AHCON TL2.0 User manual

USER MANUAL
WHEEL TROLLEY TOWER LIFT 2.0/2.1

Declaration of Conformity
FLEX1ONE
Ladelundvej 37-39
DK - 6650 Brørup
Hereby declares that the following product:
Type: WHEEL TROLLEY TOWER LIFT 2.0/2.1
Article nos.: TL2.0 / TL2.0+ / TL2.0L / TL2.0L+ / TL2.1 TL2.1+ / TL2.1L /
TL2.1L+
Product no.:
Production year:
have been produced in accordance with Council Directive:
2006/42/EC 17. May 2006
Amended by the following:
98/37EEC
have been produced in accordance with the following standards:
DS/EN 349 + A1: 2010
DS/EN ISO 12100: 2011m
DS/EN ISO 13857: 2008
DS/EN 60204-1
DS/EN ISO 13850
Date: 21/02/2019
Name: Bo Møller Signature:

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Manufacturer details
Article nos.: TL2.0 / TL2.0+ / TL2.0L / TL2.0L+ / TL2.1 / TL2.1+ / TL2.1L TL2.1L
TL2.1L+
Type: WHEEL TROLLEY TOWER LIFT 2.0/2.1
Use:
Max. tyre diameter: 680/750 mm
Max. rim width: 10.5”
Max. load: 120/180 Kg
Area of use: Used as an ergonomically correct wheel lifter for storing car wheels
in high racks.
Manufacturer: FLEX1ONE
Ladelundvej 37-39
DK –6650 Brørup
[phone]
Email: [email protected]
Distributor:

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Thank you for your purchase of an AHCON quality product. Before putting the equipment
into use, it is important that you familiarise yourself with the how it should be used, as well
as with all its safety features and requirements. It is important that all its safety
requirements are complied with in order to protect the user and others in and around the
area of the wheel trolley tower lift.
This manual contains all relevant information to ensure that the user of the lift and others
in the vicinity are able to comply with and use the lift safely.
This manual applies to several different types of lift and there may be places where the
description and/or illustrations are not quite the same as the lift you have chosen. All types
are described in this manual.
Note: It is important to comply with all relevant local laws and regulations before and
during use of the lift.
Note: If the lift is sold on, it is important that this manual accompanies the machine to the
next owner. This manual is of importance in ensuring proper and safe use of the machine.
WARNINGS!
Safety precautions
WHEEL TROLLEY TOWER LIFT 2.0/2.1 may only be used by trained personnel.
WHEEL TROLLEY TOWER LIFT 2.0/2.1 may only be used for lifting wheels and to a total
combined weight of 300 KG. (Operator and tyre.)
AHCON disclaims all responsibility for any malfunction or fault arising from work
procedures that are not in accordance with AHCON's instructions.
WARNING: Always comply with warning signs, otherwise there is a risk of personal
injury!
NOTE: It is important to observe the maintenance instructions: if maintenance is not
carried out correctly, there is a risk of damage to the lift.
Overview of abbreviations and meaning.
Abbreviation
mm
m
s
Km/s
Kg
Lb
Meaning
millimetre
metre
seconds
Kilometre(s)
kilogram
pounds
Abbreviation
%
in
min
Ah
Kw
V
Meaning
Per cent
Inches
Minutes
ampere-hour
kilowatt
volt

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Crushing hazard!
Pictograms and warning labels fitted by the manufacturer must not be removed!
Damaged or illegible signs and pictograms must be replaced before use.

