Böcker TL 1512 Operating Manual Download Page 30

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Steel frame Table form lift TL 1512

213300043

5.5 Assembly of the base frame

Fig. 10: Basic unit with a transport traverse

Transporting the basic unit:

(max. number of masts: 2 per side)

Fig. 11: Basic unit with a transport traverse

Summary of Contents for TL 1512

Page 1: ...Operating Manual Steel frame Table form lift TL 1512 Translation of the German original Doc No 213300043 Before starting any work read the operating manual...

Page 2: ...rame Table form lift TL 1512 2 213300043 B cker Maschinenwerke GmbH Lippestr 69 73 59368 Werne Germany Tel 49 0 2389 7989 0 Fax 49 0 2389 7989 9000 email info boecker group com Website www boecker gro...

Page 3: ...TL 1512 213300043 3 Layout of these instructions These assembly and operating instructions refer to Doc no 213300043 Original from May 05 2010 Version 26082015 applies to Type Steel frame Table form...

Page 4: ...25 5 Table lift assembly 26 5 1 Safety instructions for the assembly personnel 26 5 2 Danger zones 27 5 3 Assembly tools 27 5 4 Selection of location 28 5 4 1 Location requirements 28 5 4 2 Support f...

Page 5: ...ort of material 77 8 3 1 Illustration of loading points 78 8 3 2 Transporting the slap frameworks 80 8 3 3 Please note Entering the ground station 2 m area 81 8 3 4 Switch to personnel transport 81 8...

Page 6: ...instructions to avoid damage to persons and property Safe working helps to avoid remaining risks Always keep this operating manual on the site of operation The manual must always be at hand and access...

Page 7: ...t of operation operation maintenance and set up and dismantling Damage caused by incorrect transport Incorrect assembly start of operation operation maintenance or dismantling Operating the Table lift...

Page 8: ...defects represent a danger the system must be shut down immediately stopping inappropriate behaviour by the operating personnel or by the user of the Table lift TL intervening in the event of an emerg...

Page 9: ...for the legally required inspections and the intervals for inspection and maintenance defined in the operating manual are adhered to see Chapter 11 Maintenance Only qualified technicians shall be per...

Page 10: ...It requires the adherence to safety measures to protect life and limb of the persons affected CAUTION This sign indicates risks that can cause significant damage to property Under all circumstances t...

Page 11: ...ion we use pictogram in this manual that have been adapted to certain actions or a hazard situation Example DANGER Risk of falling from heights Never attempt to open the door to the loading platform o...

Page 12: ...igns on the Table lift Fig 1 Brief operating instructions Brief operating instructions This note can be found on the loading platform near the control panel Fig 2 Load capacity Load capacity This note...

Page 13: ...2 213300043 13 Fig 3 Anchor forces Anchor forces This note can be found on the loading platform near the control panel Fig 4 Rated load capacity Rated load capacity This note can be found on the loadi...

Page 14: ...e unit and contains the following information Type Manufacturing number Year of construction Alternating current max lifting height in m Current consumption in A Rated speed in m min Weight of the bas...

Page 15: ...e same time compliance with the load capacity of the platform is mandatory Using the loading platform to proceed with installation tasks Transport of material The explicit transport of material while...

Page 16: ...defined by the end user Only technical personnel trained and authorised by the manufacturer are permitted to proceed with repairs on the table the lift CAUTION All Table lift components are harmonised...

Page 17: ...ignored or the safety regulations applicable at the construction site are disregarded 2 6 Danger zones A particularly dangerous place is the area under the loading platform The area can be protected...

Page 18: ...Steel frame Table form lift TL 1512 18 213300043 3 Design and function 3 1 Overview Fig 7 Overall view...

Page 19: ...Steel frame Table form lift TL 1512 213300043 19 Fig 8 Top view 19...

Page 20: ...m 7 Trolley with drive unit 8 Safety brake 9 Electrical cabinet not shown 10 Loading platform control system Mast 11 Mast components 1 50 m with gear rack 12 Mast anchors at least every 2 65 m spacing...

Page 21: ...500 kg Rated speed with 1685 kg 12 m min Creeping speed 6 m min Sound pressure level 70 dB A 4 2 Electrical data TL 1512 Details Value Unit Rated power 2 x 2 1 4 2 kW Supply voltage frequency 380 400...

Page 22: ...um lifting height without mast anchorage 0 m Maximum lifting height with mast anchorage 50 m First anchor 3 m Maximum permitted anchor spacing 9 m max Start up current 90 A Top of mast 3 m Mast anchor...

