Toplift Toplift Eco - CLM ConstructionOperating Instructions Toplift Toplift Eco Translation based...

Operating Instructions

Toplift Toplift Eco

Translation based on the original German version

Document no.:92023200095 Every operator, before he places the device in ser-vice, must read the operating manual!

Toplift / Toplift ECO

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© Böcker Maschinenwerke GmbH Lippestr. 69-73 D-59368 Werne Tel.: +49 (0) 2389 7989-0 Fax: +49 (0) 2389 7989-9000 E-Mail: [email protected] Internet: www.boecker-group.com


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Assignment of these operating Instructions

This assembly and operating instruction…

... Document no.: 92023200095 Original from: 26.07.2006 Version 05102010

… applies to: Type: Toplift Serial number: Ab 42850

Typ: Toplift ECO Serial number: Ab 286


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CONTENTS : 1 FOREWORD ................................................................................................................................... 7

1.1 Advice on use of these operating instructions.................................................................... 7 1.2 Safety and danger advice................................................................................................... 7

2 TECHNICAL DETAILS.................................................................................................................... 8 2.1 Special characteristics .......................................................................................................... 9 2.2 Composition of the hoist........................................................................................................ 9 2.3 Accessories ....................................................................................................................... 10

2.3.1 Carriages and ladder accessories.......................................................................... 10 2.3.2 Hoisting devices ................................................................................................... 10

3 FUNDAMENTAL SAFETY INSTRUCTIONS ................................................................................ 11 3.1 Basic operation and designated use of the machine. ...................................................... 11 3.2 Organizational measures.................................................................................................... 11 3.3 Selection and qualification of personnel – Basic responsibilities ............................................ 11 3.4 Safety instructions governing specific operational phases ........................................... 11

3.4.1 Standard operation............................................................................................... 11 3.4.2 Special work in conjunction with utilization of the TOPLIFT ...................................... 11 3.4.3 Warning of special dangers: Electric energy............................................................. 11

4 ASSEMBLY OF THE HOIST......................................................................................................... 12 4.1 Indications for safety......................................................................................................... 12 4.2 Estimation of the rail length ................................................................................................. 12 4.3 Assembly of the rails........................................................................................................... 12 4.4 Setting up the rail section .................................................................................................... 12 4.5 Load indicator ................................................................................................................... 13 4.6 Mounting of bend section.................................................................................................... 13 4.7 Support of the rail section.................................................................................................... 13 4.8 Assembly of the tube support.............................................................................................. 14 4.9 Head support ..................................................................................................................... 14 4.10 Stability of the hoist............................................................................................................. 14 4.11 The undercarriage.............................................................................................................. 14

4.11.1 Assemly of the undercarriage................................................................................ 14 4.11.2 Moving the TOPLIFT ............................................................................................ 14

4.12 Securing the feet /undercarriage ......................................................................................... 14 4.13 Setting up the drive unit ...................................................................................................... 15 4.14 Assembly and adjustment of the upper limit switch (without MV)........................................... 15 4.15 Assembly and adjustment of the upper limit switch TOPLIFT Furniture (MV)......................... 15 4.16 Electric supply .................................................................................................................... 16 4.17 Fixing the hoisting rope....................................................................................................... 17

4.17.1 Attaching the rope to the standard carriage + furniture carriage............................... 17 4.17.2 Attaching the rope to the tilting carriage.................................................................. 17


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4.18 Test run ..............................................................................................................................17 5 APPLICATION OF THE HOISTING DEVICES..................................................................................18

5.1 Standard universal platform ..............................................................................................18 5.2 Uni-platform comfort............................................................................................................18 The Uni-platform standard can be used with the standard carriage as well as with the tilting carriage. .........................................................................................................................................18 5.3 Long-goods-platform ...........................................................................................................18 5.4 Platform..............................................................................................................................19 5.5 Sheet platform.....................................................................................................................19 5.6 Tilting bucket.......................................................................................................................19 5.7 Solar-Platform Standard....................................................................................................20 5.8 Solar-Platform adjustable..................................................................................................20 5.9 Sheet transport bed with adjustable inclination.................................................................20

5.9.1 Handling of the Sheet transport bed with adjustable inclination...........................21 5.10 Furniture platform Universal / Basic ..................................................................................24

5.10.1 Furniture platform extendable.............................................................................24 5.10.2 Furniture platform pivotable and extendable ......................................................24 5.10.3 Furniture platform pivotable and extendable (without front-flap)).......................24 5.10.4 Handling of the furniture platform with pluggable side guards ...........................25

6 OPERATION OF THE TOPLIFT ......................................................................................................26 6.1 Before each use..................................................................................................................26 6.2 Control system of the TOPLIFT 225/234/240/M1/M2 ............................................................26 6.3 Control system of the TOPLIFT ECO ...................................................................................26 6.4 Control system of the TOPLIFT Furniture (MV).....................................................................27 6.5 Securing the loading area....................................................................................................27

7 DISMANTLING THE TOPLIFT.........................................................................................................27 8 WARRANTY....................................................................................................................................28 9 MAINTENANCE ..............................................................................................................................28

9.1 Maintenance intervals..........................................................................................................28 9.2 Changing the rope...............................................................................................................29 9.3 Checking the rope and discarding........................................................................................29 9.4 Fitting of the hoisting rope on the cable drum Toplift 225 Universal / 234 / 240 / Furniture .......29 9.5 Placing of the hoisting cable (5mm) on the Toplift ECO cable winch ......................................30 9.6 Fixing the rope to the rope socket.....................................................................................30 9.7 Adjusting the slack rope device............................................................................................30 9.8 Checking the broken rope device......................................................................................30

10 TROUBLE-SHOOTING..................................................................................................................31 11 MASTER DATA..............................................................................................................................32 12 INFORMATION ABOUT THE EXPERT INSPECTION..................................................................34 13 TEST PROTOCOLS ON EXPERT INSPECTION .........................................................................36 14 WIRING DIAGRAMS......................................................................................................................40