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The majority of the materials used for the lift are made of recyclable steel. Waste resulting
from maintenance, cleaning and even scrapping must be recycled and stored according to
local regulations and laws, and must be carried out by authorised companies. When
recycling, a special focus must be placed on substances harmful to health such as
batteries, hydraulic oil/waste oil and electronic waste.
If there is a need for continuous improvement of the lift, the manufacturer reserves the
right to alter its own design and specifications without prior notice. The manufacturer may
be contacted for updated product specifications. All parameters and information in this
manual are valid for the delivery date of the lift.
WARNING: In order to avoid the risk of injury to the operator or others, the following
safety measures must be observed.
Lifts and other lifting gear can pose a safety risk if they are not serviced adequately, or not
at all. For this reason, it is important that service is carried out at the correct intervals and
by trained and authorised personnel.
Maintenance and inspection shall be in accordance with the information that follows.
1. The described procedure for inspection, lubrication and maintenance of the system
must be observed.
2. Only authorised and trained persons may inspect, maintain and repair the lift.
3. Before starting the machine.
a. Visually inspect the lift for cracks, dents and damage.
b. Visually inspect the chains, cylinder and other lifting components for wear,
damage and leakage.
c. Switch on the machine and check that the power supply, steering, speed,
brake and alarm function all show normal operation in the display, and with
no error codes.
4. Before leaving the machine.
a. Do NOT park the lift on a slope.
b. The basket and forks must be placed in the lowest possible position.
c. Press the emergency stop button.
d. Turn the key to OFF.
5. The lift should not be used in very dirty, contentious or corrosive environments. The
lift must not be used in areas where there is a risk of fire or explosion.
6. Regularly check the tyres, brakes, power supply, lift, hydraulics and all electrical
functions to ensure safe use of the lift.
7. Warning signs, type plates and instructions for use must always be in a clear and
legible condition. Damaged or illegible signs must be replaced before the lift can be
used.
8. All changes that may affect load capacity, stability and/or safe use may only be
implemented following receipt of the manufacturer’s written approval. Where such
an approval has been received together with a change of name plate, signage and
identification number, the user and maintenance manual must be updated to reflect
said changes.

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9. Correct use of the lift in accordance with the guidelines in this manual, as well as
local and national regulations, must be observed. The lift described in this manual is
an industrial machine intended for handling, lifting and stacking tyres. It needs to be
used and maintained accordingly. Any other use is outside the scope of application
and is not permitted, since being outside the scope of application it may well result
in injury to persons, damage to equipment or to the building. It is especially
important that the lift is not overloaded and that the maximum load signs are
respected. It is important that the lift is not loaded unevenly: always ensure that the
load is placed in the middle of the lift.

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Contents
1. Introduction.................................................................................................................10
1.1 Applications: .........................................................................................................10
1.2 Overview...............................................................................................................11
1.3 Standard version spec..........................................................................................12
1.3.1 Technical data for standard lift.......................................................................12
2Start-up.......................................................................................................................15
2.1 Before initial operation..........................................................................................15
2.2 First use................................................................................................................15
2.3 Unpacking.............................................................................................................15
2.4 Power connection.................................................................................................16
2.5 Noise ....................................................................................................................16
3Use.............................................................................................................................16
3.1 Safety requirements..............................................................................................16
3.2 Direction of motion................................................................................................19
3.3 Steering, driving and reversing.............................................................................19
3.4 Start......................................................................................................................20
3.5 Stop......................................................................................................................20
3.6 Display..................................................................................................................21
3.7 Lifting....................................................................................................................21
3.8 Instructions for use ...............................................................................................22
3.9 Emergency lowering.............................................................................................27
3.10 Use of the Wheel Trolley...................................................................................29
4Maintenance, charging and replacement of batteries.................................................30
4.1 Safe handling of lead-acid batteries......................................................................30
4.2 Maintenance.........................................................................................................30
4.3 Fire hazard ...........................................................................................................30
4.4 Maintenance of batteries ......................................................................................30
4.5 Disposal of batteries.............................................................................................31
4.6 Battery specifications............................................................................................31
4.7 Storage and installation of batteries......................................................................31
4.8 Charging...............................................................................................................32
4.9 Equalizing charge.................................................................................................32
4.10 Disconnect and re-connect the battery..............................................................33
5Maintenance manual ..................................................................................................33

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5.1 Safety regulations for maintenance and repair. ....................................................33
5.2 Daily maintenance (before each shift) ..................................................................34
5.3 Main servicing.......................................................................................................34
5.4 Maintenance of the electrical system....................................................................37
5.5 Preparation before repair......................................................................................37
5.6 Checking the hydraulic oil.....................................................................................37
5.7 Preparation for use after maintenance..................................................................37
5.8 Lift storage............................................................................................................37
5.9 Before storage......................................................................................................38
5.10 During storage...................................................................................................38
5.11 After storage......................................................................................................38
5.12 Oil and lubricants...............................................................................................39
6Diagrams....................................................................................................................40
6.1 Electrics diagram V3.............................................................................................40
6.2 Electrics diagram V2.............................................................................................41
6.3 Hydraulics diagram...............................................................................................42

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1. Introduction
1.1 Applications:
The lift described in this manual is an industrial lift used to transport lifted goods. It is
forbidden to use the lift in areas in which the clearance is lower than the top of the lift or
the top of the goods.
The lift may not be used in public areas.
The lift may only be used on surfaces that have sufficient bearing capacity to absorb the
total weight of the lift, the load and the operator. The surface must be even and clean.