Page 23: ...ntling 45 12 5 80 km h m s During operation 72 20 80 km h m s When idle not in operation 160 44 4 80 km h m s Permissible ambient temperature for operation 15 to 40 C Permissible storage temperature 2...

Page 24: ...r locking mechanisms Entry exit of loading platform Mechanically locked Monitored electrically Load position gates Mechanically locked Monitored electrically Base enclosure gate optional Mechanically...

Page 25: ...rson and explain the emergency situation The Table lift is quipped with two EMERGENCY OFF buttons and one EMERGENCY OFF button at the ground station A One EMERGENCY OFF button is located at the platfo...

Page 26: ...heights Ensure to observe the information provided in the Technical Data Compliance with the legal rules and regulations pertaining to wind speeds during the assembly and operation of the Table lift...

Page 27: ...a life threatening situation It is forbidden to remain below the loading platform during operation If the platform crashes to the ground this may cause crushing and or life threatening injuries Ensure...

Page 28: ...ame Check the load capacity of the location based on the information provided in these instructions see Chapter5 4 2 page 29 If the load capacity of the location is insufficient it may be necessary to...

Page 29: ...frame Table form lift TL 1512 213300043 29 5 4 2 Support forces in kN Spindle H 1 2 3 4 5 6 10 9 9 9 9 20 20 20 9 9 9 9 22 22 30 9 9 9 9 24 24 40 9 9 9 9 26 26 50 9 9 9 9 28 28 H Assembly height in m...

Page 30: ...e form lift TL 1512 30 213300043 5 5 Assembly of the base frame Fig 10 Basic unit with a transport traverse 1 Transporting the basic unit max number of masts 2 per side Fig 11 Basic unit with a transp...

Page 31: ...mast component and use the transport vehicle to lift the basic unit 2 Place the basic unit on level ground according to the assembly diagram 3 There are several spindles with circular bases located i...

Page 32: ...e their proper fit Fig 14 Insert the CEE power plug into the CEE wall socket below the electrical cabinet 5 Connect all power supply lines according to the information provided in the Technical Data I...

Page 33: ...Steel frame Table form lift TL 1512 213300043 33 5 6 How to assemble the Table lift Fig 15 How to assemble the Table lift in front of a wall...

Page 34: ...frame First only tighten the bolts that are easily accessible Fig 17 Pre assembled platform group in front of building wall 2 Insert the forks of the transport vehicle into the open side of the pre a...

Page 35: ...group and tighten bolts 4 Align the entire platform group and tighten bolts Fig 20 Raise the Table lift 5 Raise the Table lift in order to gain access to previously inaccessible connections at the un...

Page 36: ...sembled mounting aids used to attach the flange mounted platforms 2 With the assistance of the crane and a transport traverse the completely pre assembled loading platform of the Table lift is placed...

Page 37: ...Therefore wearing personal protective equipment in particular hard hats and safety belts during the assembly is mandatory CAUTION There is an inherent risk of injuries when raising the mast component...

Page 38: ...bled mast component It contain s already the limit switch contact plate for the ground station Use a torque wrench 135 Nm Each mast component is assembled using four bolts M14x130 8 8 DIN 444 To do th...

Page 39: ...he Table lift Chapter 4 Technical data 6 Unlock the platform s Emergency Off button and travel to the applicable assembly height 7 Press the EMERGENCY OFF button again 8 Assemble the next mast compone...

Page 40: ...bly and must be verified for each Table lift system The information pertaining to the anchor forces can be found on the following pages page 41 STOP DANGER Selecting incorrect anchorage can lead to th...

Page 41: ...Steel frame Table form lift TL 1512 213300043 41 Anchor forces Fig 23 Anchor forces when anchoring in front of the building wall...

Page 42: ...building wall The edge of the platform must be parallel to the building If necessary use a chain hoist to install the mast perpendicular to the building Subsequently anchor the mast in the ground 5 9...

Page 43: ...to connect it to the mast anchor pipe 2 5 Pin the mast anchor pipe 2 in the pockets of the anchor plate 4 6 Use the connector 1 to align the mast anchor pipe 2 horizontally if necessary loosen 1 and 3...

Page 44: ...plate we recommend the anchor type below Fischer mounting system Anchor bolt FAZ II 12 30 GS Article number 96340 NOTE The supports for the floor gate are included in this mast anchor set CAUTION Whe...