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14.1 Wiring diagram Toplift 225 – 110V................................................................................... 40 14.2 Wiring diagram Toplift 225 Universal, Toplift 234, Toplift Furniture M1........................... 43 14.3 Wiring diagram Toplift 240, Toplift Furniture M2 .............................................................. 44 14.4 Wiring diagram Toplift Furniture MV................................................................................. 45 14.5 Wiring diagram Toplift ECO.............................................................................................. 49


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1 Foreword

Dear customer, with these operating instructions we want to inform you about the safety, the usage and the technical details of the TOPLIFT. The following in-structions and advice are to be strictly adhered to. The operating instruc-tions will help to avoid danger, repair costs, to reduce downtime and to increase the reliability and lifetime of the TOPLIFT. In addition to the operating instructions and to the mandatory rules and regulations for accident prevention and the environmental protection in the country and place of use, the generally recognized technical rules for safe and proper working must also be observed. For further questions please contact your importer or the manufacturer: Manufacturer: Böcker Maschinenwerke GmbH Lippestr. 69-73 D-59368 Werne Tel.: +49 (0) 2389 7989-0 Fax: +49 (0) 2389 7989-9000 E-Mail: [email protected] Internet: www.boecker-group.com

Marking: CE marking Land of origin Germany IT IS OF MAJOR IMPORTANCE TO READ THESE OPERATING INSTRUCTIONS BEFORE USAGE: DURING OPERATION IS TOO LATE!!

1.1 Advice on use of these operating instructions The pages are numbered consecutively. The illustrations are numbered consecutively by chapters. Example: picture 3-1 means: Illustration (picture) 1 in chapter 3

1.2 Safety and danger advice The following symbols and names are used to give advice and to warn of danger.

WARNING:

Serious harm or even death can result if this ad-vice and instruction is not followed.

ATTENTION!

Machine damage or damage to property can be the result if this advice and instruction is not fol-

lowed.

HINT Following these hints will make work and operation easier.


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2 TECHNICAL DETAILS

(CONSTRUCTION)

TOPLIFT 225 Universal

TOPLIFT 225 – 110 V

TOPLIFT 234

TOPLIFT 240

TOPLIFT Eco

Hoisting speed: 25 (30) m/min 25 (30) m/min 34 m/min 20/40 m/min 25 m/min Capacity: 250 kg 200 kg 250 kg 230 kg 150 kg Standard height: 11,30 m 11,30 m 11,30 m 11,30 m 11,30 m Max. eaves height: 20,50 m 20,50 m 20,50 m 20,50 m 20,50 m Weight drive unit: 54 kg 54 kg 54 kg 54 kg 47 kg Rope diameter: 6 mm 6 mm 6 mm 6 mm 5 mm Standard rope length: 44 m 44 m 44 m 44 m 44 m

230 V / 50 Hz 110 V / 50 Hz 230 V / 50 Hz 230 V / 50 Hz 220 V / 50 HzMotor voltage: 110 V / 60 Hz 110 V / 50 Hz

Control voltage: 24 V 24 V 24 V 24 V 24 V Motor power: 1,3 kW 1,3 kW 1,3 kW 0,6/1,2 kW 1,6 kW Max. operating time 40 % ED 40 % ED 40 % ED 40 % ED 40 % ED

Supply line 3 x 2,5 mm² 3 x AWG10“ (3 x 5.26mm²) 3 x 2,5 mm² 3 x 2,5 mm² 3 x 2,5 mm2

Length supply line max. 40 m max. 40 m max. 40 m max. 40 m max. 40 m Fuse 16 A träge 32 A träge 16 A träge 16 A träge 16 A träge sound pressure level Lpa <70dB <70dB <70dB <70dB <70dB

(FURNITURE)

TOPLIFT Furniture

(MV)

TOPLIFT Furniture

(M1)

TOPLIFT Furniture

(M2) Hoisting speed: 36 m/min 34 m/min 20/40 m/min Capacity: 200 kg 200 kg 200 kg Standard height: 11,30 m 11,30 m 11,30 m Max. eaves height: 20,50 m 20,50 m 20,50 m Weight drive unit: 57 kg 54 kg 54 kg Rope diameter: 6 mm 6 mm 6 mm Standard rope length: 44 m 44 m 44 m Motor voltage: 220 V / 50 Hz 230 V / 50 Hz 230 V / 50 Hz Control voltage: 24 V 24 V 24 V Motor power: 2,2 kW 1,3 kW 0,6/1,2 kW Max. operating time 40 % ED 40 % ED 40 % ED Supply line 3 x 2,5 mm2 3 x 2,5 mm² 3 x 2,5 mm² Length supply line max. 40 m max. 40 m max. 40 m Fuse 16 A time lag 16 A time lag 16 A time lag sound pressure level Lpa <70dB <70dB <70dB


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Fig. 2-1

2.1 Special characteristics The TOPLIFT is an easily assembled aluminium ladder hoist for construction work under the terms of EN 12158-2.

2.2 Composition of the hoist Find the composition of the hoist in the current price list. .


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2.3 Accessories

Standard carriage

picture 2-2

Tilting carriage

picture 2-3

Furniture carriage universal

picture 2-4

2.3.1 Carriages and ladder accessories Part No. 0220135000 Standard carriage 22 kg0226832000 Tilting carriage 59 kg2023200056 Furniture carriage universal 26 kg0220113000 Head support 7 kg0225300000 Aluminium double support 19 kg0225000000 Bend section 19,5 kg2023200031 Undercarriage 26 kg0221605000 Extension 2 meter 12 kg0221603000 Extension 1 meter 6 kg0000550012 Cable drum 3x2,5 mm² 13 kg5020700000 Tile roller 10 kg

2.3.2 Hoisting devices Part No. 0226700000 Tilting bucket 80 ltr. 29 kg 0224200000 Uni- platform standard 28 kg 2023200020 Uni – platform comfort 32 kg 0224300000 Sheet platform 22 kg 394010020 Sheet transport bed with ad-

justable inclination 40 kg

2023200021 Long-goods-platform 38 kg 0224900000 Platform 26 kg 2023200036 Solar-platform standard 31 kg 2023200037 Solar-platform adjustable 25 kg 2023400001 furniture platform universal

(pivotable and extendable) 84 kg

2023400012 furniture platform universal (extendable)

2023400013 furniture platform universal (pivotable and extendable, without front-flap)

WARNING! The furniture carriage universal 2023200056 is not ap-propriate for operation with knee joint!