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1.2 Overview
1. Top rack: Available in different configurations depending on the model.
2. Display: All relevant information is available on the display: the steering wheel
position, lift status, error codes (if any), battery capacity, direction of travel, etc.
3. Unloading tray: Not available for tyre lifting machines.
4. Control buttons: Control buttons for forward and backward, turning handle for
steering, horn, light and other functions.
5. Emergency stop: Press emergency stop if a dangerous situation arises. The
emergency stop closes down all electrical functions.
6. Safety arms: The lift cannot be operated if the arms are not folded down.
7. Dead man’s control: To operate the lift, the foot pedal must be activated.
8. Driving wheels: High-strength wheels, suitable for hard and flat surfaces.
9. Frame construction: Frame construction in high-strength steel.
10.Shelf: Available in different configurations depending on the model.

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11.Anti-tip block: Fittings that ensure that the lift does not tip over, safety fittings that
must be inspected regularly.
12.Hydraulic station: High pressure unit to drive the hydraulic system.
13.Pull ring: The lift can be pulled along using this ring.
14.Drive unit: The unit is mounted on the frame in the lift. The electronic traction
controller ensures smooth motor start-up and provides a smooth start and
acceleration.
15.Warning light: Warns people in the vicinity that there is a working lift. Warning
lights are available in different versions.
1.3 Standard version spec.
Technical specification is JB/ T3773.1-84.
1.3.1 Technical data for standard lift.
Model
QDJ-V2
QDJ-V3
Propellant
Electric
Electric
Loading ability (Goods tray
+ forks +operator)
Q（kg）
400 kg
400 kg
Goods tray
Q1（kg）
250 kg
250 kg
Shelf
Q2（kg）
150 kg
150 kg
Wheel material
polyurethane (PU)
polyurethane (PU)
Drive wheel size
mm
Φ250×75
Φ250×75
Load wheel size
mm
Φ152×75
Φ152×75
Lowered mast height
h1（mm）
1595/1700/1955
1700/2230
Max. height
h4（mm）
4630/4985/6075
4985/7055
Max. cabin height
h3（mm）
3200/3500/4200
3500/5000
Length (shelf folded in)
l1（mm）
1500
1510
Length (shelf folded out)
mm
1980
1745
Width
b1（mm）
832
832
Handle height
h5（mm）
1065
1065
Vertical clearance
m2（mm）
81
81
Aisle width
Ast（mm）
1930
1835
Turning radius
Wa（mm）
1500
1405
Drive speed（1st）
Km/h
5
5
Drive speed（2nd）
Km/h
2.5
2.5
Drive speed（3rd）
Km/h
1.2
1.2
Drive speed（4th）
Km/h
0.6
0.6
Max. inclination, when
loaded and unloaded.
%
0
0
Drive motor
Kw
1.5
1.5
Lift motor
Kw
2.2
2.2
Battery volt/amp hours
V/Ah
24V/210Ah
24V/210Ah
Steering type
Electric
Electronic
Drive control type
AC
AC

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The table contains the technical data for a standard lift only. The technical data may vary
on non-standard lifts, lifts with other accessories or other combinations as shown above
with and without forks. The manufacturer reserves the right at all times to update the
technical parameters of the lift.

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Shipping measurement
Height: 1990/2260mm
Length: 2300mm
Width: 850/1060mm
Working height: 5300/6000 mm
Max. load: 120/ 180 kg
Max. total load: 300 kg
Max/min usage temp.: +40 -250C
Net weight WTTL 2.0: 1700 kg
Net weight WTTL 2.0L:1565 kg
Net weight WTTL 2.1: 1790 kg
Net weight WTTL 2.1L: 1665 kg
Gross weight WTTL 2.0: 1786 kg
Gross weight WTTL 2.0L: 1651 kg
Gross weight WTTL 2.1: 1876 kg
Gross weight WTTL 2.1L: 1751 kg

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2 Start-up.
Warranty provisions
AHCON guarantees that the product meets the specifications at the time of delivery, and
will be free from defects in materials and workmanship for a period of 12 months after the
product has been invoiced to the end user.
Components and parts subject to normal wear and tear are not covered by the warranty
scheme.
AHCON assumes no responsibility for damage caused by accidental and careless use,
incorrect installation etc.
Goods and machine parts returned to AHCON for repair and exchange must be sent
carriage paid.
2.1 Before initial operation.
The lift can/may only be used with a battery as power supply.
The lift is ready for use upon receipt.
Check that the equipment has not been damaged in transit and is complete with charger
and other accessories.
Check the hydraulic oil level.
Check the battery is connected. Refer to section 4.10 if necessary.
Charge the battery, refer to section 4.8.
During long-term storage/standstill, the wheels may develop a flat spot, which will
gradually diminish when put into use.
2.2 First use
We recommend using the machine under light load conditions, i.e., low weight and low
lifting height, until you have become an experienced user and know the lift's operation,
functions and limitations. The recommendation from the supplier is 100 hours of
use/driving with the lift.
We recommend that you avoid heavy braking, turning or deceleration, especially with a full
load.
2.3 Unpacking