Page 45: ...type below Fischer mounting system Anchor bolt FAZ II 12 30 GS Article number 96340 NOTE The supports for the floor gate are included in this mast anchor set CAUTION When installing the floor gates c...

Page 46: ...of the mast Fig 27 Installed cable guide 1 Attach the first cable guide 1 m from the top edge of the cable bin 2 Attach the second cable guide at 3 m and all following cable guides at 6 m spacings 3...

Page 47: ...kinks will form and the cable may be damaged 5 12 Installation of the Table lift s switch cabinet CAUTION Ensure to inspect the plug connections of the switch cabinet after each structural change of t...

Page 48: ...Steel frame Table form lift TL 1512 48 213300043 Illustration of the assignment of the fold down ramp monitoring Fig 31 Bottom view of switch cabinet...

Page 49: ...allation of the floor limit switch rail 2 The floor limit switch rail must be attached to the mast below each floor Fig 34 Installation of the floor limit switch plate 3 Use the limit switch plate to...

Page 50: ...t must always sit horizontally on the edge of the building see Fig 35 Ramp support area on the building page 50 CAUTION The max permitted horizontal force during loading with the pallet truck EJB 213...

Page 51: ...1512 213300043 51 CAUTION All dimensions must be maintained 0000391640 Install the upper limit switch plate 1 58 m below the top of the mast Distance of the floor limit switch s actuating cam to the u...

Page 52: ...by the safety brake after 1 5 m CAUTION If the safety brake has not been activated after about 2 5 m release the pushbutton Now the motor brake will stop the platform Should this happen a service tec...

Page 53: ...00043 53 5 15 Installation of the base enclosure optional Secure the lower hazard zone by installing an enclosure 1 10 m high The clearance between the enclosure and any moving parts of the lift must...

Page 54: ...st anchor attachment support already installed and subsequently bolted onto the support see 1 Fig 40 Mount pivoting floor gate to floor of the relevant storey variant 2 The following applies 213300001...

Page 55: ...order to attach the anchor plate we recommend the anchor type below Fischer mounting systems Anchor bolt FAZ II 12 30 GS Article number 96340 Fig 42 Locking mechanism of pivoting floor gate The locki...

Page 56: ...56 213300043 5 16 1 Cable routing at the loading point gates Cable routing at the pivoting gate platform Cable routing at the first loading point Cable routing at the last loading point Blind plug if...

Page 57: ...l From the loading positions The available buttons are explained in the text below 6 1 Ground station next to the cable bin Fig 43 CEE ground station with EMERGENCY OFF master switch connector for pen...

Page 58: ...rm lift TL 1512 58 213300043 Secure the lift to prevent accidental restart The EMERGENCY OFF switch is a rotary switch and can be activated and locked as shown inFig 44 Fig 44 Activation of the EMERGE...

Page 59: ...e platform control is in the following positions 1 Outside The operation of the lift from the inside is not possible 3 Automatic The lift can be operated from the outside only if the lift was not acti...

Page 60: ...Operating buttons of the platform control system Position Fig 46 Designation Function 1 EMERGENCY OFF Stopping the lift in an emergency situation 2 Overload display An excessive payload triggers the i...

Page 61: ...the lift only possible from the outside 2 OFF Lift activation not possible 3 Automatic mode Activation of the lift possible from the inside and outside In this instance the operation from the inside a...

Page 62: ...platform move up Activation is possible only in switch positions 1 3 The following applies to position 3 Precedence for control from the inside of the platform 3 DOWN The platform moves down Activati...

Page 63: ...at next floor is active while material and personnel are transported From the load position control stations the platform can only be moved to the 2 meter zone After reaching this height the platform...

Page 64: ...ift TL 1512 64 213300043 6 4 Diagnosis system Art No 2160000004 1 Error message and troubleshooting US User LO Lift operator TE Technician NOTE All illustrated malfunction refer to a machine with inte...

Page 65: ...ted a Unlock button a Unlock button c Close electrically control enclosure door d Plug in the blind plug for the Operation socket e Plug in the blind plug for the safety chain f Check all connections...

Page 66: ...t is brake worn out is operating limit switch faulty a LO b TE b LO b TE NO5 Entry door A a Door is not properly closed b Connector of door A not plugged in c Door A not installed blind plug not inser...

Page 67: ...plug not inserted d Limit switch for pivoting door support leg 1 or 2 faulty a Ensure pivoting door support leg 1 or 2 operates smoothly b Insert connector for pivoting door support leg 1 or 2 is inse...