The hoisting devices will be explained in chapter 5!


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3 FUNDAMENTAL SAFETY INSTRUCTIONS

3.1 Basic operation and designated use of the machine.

The TOPLIFT has been built in accordance with state-of-the-art standards and recognized safety rules. Nevertheless, its use may constitute a risk to life and limb of the user or third parties, or cause damage to the lift and to other material property. The lift must only be used in good working condition in accordance with its designated use and the in-structions set out in the operating manual, and only by safety-conscious persons who are fully aware of the risks involved in operating the TOPLIFT. Any functional disorders, especially those affecting the safety of the lift, should be rectified immediately. The TOPLIFT is an easily assembled construc-tion hoist designed only for the transportation of products under the terms of the operational safety order in accordance with BGV D7 Transportation of personnel is strictly forbidden Using the TOPLIFT for purposes other than those mentioned above (such as transportation of person-nel) is considered contrary to its designated use. The manufacturer cannot be held liable for any damage resulting from such use. The risk of such misuse lies entirely with the user.

3.2 Organizational measures The operating instructions must always be at hand at the place of use of the lift. Anyone who will have to work with the TOPLIFT has to read the operating in-structions before starting to work.

3.3 Selection and qualification of per-sonnel – Basic responsibilities

Any work on and with the TOPLIFT must be exe-cuted by reliable personnel only. Statutory minimum age limits must be observed. Make sure that only authorized personnel works on or with the TOPLIFT.

3.4 Safety instructions governing specific operational phases

3.4.1 Standard operation Avoid any operational mode that might be prejudicial to safety. Before beginning to work, familiarize yourself with the surroundings and circumstances of the site, such as obstacles in the working and travelling area, the soil bearing capacity and any barriers separating the construction site from public roads. Take the necessary precautions to ensure that the machine is used only when in safe and reliable state, so that no one can be exposed to danger.

3.4.2 Special work in conjunction with utilization of the TOPLIFT Spare parts have to conform to the technical re-quirements stated by the manufacturer. This is al-ways guaranteed by original spare parts. Observe the adjusting, maintenance and inspection activities and intervals set out in the operating in-structions, including information on the replacement of parts and equipment. These activities may be executed by skilled personnel only. Annual audit by the operational safety order in accordance with BGV D7 Always tighten any screwed connections that have been loosened during maintenance and repair. Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked im-mediately upon completion of the maintenance and repair work. Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact.

3.4.3 Warning of special dangers: Elec-tric energy

Use only original fuses with the specified current rat-ing. Switch off the TOPLIFT immediately if trouble occurs in the electrical system. Work on the electrical system or equipment may only be carried out by a skilled electrician or by specially instructed personnel under the control and supervi-sion of such electrician and in accordance with the applicable electrical engineering rules. Before opening the control box, draw in any case the mains plug.


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4 ASSEMBLY OF THE HOIST 4.1 Indications for safety Make yourself familiar with the surroundings before assembling the TOPLIFT. Pay attention to the soil bearing and separate the construction site from pub-lic access. The working area of the TOPLIFT has to be separated by a fence. This fence has to consist of at least two horizontal elements which have to be marked with contrasting colours (for exp. red/white).

picture 4-1 (All dimensions in meters)

4.2 Estimation of the rail length Take vertical lifting height and add approximately 20% for inclination. Increase to full meter.

4.3 Assembly of the rails 1. Place foot section on the ground and fit feet or

undercarriage. 2. Introduce carriage with rollers onto the rail.

picture 4-2

Hint! The knurled cams of the broken rope device located on the upper axle have to be released by raising the linkage.

3. Slide the carriage to the bottom of the foot sec-tion.

4. Place the extensions of 2 or 1 m on the ground.

5. Join the extensions.

Attention! The ring nuts are on the outside of the rails!!!

picture 4-3

6. Place the head section on the rails and tighten as well.

7. Tighten all ring nuts.

4.4 Setting up the rail section Up to 8 m length, the rail can be set up by hand and brought in the right inclination as a ladder. Anchor the feet with pins. Up to 13 m length, the rail can be raised from above by a rope.

Hint! The rope has to be at-tached in the middle of the

head section or upper end of the rail to avoid that the hoist will not tilt sideways.

Push along the rail section until the right inclination has been reached. Above 13 m length, assemble the rail on the ground and raise as above until vertical. 1. Raise the rails about 2.30 m. 2. Add further sections to the bottom of the rail. 3. Finally add the foot section with carriage fitted. 4. Incline to correct angle, then fit adjustable sup-

port.


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4.5 Load indicator The capacity of the hoist depends on length and angle of inclination of the rail. Refer to the load indicator on the foot section (picture 4-4).

picture 4-4

The load indicator is placed on the left side of the foot section. The indicator shows, to which height the rails can be loaded in the current inclination. The maximum load is 250 kg.

Hint! See to it that the load indicator can always move freely so that the exact inclination can be seen.

Attention! If, by assembling, the extensions with the old profile form (type TOPLIFT Standard, B or C) and extensions with the new profile form (Type TOPLIFT standard 150, 200 or 200 HS) are com-bined, then the total maximum capacity is 150 kg.

4.6 Mounting of bend section 1. Set up the rail with carriage fitted. 2. Place the bend section and tighten the screws. 3. Add further extensions (min. 1 meter). 4. Add the head section and attach it to the exten-

sions. 5. Adjust the bend section according to the inclina-

tion of the roof and tighten screws firmly.

picture 4-5

4.7 Support of the rail section The rail should be supported by the adjustable tube support if the rail is longer than 8 m or inclined more than 75°.

Attention! When transporting long goods the rail has always to be reinforced by the tube support. It is important that the maxi-

mum unsupported length does not exceed 8 m. If the rail length exceeds 13.30 m (without rail being sup-ported by roof), use an additional tube support or the Alu-support for window openings.


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4.8 Assembly of the tube support

picture 4-6

The tube support is to be fixed to a rung and to be extended to a suitable length and the lower section is to be placed on a plank or similar on the ground.

