Beacon BWL-100 Manual
//201Manual, BWL-100.doc
OPERATION &
MAINTENANCE
MANUAL
Beacon Industries, Inc.
12300 Old Tesson Rd., St. Louis, MO 63128
Ph: 314-487-7600 · Fax: 314-487-0100
E-mail: [email protected]
Website : www.beacontechnology.com
MODEL BWL-100
Pre-installation Instructions ............................................2
Installation Instructions ...................................................3
Routine Maintenance & Safety Checks ..........................4
Operation Instructions .....................................................5
Structural Expl View & BOM .......................................6
Power Unit’s Operation .................................................. 7
Motor & Transformer Connections ................................ 8
Electrical Diagrams ..................................................... 9-10
Power Unit Expl Parts Drawing & BOM ....................11
Manifold Expl View & BOM, Hydraulic Diagram .....12
Power Unit Expl View & BOM ..................................13
Troubleshooting …………………………....….……. 14
Safety Label Identification ..........................................15
Warranty ………………………………….….………16
Material handling is inherently dangerous. To reduce
the likelihood of operator and bystander injury:
oEach person who might operate, use, or maintain this device must
Read and understand this manual in its entirety before operating,
using or performing maintenance on the scissor dock.
oDO NOT work on this device unless it is fully lowered and unloaded
and maintenance props are in place.
oEnsure that all safety and warning labels stay in place and are
legible. See the labels page in this manual.
oThe scissor dock’s frame must be securely anchored in concrete.
See the installation instructions.
oDo not use the lift if any damage or unusual noise is observed.
oAlways watch the platform and any load on it carefully when the lift
is in operation.
oDo not exceed a travel rate of two feet per second when moving
across the platform.
oThe platform’s load ratings must be observed at all times. See the
operation instructions.
oDo no modify the lift without the express, written authorization of
Beacon. Unauthorized modifications might make the scissor
lift unsafe to use.
oDO NOT attempt to repair this scissor lift or perform maintenance on
it unless you are trained and authorized to do so.
oDo not use brake fluid or jack oils in the hydraulic system. If oil is
needed, use an anti-wear hydraulic oil with a viscosity grade of
150 SUS at 100°F, (ISO 32 cSt @ 40°C), or Dexron transmission fluid.
oUse only replacement parts either supplied or approved by the
manufacturer.
WHEN ORDERING
REPLACEMENT PARTS:
We take pride in using quality
parts on the equipment we
manufacture. We are not
responsible for equipment
problems resulting from the use
of unapproved replacement
parts.
To order replacement or
spare parts for this equipment,
contact the factory.
In any communication with
the factory please be prepared
to provide the machine’s serial
number, which is indicated on
the machine dataplate.
RECEIVING INSTRUCTIONS
Every unit is thoroughly
tested and inspected prior to
shipment. However, it is
possible that the unit could
incur damage during transit.
Inspect the unit closely when
it arrives. If you see evidence
of damage or rough handling to
either the packaging or to the
product when it is being
unloaded, immediately make a
note of it on the Bill Of Lading!
It is important that you
remove the product’s packaging
upon its arrival to ensure that
there is no concealed damage
or to enable a timely claim with
the carrier for freight damage.
Also, verify that the product
and its specifications are as
ordered.
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INSTALLATION NOTES – BWL-100
Review these requirements and procedures before installing the lift.
Contact the factory for answers to any questions that remain after reading this manual or for assistance if you
encounter difficulties during installation.
iThe standard model dock scissor lift is suitable for use outdoors in most industrial and commercial locations.
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Installation notes:
xAll pit and cement work, curb angles, bumper posts, conduit, and electrical installations, as well as the
materials for the same, are the responsibility of the installer or building owner.
xFor a pit installation: a minimum 2” conduit installed in the pit floor or wall is recommended for allowing the
hose and wire access to the lift, and a drain should be installed.
xFive minimum 18 AWG wires (or an appropriate hard service cable) are required between the power unit’s
control enclosure and the lift’s frame. These wires, the power unit’s disconnect, and the branch circuit
overcurrent and short-circuit protection are the responsibility of the installer or building owner.
xThe installation must be made so that it complies with all the regulations applicable to the dock, the lift, and their
location. The installer or building owner must verify that the supplied equipment is installed so it will be suited to
the environment in which it will be used, and it must be mounted onto, and anchored into, suitable concrete.
An architectural review of the planned installation is recommended.
xThe installation of the dock lift must be performed by suitably trained personnel with access to the appropriate
equipment. The electrical aspects of the installation should be performed by an electrician.
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Installation will require the following tools and equipment:
oA lifting boom with rigging, a fork truck with adequate fork length and capacity, or some other appropriate
hoisting means to remove the lift from the freight truck when it arrives and to set the lift into place. The models’
weights can vary from 2,800 – 6,700 pounds.
oConcrete anchors, a masonry drill, a masonry bit, hand tools, grout, and steel shims. Consult the building’s
architect or facility engineer to determine the best size and type of hardware with which to anchor the lift to the
dock approach.
oA power supply circuit and disconnect matching the motor voltage and current requirements. Refer to the labels
on the control enclosure and to the electrical section in this manual for more information.