Page 68: ...d is 12 m min Use the operating unit to change the parameters and switch to 24 m FM 2 Reading the software version If a malfunction cannot be detected the SW version is displayed at the bottom of the...

Page 69: ...of fatal injuries if entering the area underneath the loading platform This area is protected by a 1 10 m high enclosure Remaining underneath the platform is prohibited You can be crushed under the lo...

Page 70: ...witching the lift on check the lift for external damage the integrity of the power supply line the mast to ensure its path is unobstructed e g check for protruding building parts foreign objects on th...

Page 71: ...Turn on the EMERGENCY OFF master switch 4 The lift is now ready for operation CAUTION Malfunctions during the switch on procedure The indicator light at the ground station displays the correct power...

Page 72: ...personnel remains outside this area Storing materials or objects underneath the platform is prohibited Ensure the unauthorised use of the lift is prevented 8 1 2 Safety instructions during loading an...

Page 73: ...per behavior may cause life threatening injuries Compliance with the instructions by the platform supervisor are mandatory While travelling on the lift do not lean over platform gates While travelling...

Page 74: ...rm must only be operated from the platform by an operator who is named by the owner and authorised The hatched area must never be occupied by personnel Red white safety chain is used to block prevent...

Page 75: ...now the platform travels in the appropriate direction 4 Stop at next floor Before reaching target floor briefly press this button during the travel See Fig 46 No 4 page 60 5 The platform stops automa...

Page 76: ...ly continue if you are sure there is no personnel underneath the platform After approx 3 seconds the platform is lowered at reduced speed into the ground station 8 2 2 Automatic change over from perso...

Page 77: ...k platform and loading position gates 4 Activate the applicable travel direction UP DOWN on the pedant control panel or on the loading point control system Stop at next floor NOTE While in the 2 m are...

Page 78: ...Steel frame Table form lift TL 1512 78 213300043 8 3 1 Illustration of loading points...

Page 79: ...12 213300043 79 Illustration of loading points loading point load kg quantity pallet cage stacking frame size pallet cage stacking frame Q1 200 1 120x80 Q2 67 3 120x80 Q3 150 1 120x160 Q4 150 1 240x80...

Page 80: ...to prevent slipping Fig 48 Attachments on platform top view CAUTION Only use the specified lift truck EJB 213 EHW table to transport the slap frameworks All pertinent information about the lift truck...

Page 81: ...personnel transport Switching to personnel transport after the platform has stopped If the platform stops at a floor or at the ground station after a material transport the platform must be entered an...

Page 82: ...e in the same way 8 4 1 Opening the loading ramp If the loading ramp must be opened the transport platform must have come to complete halt on one of the loading positions Now the ramp lever can be mov...

Page 83: ...the ramp support bracket CAUTION The ramp of the lift must always sit horizontally on the edge of the building see Fig 51 page 83 CAUTION The max permitted horizontal force during loading with the pal...

Page 84: ...locking mechanism of the pivoting gate 9 Shutting down the Table lift 1 Lower the platform to the ground station 2 Completely close the platform gate and the loading position gate 3 Switch off the EME...

Page 85: ...rne Germany Tel 49 0 2389 7989 0 Fax 49 0 2389 7989 9000 email info boecker group com Internet www boecker group com The text below describes the individual actions to take and options available 10 1...

Page 86: ...Any solutions above and beyond this and for every imaginable emergency situation cannot be part of this manual First of all try to assess the respective emergency situation and the potential danger fr...

Page 87: ...rson and explain the emergency situation The Table lift is quipped with two EMERGENCY OFF buttons and one EMERGENCY OFF button at the ground station A One EMERGENCY OFF button is located at the platfo...

Page 88: ...s First check the cause of the breakdown then attempt to contact a person on the outside Only proceed with the rescue of the personnel and emergency mode after a technical inspection and following the...

Page 89: ...ed Travel is made impossible Floor control system pendant control panel and platform control system are working anymore Only by technical personnel STOP DANGER After a technical breakdown or emergency...

Page 90: ...as the control button is pressed If the button is released the lift stops Fig 55 Opening the platform electrical cabinet 1 Remove the platform cover in front of the electrical cabinet and open the ele...

Page 91: ...tion switch back to its the normal position 6 Close the electrical cabinet and replace the cover 10 2 3 Using manual venting to lower the platform only by technical personnel If the lift control syste...