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Remove the wrapping foil and remove the lift from the pallet with a forklift.
Place the machine on an even floor.
2.4 Power connection
Charging is undertaken via the accompanying battery charger, which requires standard
220V.
2.5 Noise
Noise from this machine is below 70 Db.
3 Use.
3.1 Safety requirements
Operator authorisation: the lift may only be used by properly trained and instructed
personnel who can prove to the owner/employer that they can drive and operate the lift
safely with and without load. The operator must not use the lift before it has been
approved by the employer.
It is the employer's responsibility to ensure that the operator has been informed of his/her
duties, responsibilities and requirements. The operator must be informed and instructed in
the use of the machine and must have read and understood the accompanying user
manual . The operator must wear safety shoes when using the lift.
The operator must ensure that the lift is not used by untrained personnel, who do not have
sufficient approvals and training.
It is not permitted to transport other people on the lift.
Defects: any error or defect must be reported to the immediate manager or employer.
Damaged safety components must be replaced before further use. If in doubt, take the lift
out of service.
The operator must not carry out repairs or maintenance on the lift without the necessary
training and qualifications. The operator must NOT fix, block or adjust any safety devices.
The lift is constructed in such a way that the user cannot be injured during normal use of the
lift, as long as the instructions for use are followed.
The lift is extremely ergonomic and user-friendly.
A type sign is placed on the lift which must be easy to read and which clearly shows the
model, main parameter, manufacturer and date.
Hazardous areas: the area in which the lift is operated is designated as a hazardous
area. When the lift is being driven with raised forks, raised load, raised basket or transport,
there is an increased risk of personal injury.
Unauthorised persons must not be within the lift's operating area.

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It is not recommended to use the lift if you are emotionally affected and/or are not fully
focused on operating the lift and any potential hazard.
Always follow recommendations from warning signs and warning instructions, and ensure
full and correct operation of all safety devices.
Failure to comply with the foregoing instructions and recommendations will result in loss of
warranty in the event of damage to the vehicle.
Surface: The lift must never be raised on a surface with an incline in excess of 30. An
acoustic warning sound is emitted if the lift is driven with a raised basket or is raised on a
surface with an incline of 30or more. The basket must be lowered immediately and the lift
placed in or used in another area where the surface allows it.
When transporting/driving loads on slopes or loading ramps, the forks and goods must
always be placed in the lowest possible position. When carrying a load, always drive up
forwards and down backwards.
Never drive across slopes, as there is a possibility of the lift tipping over!
Warning and information on the lift.
This machine must only be
operated by personnel who
have carefully read and
understood the user manual.
Crushing hazard!
Be aware of the risk of
crushing with moving
parts.

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Max. load capacity:
never exceed the
maximum load capacity!
Sign and date for the next
annual safety inspection.
The inspection must be
carried out by an
approved service
technician.

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3.2 Direction of motion.
RIGHT LEFT FRONT BACK
3.3 Steering, driving and reversing
The dead man's control, which is the foot pedal
on the right side of the bottom of the platform,
must be activated in order to drive and operate
the lift.

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Warning!
When the lift is switched on, it first runs a self-test of
the control systems. Wait until the display is in normal
mode before using the lift.
There is an emergency stop located next to
the ignition key. This should be activated
when sudden hazardous situations arise
and where the operator has no control over
or cannot handle the situation. Deactivate
the emergency stop only when the
hazardous situation has been removed or
rectified. Should the lift be damaged, it
must not be used until the damage has
been repaired.
3.4 Start
- The protective arm is tilted down. (Closed)
- Put the key in the ignition and turn it to "on".
- Pull out the emergency stop if it has been activated.
- The speed can be controlled via the rocker switch as well as in intervals.
- Use the rotary handle on the left-hand side to steer the lift. The steering wheel
angle/direction can be seen in the display.
3.5 Stop.
Stopping depends to a large extent on the surface. It is important that the operator takes
the surface into account when operating the lift, and is very aware of the drive path in front
of the lift and of any obstacles as well as vertical clearance.