4.9 Head support

picture 4-7

When the hoist is used on flat roofs, floors or win-dows, the rail should be protected against lateral movement, by using the head support. This can be fitted directly beneath the head section or between two rungs.

4.10 Stability of the hoist

The rail must be secured on the upper point (head section) by attaching the ring nuts with a cable or rope to the building.

When using the bend section, this must also be at-tached to the building with a cable or rope.

4.11 The undercarriage If the hoist is equiped with an undercarriage, it can be moved sideways along the building.

4.11.1 Assemly of the undercarriage

The undercarriage has to be fixed before setting up the rail section.

1. Dismantle the feet, these are fixed with a bolt and a split-pin.

2. Add the undercarriage and secure by bolt and split-pin (picture 4-8)

picture 4-8

4.11.2 Moving the TOPLIFT

Attention! Before moving the hoist, make sure that the carriage is in the low-

est position. Detach the rope or cable from the head section. Never move the hoist when loaded.

1. Ride the carriage down. 2. Unload the hoisting device. 3. Release the brakes of the undercarriage. 4. Move the hoist. 5. Set the brakes again. ( Turn the brake shoes at

the wheels to the outside)

4.12 Securing the feet /undercarriage Place the hoist with its feet on solid ground and se-cure by pins. (If necessary place plank below for dis-tribution of pressure). When using the undercarriage adjust spindles so that both wheels are firmly on the ground. Put on brake shoes.


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4.13 Setting up the drive unit The drive unit is to be put onto the lower rung of the foot section. Make sure that the drive unit is placed in the middle of the ladder rung (picture 4-9)

Neues Bild

picture 4-9

1. Put the drive unit into the rail and unlock it by pull-ing up the handle.

2. At lock-in device in position “unlocked” put the drive unit with energy into the next rung.

3. Check that the locker hooks on the rung. 4. Put the 5-pole plug of the hand control in the

middle socket on the drive unit. 5. Put the 3-pole plug of the limit switch cable in the

upper socket on the drive unit.

4.14 Assembly and adjustment of the upper limit switch (without MV)

picture 4-10

1. Screw the limit switch holder on to the head section.

2. Take limit switch cable up to the head section and fix it to the holder with the wing-screw.

3. Lead the limit switch cable down the rails and fix it to the eye screws of the rails.

4. Wind the remaining cable carefully and fix it to the side of the drive unit.

4.15 Assembly and adjustment of the upper limit switch TOPLIFT Furni-ture (MV)

picture. 4-11

1. Screw the limit switch holder with the limit switch already mounted and the limit switch cable (2) to the first rail underneath the head piece.

2. In doing so, please observe the measure-ments given in Fig. 4-11.

3. Now fasten the limit switch holder to the rear side of the rail using the knurled screw, so that it can no longer be moved.

4. The position of the limit switch roll must be adapted to the respective furniture car-riage.(Fig. 4-12)

5. Direct the connecting cable (1) behind the head piece and guide it downwards.

6. Wind the remaining cable carefully and fix it to the side of the drive unit.


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picture 4-12

4.16 Electric supply

Warning! Electrical shock, burning and injuries can result

from:

• Touching • Damaged insulation • Unsufficient maintenance • Short circuit

The electrical connection has to be executed by a skilled electrician and in accordance with the appli-cable engineering rules. Electric supply must be made by a distribution unit with an earth leakage breaker. Secure with a 16A time lag

Hint! The cable has be totally un-wound. The use of the proper supply

cable is essential as otherwise there may be a loss of voltage resulting in damage in the controls.

Type Toplift 225 / 234 / 240 / Eco/ Furniture (MV,M1,M2) : Cross section of the cable: 3 x 2.5 mm² Maximum length supply line: 40 m

Type Toplift 225 / 110 Volt/50 Hz:

Cross section of the cable: 3 x AWG10”

(3x5.26 mm²) Maximum length supply line: 40 m

Furniture carriage

limit switch roll


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4.17 Fixing the hoisting rope

Attention! Wear gloves to avoid injuries while fix-ing the hoisting rope.

1. Take the end of the hoisting rope in one hand

and operate the hand control with the other one. Push the button "DOWN". See to it that the rope remains raught during unwinding, to avoid that the slack rope device stops the motor.

2. Take the rope up the righthand side to the head

section.

picture 4-13

3. Put the rope from the right to the left over the rope pulley. ( see picture 4-13) .

Make sure that the cable is seated correctly in the trail of the cable deflection pulley.

4. Lead the rope down at the lefthand side.

4.17.1 Attaching the rope to the stan-dard carriage + furniture car-riage

The rope locker at the end of the rope is to be at-tached to the rope connection on the standard car-riage (pins). At this point the broken rope device is still on, push the button UP on the hand control to tighten the rope.

4.17.2 Attaching the rope to the tilting carriage

1. Open the lids of the rope pulleys. 2. Lead the rope from the left to the right on the

lower pulley at the rear. (The rope lies behind the bar of the broken rope device)

3. Now lead the rope from the right to the left over the pulley roller and switch back the lid. ( The rope lies now in front of the bar of the broken rope device)

4. Lead the rope from the left to the right over the the upper pulley in the front and close the lid. (The rope lays in front of the bar of the broken rope device)

5. Attach the rope locker to the carriage.

6. Check the moving direction of the rope. Seen

from above the rope goes two times behind the bar of the broken rope device and three times in front of it.

4.18 Test run Before the initial operation of the TOPLIFT check whether: • All safety devices are in working order, • The limit switches at the top and at the bottom

are in order, • The broken rope device on the carriage is in or-

der, • The loading area is secured, • When using the bend section, the bend section

and the extensions are properly supported on the roof,

• The inclination of an extension on the roof is at least 25°,

• The hoist is supported, • The voltage is sufficient, when the TOPLIFT is

operated carrying the rated load.


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picture 5-1

picture 5-2

picture 5-3

5 Application of the hoisting de-vices

Warning! The transportation of per-sonnel and entering the platform is for-bidden.

For the intended use of the Toplift the only hoisting devices allowed to be used are those described here. All hoisting devices are fixed to the carriage by 4 pins. The upper pins are secured by spring lockers

5.1 Standard universal platform The dimensions of the platform are 60x35x85 cm. The standard universal platform can be used with the standard carriage as well as with the tilting car-riage. For loading the universal platform the side gratings can be lifted up and swung to the side at the same time. The standard universal platform has a load-bearing capacity of max. 250 kg, reduction depending on type.