Page 92: ...n lowering the platform from great heights the drive and the brakes become extremely hot Never touch the motor When lowering from great heights stop after several meters and let the brake and the driv...

Page 93: ...nsure there is a safe crossing between platform and loading position Use a safety belt to secure the person that must be rescued 10 2 4 1 Escape route CAUTION Attempt to create a safe crossing between...

Page 94: ...rm lift TL 1512 94 213300043 10 3 Disassembling the lift The lift is disassembled in the reverse order of the assembly procedure CAUTION Only properly trained personnel shall be permitted to proceed w...

Page 95: ...er shall be permitted to proceed with maintenance and repair tasks Ensure to complete the specified maintenance and inspection tasks according to schedule STOP DANGER Starting the lift without authori...

Page 96: ...see Chapter14 Screw tightening torque STOP DANGER If using incorrect replacement parts there is a risk of fatal injuries Use only original spare parts from the manufacturer Use only original spare par...

Page 97: ...shorter Please contact the manufacturer see page 2 Interval Description Task Comment To be performed by weekly Instruction and load sticker Visual inspection whether mounted and legible Operator EMERG...

Page 98: ...omer service technician Inspect cable trolley if installed Visual inspection check support rollers or pulleys for wear Operator Track rollers Visual inspection check track rollers on the mast for wear...

Page 99: ...espective parts Customer service technician every 3 years Transmission oil of the drive motor Replace Types of oil quality Gearbox oil Mobilgear 630 made by ESSO Customer service technician every 5 ye...

Page 100: ...f the motor brakes ZFB 62 So Fig 59 ZFB brake Overall size ZFB 60 Working air gap SA mm 0 4 Max air gap SA max mm 1 Stroke limitation y mm 1 Minimum thickness of the brake disc Smin mm 11 5 Fig 60 Wor...

Page 101: ...e in braking position measure the anchor plate Pos 3 and the magnet body Pos 2 The brake must be adjusted if the wear of the brake lining has increased so that the maximum possible working air gape sA...

Page 102: ...cally secured pivoting gate not closed Close the pivoting gate of the platform enclosure Check plug see 6 1 page 57 Loading position gate monitoring one gate is not closed Close loading position gate...

Page 103: ...pected by an electrician The maximum load capacity was exceeded The overload indicator is illuminated the payload must be reduced Platform gate loading position gate cannot be opened The operation lim...

Page 104: ...small branches begin to move dust and loose paper raised 5 Fresh breeze Light wind 7 5 10 4 28 37 Small trees begin to sway 6 Strong wind 10 5 13 4 38 48 Whistling heard in overhead power lines large...

Page 105: ...Always use a torque wrench when checking the torque of threaded components Standard metric threads Torque in Nm applicable to galvanized or slightly oiled screws bolts Diameter Strength category 8 8 1...

Page 106: ..._____ ___________________________________________________________________________ The initial start up causes concerns no concerns The inspection must be repeated not repeated ___________________ ____...

Page 107: ...____ ___________________________________________________________________________ The initial start up causes concerns no concerns The inspection must be repeated not repeated ___________________ _____...

Page 108: ...____ ___________________________________________________________________________ The initial start up causes concerns no concerns The inspection must be repeated not repeated ___________________ _____...

Page 109: ...____ ___________________________________________________________________________ The initial start up causes concerns no concerns The inspection must be repeated not repeated ___________________ _____...

Page 110: ...tallation places of manufacturing number 1 Layout Date from 20 to 20 Place of operation Product description Name of owner ______________________________ 2 Layout Date from 20 to 20 Place of operation...

Page 111: ...m lift TL 1512 213300043 111 3 Layout Date from 20 to 20 Place of operation Product description Name of owner 4 Layout Date from 20 to 20 Place of operation Product description Name of owner _________...

Page 112: ...m lift TL 1512 112 213300043 5 Layout Date from 20 to 20 Place of operation Product description Name of owner ______________________________ 6 Layout Date from 20 to 20 Place of operation Product desc...

Page 113: ...Steel frame Table form lift TL 1512 213300043 113 17 Appendix 17 1 Lift truck data sheet EJB 213 EHW Table...

Page 114: ...Steel frame Table form lift TL 1512 114 213300043...

Page 115: ...gravity for standard fork length 450 mm Speed with nominal load without load 3 7 km h Speed with raised table h3 1150 mm 2 4 km h Dimensions of standard vehicles Description EJB 213 h1 Height 1970 mm...

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Böcker TL 1512, Operating Manual

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