In

Lifting speed (ca.)

35 sec.

Motor power

2.2 kW

Power supply

230 V

Frequency

50Hz/60 Hz

Oil Pressure

115 bar / 1687 psi

weight (ca.)

720 kg / 1587 Lb

Loudness

<60 dB

dimension (ca.)

2470x2030x2600 mm

2060x2030x2600 mm

Protect class

IP 64

Working temperature

-5°C / 23°F till +40°C / 104°F

operating environment

inside and outside (limited)

7.1 Technical data

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7.2 Dimension / TW 125 M Ultra

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7.3 Dimension / TW 125 F

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7.4 Wire diagram 230V

TC

Transformer

HL

lamp

FU

fuses

KM

Motor protection

QS

Main switch

SA

switch

SB

button

Wire diagram 230V TW 125 M, TW 125 F © Twin Busch GmbH

27.01.2016

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7.5 Hydraulic diagram

1. Cylinder

2. Valve

3. Pump

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7.6 24V- diagram

Motor (3-Phasen)

24V-diagramm

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7.7 Spear parts

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S/N.

name

picture

QTY.

Spez.

TW 125-1

Colum cover

1

TW 125-2

Limit switch

1

TW 125-3

Control box

1

TW 125-3,1 (1)

main switch 20A

1

TW 125-3,1 (2)

Transformer BK-30

1

TW 125-3,1 (3)

button

1

TW 125-3,1 (4)

Motor switch

CJX2-1201/24V

1

220/230 V

TW 125-3,1 (5)

Holder for fuses

3

TW 125-3,1 (6)

fuses 16A

3

TW 125-3,1 (7)

CEE-plug 16A

1

TW 125-3,1 (8)

cable

6

TW 125-4

screw M10*30

4

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TW 125-5

nut M10

4

TW 125-6

Manual Pump

1

TW 125-7

carrier

1

mobil

TW 125-8

bolt 2

TW 125-9

bush

2

TW 125-10

axle 1

mobil

TW 125-11

screw M12*20

2

TW 125-12

washer

10

TW 125-13

screw

10

TW 125-14

Colum

1

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S/N.

name

picture

QTY.

Spez.

TW 125-15

roll 1

TW 125-16

Bearing 30*50

1

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TW 125-17

nut M27*15

3

TW 125-18

holder

1

TW 125-19

Axle

1

TW 125-20

screw

M6*12

1

TW 125-21

chain Duplex

1

TW 125-22

Chain holder

1

TW 125-24

pin 2 2

TW 125-25

nut M20

1

TW 125-26

screw

M16*70

2

TW 125-27

Chain connector

1

TW 125-28

washer

2

TW 125-29

Spring washer 16

2

TW 125-30

Nut M16

2

TW 125-31

Hydraulic cylinder

1

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S/N.

name

picture

QTY.

Spez.

TW 125-31 (1)

Cylinder pipe

1

TW 125-31 (2)

O-ring 69*5.3

1

TW 125-31 (3)

valve

1

TW 125-31 (4)

Cylinder part

1

TW 125-31 (5)

sealing Ф45

1

TW 125-31 (6)

Cylinder head

2

TW 125-31 (7)

sealing

1

TW 125-31 (8)

Limiter

1

TW 125-31 (9)

Piston rood

1

TW 125-31 (10)

O-rings

1

TW 125-31 (11)

piston

1

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TW 125-31 (12)

sealing

2

TW 125-31 (13)

U-rings

1

currently use Green,

later Blue

TW 125-31 (14)

nut

1

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S/N.

name

picture

QTY.

Spez.

TW 125-32

lever 1

TW 125-32

(1)

pin Ф4*30

1

TW 125-33

lock 1

TW 125-34

bolt 1

TW 125-35

handle

1

TW 125-35 (1)

Ball for handle

1

TW 125-36

Lift slet

1

TW 125-37

PA-slider

1

TW 125-38

arm 2

TW 125-39

Arm

2

TW 125-39,1

arm 2

TW 125-40

arm 2

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TW 125-41

arm 2

TW 125-41,1

arm 2

TW 125-42

Bolt for arm

1

TW 125-43

Tooth block

2

TW 125-44

spring

1

TW 125-45

Lock system

2

TW 125-46

Holder

4

TW 125-46 (1)

rubber

4

TW 125-46

(1,1)

rubber/Ultra flat

4

TW 125-47

Main arm

1

TW 125-48

screw M16*40

8

TW 125-49

washer

8

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S/N.

name

picture

QTY.

Spez.

TW 125-51

Base frame

1

Mobil

TW 125-51,1

Base frame

1

Fixed mounted

TW 125-51,2

Base Frame/Ultra flat

1

Mobil

TW 125-52

axle 2

TW 125-53

ring 4

TW 125-54

spacer ring

4

TW 125-55

bearing

4

mobil

TW 125-56

Wheel 2

mobil

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S/N.

Name

picture

QTY.

Spez.

TW 125-57

hoses

1

TW 125-58

connector

1

TW 125-59

Motor

1

300/400 V

TW 125-59,1

Motor

1

300/400 V

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Space for my notes:

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Space for my notes:

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Space for my notes:

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http://www.youtube.com/watch?v=UI82fUVgsSU

http://www.youtube.com/watch?v=3A9rlP27Ylw

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