5.2 Uni-platform comfort The Uni-platform comfort has a load-bearing ca-pacity of max. 250 kg, reduction depending on type. The dimensions of the uni – platform com-fort are 70 x 44 x 70 cm.

The Uni-platform standard can be used with the standard carriage as well as with the tilting car-riage.

5.3 Long-goods-platform The Long-goods-platform can be used in conjunction with both carriages. The dimensions of the Longs-good platform are 120x35x45 cm. For loading, the gratings can be opened.


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picture 5-4

picture 5-5

picture 5-6

5.4 Platform The Platform is only to be used with the standard carriage. The Platform is height-adjustable and is equiped with tiltable side-boards. Dimensions are 60x85 cm.

max. capacity: 200 kg

5.5 Sheet platform The Sheet platform serves for the transportation of large plates (plasterboards) and windows. The di-mensions are 90x15x220 cm. To use this Sheet plat-form in conjunction with the tilting carriage, the sup-plied switch cam has to be bolted to the platform. The advantage of using the tilting carriage is that the Sheet platform, can be tilted to the horizontal posi-tion, when arrived at the top, so that unloading of boards is easier. The maximum width of the products is 150 cm. The material has to be secured by the chain.


5.6 Tilting bucket The Tilting bucket is only to be used with the tilting carriage. The maximum contents is 80 Ltr. The bucket can be manually tipped at the bottom, to off load the material or debris. 1. Release the catch lever at the right side of the

bucket. 2. Tilt the bucket forwards using the handle. 3. Latch the bucket back into the catch lever. max. capacity: 250 kg


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picture 5-7

picture 5-8

picture 5-9

5.7 Solar-Platform Standard The solar-platform-standard may be used in combination with standard or tilting carriage. This platform is particularly designed for the transport of smaller solar and photovoltaic instal-lations. The modules are fixed by means of a continu-ously variable clamping device with rubber vibra-tion pad.


5.8 Solar-Platform adjustable The adjustable solar platform can be used with standard or tilting carriage. It is mainly used for the handling of larger solar elements. The base frame is rubber cushioned. The lateral bars can be extended to 1.55 m. max. capacity: 200 kg

5.9 Sheet transport bed with adjust-able inclination The sheet transport bed with adjustable inclina-tion serves to convey large sheets and panels (gypsum board panels, windows, etc.). The parts to be conveyed may have a maximum width of 150 cm, a maximum height of 210 cm and a maximum depth of 15 cm. The platform bed can be used with a carriage or a tilting carriage. With the tilting carriage combination it must be en-sured that the tilting function is not activated.

The use of the sheet transport bed with adjust-able inclination is advantageous, as the con-veyed material can be horizontally unloaded at the loading point and then fits through window openings due to the second tilting option. The material is secured by chains. max. capacity: 150 kg


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5.9.1 Handling of the Sheet transport bed with adjustable inclination

1

Upper frame

2 base frame

3 support 21 cm

4 support 45 cm

5 floor extension

6 lateral extension

picture 5-9.1

WARNING ! Danger due to the inclination function of the sheet transport bed!

If the supports (3; 4) are not secured by the bolted connection or if the snap pins are not engaged, the loaded or unloaded platform bed will tilt. Danger of crushing!

Before loading or using the sheet transport bed, check the bolt lock and the snap pins and lock if necessary.

WARNING ! Danger due to falling load!

Loads may fall due to incorrect operation or insufficient securing.

So not exceed the permissible payload (depending on the position of the supports, see 5.9.1 )

Never stand underneath the load or the load-bearing device.

Always secure the load with the chains supplied by the manufacturer.

Never extend the floor of the sheet transport bed when loaded.


22 92023200095

picture 5-9.2

After the sheet transport bed with adjustable inclination has been safely hung into the carriage (standard or tilt carriage), it is in basic position (picture 5-9.2).

In its basic position with the dimensions:

90 x 140 x 15 cm,

the sheet platform bed can be used with a maximum load of 150 kg. In this case the lateral extensions (6) and the floor extension (5) are not extended or length-ened.

WARNING !

Snap pins must be engaged before material transport.

The material is secured by the chains provided by the manufacturer.

After the extensions integrated into the floor and sides are used (Fig. 5-9.3), the sheet transport bed with ad-justable inclination can transport loads up to a maxi-mum of 100 kg.

The extensions can be pulled out to their maximum po-sition by removing the snap pins.

WARNING !

Snap pins must be engaged before material transport.

WARNING !

The floor extraction is not mechanically limited! Maximum extension is 70 cm.

picture 5-9.3

The maximum dimensions of the extended sheet transport bed are:

150 x 210 x 15 cm

The material is secured by the chains provided by the manufacturer.


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picture 5-9.4

The sheet transport bed with adjustable inclination can be turned by up to 45° in its first inclination option (pic-ture 5-9.4). The supports are secured by means of the bolted connection. The smaller supports (3) with a length of 21 cm serve in this position to support the up-per frame (1).

picture 5-9.5

In the second inclination option (picture 5-9.5) the up-per frame (1) is held using the long supports (4) and the bolted connections. The upper frame (1) stands at a maximum angle of 70° to the base frame (2).

picture 5-9.6

In the third position (picture 5-9.6) of the sheet trans-port bed, the upper frame (1), on which the material to be transported is retained, is secured using the bolted connections in the 45° and 70° inclination.


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picture 5-10

Abb. 5-11

Abb. 5-12

5.10 Furniture platform Universal / Basic The Furniture platform Universal / Basic is only to be used with the furniture carriage.

5.10.1 Furniture platform exten-dable

The Furniture platform (picture 5-10) is extend-able, incl. telescopic support. Dimensions are: 1200 x 800 mm (B x T).


5.10.2 Furniture platform pivotable and extendable

The furniture platform (picture 5-11) is pivotable and extendable, incl. telescopic support. Dimensions are: 1200 x 800 mm (B x T).


5.10.3 Furniture platform pivotable and extendable (without front-flap))

The furniture platform (picture 5-12) is pivotable and extendable, without a front-flap, incl. tele-scopic support. Dimensions are: 1040 x 870 mm (B x T).



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5.10.4 Handling of the furniture platform with pluggable side guards • Regulate both telescopic supports in such a way, that furniture platform is in horizontal position. For

bulky goods and for loading of the platform, both side guards can be removed respectively placed in horizontal position.

• Safety catch stop has to secure that side guards will not fall out when mounted in horizontal posi-tion

A T T E N T I O N ! The centre of gravity of the cargo to be transported must always be placed in the centre and as near as possible to the guide rails. If - in the case of bulky pieces of furniture - the feet extend beyond the bottom of the platform, then it is allowed to load the side guards with no more than 30 kg each.

• Always secure load by means of belts against falling down. For loading or unloading in upper position, the platform can be drawn towards the window sill or over the balcony parapet.

• Unlock and hinge down the extension rail. • Release the lock with the lever and simultaneously pull the furniture platform in forward direction. • Allow locks to snap in again.

A T T E N T I O N ! During the „lifting“ and „lowering“ movements, the furniture platform must always be snapped in transverse to the lift rails and be arrested within the carriage telescopic rail in the rear hole. Front part of extension rail has to be tilted upwards.

• Securing rings have to be pulled out. • During movement, the furniture platform can be pulled backward out of the extension rail. For this,

safety hook to be pushed upwards and locks to be released.

NOTE! A detailed description / instruction for each furniture platform, explained at the pages

before, can be requested by the manufacturer.


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6 OPERATION OF THE TOPLIFT • The operator must always watch the load

during transport. • Transportation of personnel is forbid-

den. • The maximum eaves height of 20 meters is

not to be exceeded. • With wind speeds over 70 km/h work has to

be stopped. • Do not use the TOPLIFT as a ladder. • It is not allowed to enter the platform. • Do not stand underneath the hoist. • Before starting to work, make yourself famil-

iar with the surroundings, the soil bearing capacity, the necessary security measures to secure the construction site from public access.

• Secure the construction site by placing in-formative signs as: “Caution, falling ob-jects.”

•

6.1 Before each use Check if the broken rope device on the carriage is working smoothly. Check if the rope is damaged/worn. Check the functioning of the limit switches.

6.2 Control system of the TOPLIFT 225/234/240/M1/M2

The TOPLIFTS 225 Universal and TOPLIFT 234 are controlled with the hand control by pushing the but-tons EMERGENCY-STOP/UP/DOWN. It works in hold-to-run mode.

The upwards movement is limited by the upper limit switch. The downwards movement is stopped by the slack rope device. The travel can always be stopped by pushing the EMERGENCY-STOP button or by releasing the but-ton. The EMERGENCY-STOP button has to be turned and pulled out when used, to reset the func-tion. The TOPLIFT 240 has two hoisting speeds. When pushing-in the buttons UP/DOWN to inter-mediery position, the winch will operate at half speed (after start, before stop and passing the bend-section). When pushing the button fully, the winch will operate at full speed. The control works in hold-to-run mode. See further as described before.

6.3 Control system of the TOPLIFT ECO

The TOPLIFT ECO are controlled with the hand con-trol by pushing the buttons EMERGENCY-STOP/UP/DOWN. It works in hold-to-run mode. The upwards movement is limited by the upper limit switch. The downwards movement is stopped by the down limit switch. The travel can always be stopped by pushing the EMERGENCY-STOP button or by releasing the button. The EMERGENCY-STOP but-ton has to be turned and pulled out when used, to reset the function.


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6.4 Control system of the TOPLIFT Fur-niture (MV)

The TOPLIFT Furniture is controlled with the hand control by pushing the buttons EMERGENCY-STOP/UP and a key-switch for moving DOWN. It works in hold-to-run mode. The upwards movement is limited by the upper limit switch. The downwards movement is stopped by the down limit switch or by the slack rope device (in case of emergency). The travel can always be stopped by pushing the EMERGENCY-STOP button or by re-leasing the button. The EMERGENCY-STOP button has to be turned and pulled out when used, to reset the function. The Toplift Furniture can be operated from the top on the roof and from the bottom on the ground. The conveying equipment can be ma-noeuvred in upward and downward direction.

WARNING !

When loading/unloading, it is essential that the EMERGENCY-OFF BUTTON is pressed in the corresponding control sta-tion in order to prevent inadvertent start-ing.

6.5 Securing the loading area Operational safety order in accordance with BGV D7

At any loading or unloading point of construc-tion hoists, means have to be provided to assure persons do not fall down. These means must be of such nature that the loading/carrying devices can be safely loaded and unloaded.

The safety device has to be strongly fixed and must at least be 1.1 m high.

Openings in the safety device for a certain move-ment of the loading device must be as small as pos-sible.

If, for example, for the transportation of roofing mate-rial to a roof, safety devices cannot be fitted, then the carriage must be monitored by the operator during the whole travel, from a point from which he has view of the complete hoistway.

The base guard of the lift has to consist of at least two horizontal elements which have to be marked with contrasting colours (for exp. red/white). One element has to be mounted at a height between 1.0 and 1.2 m, the second one at height of about 0.5m. For protection, the base guard has to be mounted at at least 1.4m from the widest load that can be trans-ported. The maximum width has to be 1.4m.

7 DISMANTLING THE TOPLIFT

The TOPLIFT is to be dismantled by skilled personnel only. These skilled personnel have to be familiar with these

operating instructions and needs to have suffi-cient experience as well as knowing the risks in-volved with constructing hoists. 1. Secure the danger zone. 2. Dismantle the hoist in reverse order.


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8 WARRANTY The warranty period of the TOPLIFT is 12 months from the supply date. The conditions for claims are: defective construction, faulty material or faulty execution. Such defects have to be reported immediately to the supplier in writing. Replaced parts become property of the supplier. Damage caused by natural wear cannot be claimed. No warranty is given on the damage caused by: • Faulty use or application. • Faulty assembly of the hoist. • Faulty or careless treatment, in particular in re-

gard to these operating instructions. • Excessive use and • By the use of inappropriate equipment or spare

parts. If the products are sent to our factory for repair and if damages occur due to faulty packaging, they will be at buyer’s expense.

9 MAINTENANCE 9.1 Maintenance intervals General The TOPLIFT has to be checked, depending on the operation frequency, at least once a year by a competent person. Make sure that replaced parts are disposed in a safe way in accordance with the requirements of environmental protection. The maintenance comprises visual checks, func-tional checks and cleaning. The intervals are indicated as follows:

w weekly 3 M 3- monthly 12 M annually

Description w 3 M 12 M Activity CommentsInstruction and load labels X Visual check legibility Drive Unit X Functional check Upper limit switch X Functional check Lower limit switch X Functional check Electrics X Functional check Supply line X Visual check Rope X Visual check

Breakage of strands, birdcaging, cor-rosion, kinks, squeezing

see chapter 9.3

Broken rope device X Functional check see chapter 9.7 Pulleys carriage X Functional check Pulley head section

X Functional check

Pulleys bend section X Functional check The pulleys have to be cleaned of concrete and mortar.

Slack rope device X Functional check The slack rope device has to be regu-larly cleaned of concrete and mortar so that it is always operative.

Extensions screws/nuts condition of welds

X X

X

Visual check Visual check Visual check

External electric terminals on the drive unit

x Visual check

Periodic checking and testing by the operational safety or-der in accordance with BGV D7

X Testing by a competent person Sea appendix


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9.2 Changing the rope The operational security and the lifetime of the rope depends on proper use and good maintenance. It is important to totally unwind the rope regularly and ex-amine the rope for damage. The rope has to be regularly cleaned from old grease, dust and corro-sion and has to be lubricated.

9.3 Checking the rope and discarding The ends of the rope have to be properly attached. Upon checks by the competent person the rope has to be checked for fractures. Damage that is visually easy to establish are: Kinks, untwisting, crushings, sharp bends, corrosion, birdcaging, strong reduction of the rope diameter and breakage of a strand.

Attention! Always wear gloves when re-placing the rope.

Before fiitting unroll the wire rope completely on the ground before fitting to the drum to avoid twisting.

9.4 Fitting of the hoisting rope on the cable drum Toplift 225 Universal / 234 / 240 / Furniture

• Remove the front wall by loosening the four hexagon screws.

• Remove the old cable from the drum winch and dismantle the cable lock for the new cable.

• Loosen the hex socket screw (use a 4mm hex socket wrench) on the left-hand side of the winch in order to be able to remove the cable

• Completely unroll the new cable on the floor. • Now place the cable onto the drum winch

from the left. • The cable is placed onto the cable drum by

three winds and clamped in using the hex socket screw (use a 4mm hex socket wrench).

• Push the button UP and wind the rope on the ca-ble drum. See to it that the windings lay properly next to each other

• Then guide the end of the cable through the roll-ers of the slack cable safety device and secure the front wall using the four hexagon screws.


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9.5 Placing of the hoisting cable (5mm) on the Toplift ECO cable winch

• Remove the old cable from the drum winch and dismantle the cable lock for the new cable.

• Loosen the hex socket screw (use a 6mm hex socket wrench) on the left-hand side of the winch in order to be able to remove the cable

• Completely unroll the new cable on the floor. • Fasten the new cable to the cable drum using

the hex socket screw (use a 6mm hex socket wrench).

• Push the button UP and wind the rope on the ca-ble drum. See to it that the windings lay properly next to each other

9.6 Fixing the rope to the rope socket. 1. Lead the end of the rope the back through the

rope socket. 2. Put the rope around the wedge and lead the end

of the rope from the front through the rope socket.

3. Tighten the end of the rope, so that the wedge jams in the rope socket.

4. Secure only the end of the rope by attaching a rope clamp.

9.7 Adjusting the slack rope device The slack rope device has been adjusted with the aid of a spring. The slack rope device has been fac-tory adjusted and only has to be readjusted when parts have been replaced.

9.8 Checking the broken rope device The broken rope device has to be checked before each application and at least once a week. To guarantee the function, it has to be regularly cleaned of concrete and morter, etc. 1. Drive the unloaded carriage appr. 1 meter up. 2. Push the carriage up (by hand). The rope is

now slack and the brake shoes at the upper support rollers of the carriage will clamp on the rails.

3. To release the broken rope device, the button UP has to be pushed so that the carriage will move upward. The rope will tighten and the brake shoes will release the rails. Downward travel is not possible, because this is inter-rupted by the slack rope device.


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10 Trouble-shooting Works at electrical installations or machines are only to be exectuted by skilled electrical personnel in accordance with the electric engineering rules. Before attempting repair, the load has to be removed or secured. Always pull out the plug before opening the control box. Interruption Cause Measures

TOPLIFT does not work. No voltage. Check Supply voltage and the slow secured (16A)

EMERGENCY-STOP button is set.

Button (red) turn and pull.

Motor hums but does not start Brake rectifier defective. The brake rectifier is connects the brake with approx. 200V d.c.. The fuse is located on the motherboard next to the motor connectors. The defective fuse can only be exchanged by fuse “1A slow”. If it happens again, please check the brake coil.

Brake coil defective. The brake coil has a resistance between 1.7 and 1.9k Ω.

Lift does not pull rated load.

Supply voltage is not constant. Feed line too long. Max. length is 40m ∅ 2.5 mm²./

Load slides downward when push-ing the UP button.

Supply voltage is not constant. Check supply voltage, it must not be less than 207V during start of upward travel with load. At 110 Voltage must not be less than 105V dur-ing start of upward travel with load.

Operational capacitor defective. Replace, see to it that the right capacitor is re-placed.

Starting capacitor defective. Replace, see to it that the right capacitor is re-placed.

The motor heats up quickly, also with a small load.

Supply voltage or supply line not in order.

Check as described above.

Operating factor of the TOPLIFT is to high.

Reduce maximum operating factor to 40%.

The carriage does not move up when pushing the UP button.

Upper limit switch is defective or faulty adjusted.

Check limit switch and if necessary replace, see spare parts list.

The limit switch cable is damaged Check cable and if necessary replace by an electrician

Plug or socket connection of the limit switch is defective.

Check and replace. (by an electrician)

Motor heats up and stops. Thermal contact of the motor was tripped.

Let the motor cool down, check voltage and supply line reduce load if necessary. After cool-ing down the motor can be operated again.

The TOPLIFT does not react of or-ders, although the current supply is good.

One of the control fuse defective. Because of a short circuit in the limit switches or at the suspended controls, one of the safety fuses on the control board (by the side of the trafo) is fused. The defective safety fuse shall be replaced with an identical fuse. Prim.=0..2A slow or sec.=630mA slow.


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11 master data

manufacturer: ____ Böcker Maschinenwerke GmbH

Lippestrasse 69-73

D-59368 Werne

dealer: owner: Serial-number: year of contruction: implementing:


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Extraordinary inspection Hoists have to be checked by an expert after after major changes (Operational safety order in accordance with BGV D7).

Major changes are for example the increase of the loading capacity, changes of construction, changes of tensile force of the engine, raising the lifting height over the manufactor’s settled height, welds on sup-porting parts. No major change is in comparison a replacement of identical parts.

The TOPLIFT is has been designed and manufactured to fully comply with:

• EC-Machinery Directive 98/37/EG • EC-low voltage Directive 2006/95/EG • EN 12158-2

Attached you find a copy of the EC Declaration of Conformity. Furthermore each TOPLIFT is tested and checked before delivery. Returning inspections Hoists have to be checked, depending on the operation frequency, at least once a year by an expert.

Experts are persons, who have sufficient knowledge in terms of in terms of hoists because of their professional training and experiences. They are confident (familiar) with the guidelines of public safety at work, guidelines of accident prevention and guidelines according to the technique (e.g. VDE-Directive, DIN standards), so that they can judge (access) about the safety conditions of hoists.

The inspections are to be determined by the elevator’s manufacturer. He’s responsible for the choice of the experts. Experts could be e.g. maintenance engineers, foremen, customer service technicians of the manufactory or special qualified personnel. The manufacturer always has a high responsibility, if he chooses people, working in his own company, for experts (to be experts). The results of this inspection are to be recorded in writing and kept. Therefore use the expert inspections on the following pages.


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12 Information about the expert inspection Information about the visual and functional inspection acc. to the operational safety order in accordance with BGV D7 To check are: Information at the lift: Type plate Fastening Writing / label Readability Brief instruction Completeness / totality Detailed instruction Condition Readability Protection against unauthorized use Control buttons EMERGENCY-OFF Condition UP Function DOWM Movement Permanent marking of the movement directions Limit switches lower sledge Condition Upper sledge Function Movement Elements for fastening and stable mounting Support elements Condition Spindles Function Bottom plates (food section) Movement Carriage Corrosion Abrasion Deformation / cracks Load-bearing elements Rail profiles Corrosion Bend section Abrasion Deformation / cracks Pollution Fastening unfixed connection Loading devices Carriage Condition Rollers Function Tilting carriage Broken rope device Condition Function Hoisting devices Gratings Locking systems


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Electrics Electrical lines Damaging Plug-in connections Fastening Control Function Steel wire ropes Pulley-rollers Damaging Forms of abrasion Feathering in the rope-rill Alignment of the pulley roll Rope connections Pinch points / squeezing Corrosion (inside/outside) Wire breaking Bird-caging Breakage of a strand Rope windings Fastening Function Guideline for rope windings according to DIN

15020 page 2


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13 Test protocols on expert inspection The test depends on the national prescriptions. In Germany, the test-requirements for the user/operator are determined by the operational safety order. The results of the expert test according to the operational safety order

The TOPLIFT, factory number ___________ was subjected on ____________________ to a visual and functional inspection. No defects were detected/The following defects were detected: ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ There are - no - objections to putting the device into operation. A new inspection is - not - necessary.

___________________ ___________________ ___________________ Place / Date Signature Signature Expert Works Manager Name of expert: _________________________________________ Address: _________________________________________ Job title _________________________________________ employed by: _________________________________________ New inpection The TOPLIFT, factory number _________ was subjected on ____________________ to a new inspection. The objections resulting from the test on _____________________ have – not – been remedied. ___________________ ___________________ ___________________ Place / Date Signature Signature Expert Works Manager


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Test protocols on expert inspection The test depends on the national prescriptions. In Germany, the test-requirements for the user/operator are determined by the operational safety order. The results of the expert test according to the operational safety order


___________________ ___________________ ___________________ Place / Date Signature Signature Expert Works Manager Name of expert: _________________________________________ Address: _________________________________________ Job title _________________________________________ employed by: _________________________________________ New inpection The TOPLIFT, factory number _________ was subjected on ____________________ to a new inspection. The objections resulting from the test on _____________________ have – not – been remedied.

___________________ ___________________ ___________________ Place / Date Signature Signature Expert Works Manager


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___________________ ___________________ ___________________ Place / Date Signature Signature Expert Works Manager Name of expert: _________________________________________ Address: _________________________________________ Job title _________________________________________ employed by: _________________________________________ New inpection The TOPLIFT, factory number _________ was subjected on ____________________ to a new inspection. The objections resulting from the test on _____________________ have – not – been remedied. ___________________ ___________________ ___________________ Place / Date Signature Signature Expert Works Manager


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___________________ ___________________ ___________________ Place / Date Signature Signature Expert Works Manager Name of expert: _________________________________________ Address: _________________________________________ Job title _________________________________________ employed by: _________________________________________ New inpection The TOPLIFT, factory number _________ was subjected on ____________________ to a new inspection. The objections resulting from the test on _____________________ have – not – been remedied.

___________________ ___________________ ___________________ Place / Date Signature Signature Expert Works Manager


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14 Wiring diagrams 14.1 Wiring diagram Toplift 225 – 110V


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14.2 Wiring diagram Toplift 225 Universal, Toplift 234, Toplift Furniture M1

KONFORMITÄTSERKLÄRUNG

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14.3 Wiring diagram Toplift 240, Toplift Furniture M2


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14.4 Wiring diagram Toplift Furniture MV


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14.5 Wiring diagram Toplift ECO

wiring diagram

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Toplift Toplift Eco - CLM ConstructionOperating Instructions Toplift Toplift Eco Translation based...

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