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iDo not work underneath the platform unless the maintenance props are installed in the frame.
iThe dock lift must be adequately anchored into the concrete at each corner of its frame.
iIf the supply voltage installed for the lift is different from that originally specified for the order, the
connections of the motor leads and the control transformer’s primary wires must be changed. Consult the
electrical diagrams in this manual.
iModifications or additions to the lift without prior manufacturer’s authorization may void the lift’s warranty
(see ANSI MH29.1, Safety Requirements for Scissor Lifts, section 12.6). The addition of ancillary equipment to the
platform may necessitate that its load capacity be reduced.
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INSTALLATION INSTRUCTIONS – BWL-100
1. For pit-mounted units, check that the pit conforms to the pit diagram.
Note: If the unit is to be placed into a pit, the required electrical and hydraulic connections to the dock lift should
be made before it is set into place.
2. Mount the power unit in the desired location. The standard 8’ hose will allow the power unit to be mounted
immediately adjacent to the lift. For mounting in other locations, a longer hose will be required. (Use ½” SAE
100R2 2-wire hydraulic hose with a 3,000 psi working pressure rating.)
3. Using an appropriate wiring method, connect the power supply to the power unit’s motor relay. Verify that the
motor supply voltage is the same as that shown on the machine dataplate (located on the middle of the right
platform side). Also verify that the correct control transformer primary leads are connected to the power supply
at the motor relay’s terminals.
4. Remove all steel strapping and shipping materials from the lift. Do not remove the lifting tabs.
5. Use rigging to pick up the unit at the two lifting tabs (one on each end of the platform) and move the lift into
place. Note: If the lift is being pit-mounted, guide the hose and the wires or cable into the pit (such as when a pit
conduit is present) when lowering it. Use care to avoid damage to the lift’s internal electrical and hydraulic
components from the underside. Remove the lifting tabs.
6. Connect the ½” hydraulic hose between the power unit and the lift’s frame.
Note: First, either flush or blow out the hose and fittings if any contaminants are observed inside them.
7. Install a jumper wire from terminal #3 to terminal #4 in the power unit’s control enclosure. Verify that the
overload relay setting matches the motor’s full-load amperage at the selected supply voltage.
8. Use the pendant control to raise the platform just high enough to allow the table’s safety maintenance props to be
placed into the frame. Use the manual valve to lower the platform so the leg set rests on the props. (Push down,
turn the knob CCW, and release it to open the lowering valve. Push down and turn CW to close it.)
9. Remove the jumper wire between terminal #3 and terminal #4.
10. At both the lift’s frame junction box and the power unit’s control enclosure, connect the five wires (including the
grounding wire) to the limit switch and toe guard circuit wires. See the electrical diagram in this manual.
11. Close and secure the control enclosure door and put the plastic cover over the power unit.
12. Cut and remove the plastic ties that hold the aluminum toe guard strips up during shipping. Verify that all the
strips drop down and move freely, and that the switch in the middle of each strip is not actuated.
13. Raise the platform to a height of 60”, measured from the bottom of the frame. Adjust the upper limit switch arm
(mounted on the non bridge-end of the frame) so that the motor turns off at that height.
14. Bleed the cylinders following the air bleed procedure at the bottom of the “Power Unit Operation” page.
Afterward, remove the maintenance props and lower the platform using the pendant control. Hold the “DOWN”
pushbutton for several seconds after the platform is lowered so that any air in the hose will be able to more easily
migrate to the reservoir.
15. While lowered, check the platform for proper lowered height, or that it is flush with the ground if pit mounted.
16. Raise the lift, install the maintenance props, and lower the leg set onto them once again.
17. Anchor the frame to the floor through each of the two 13/16” holes located near each frame corner.
18. Shim and/or grout under the full length of the frame sides.
19. Remove the maintenance props and operate the lift through several full up/down cycles. Verify that the upper
travel limit switch (mounted in the frame) and the toe guard switches (around the perimeter of the platform)
function properly.
20. Check the hydraulic oil level. It should be filled to within 3” of the top of the reservoir. If oil is needed, use an
anti-wear hydraulic oil with a viscosity grade of 150 SUS at 100°F (ISO 32 at 40°C) or a non-synthetic automatic
transmission fluid.
21. Clean up any debris or spilled oil, and verify that all of the warning and safety labels are intact.
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ROUTINE MAINTENANCE &SAFETY CHECKS – BWL-100
oWarning: Care should be taken to identify all potential hazards and comply with applicable safety procedures
before beginning work.
oWarning: Raise the platform and install the maintenance props before beginning any inspections or work on the
unit.
oOnly qualified individuals trained to understand mechanical devices and their associated electrical and hydraulic
circuits should attempt troubleshooting and repair of this equipment
(A) Before each use inspect for the following:
1.) Frayed wires
2.) Oil leaks
3.) Pinched or chafed hoses
4.) Damage or structural deformation to the structural members, the cylinder brackets, etc.
5.) Unusual noise or binding, or evidence thereof.
6.) Proper functioning of all limit switches, including those on the perimeter pinch point guard.
(B) Inspect monthly for:
1.) The oil level. Oil should be 1½” to 2” below the reservoir’s fill hole with the lift fully lowered.
See below for the hydraulic oil specification.
2.) Worn or damaged hydraulic hoses and electrical wires.
3.) Pivot point wear.
4.) Rollers’ looseness and wear.
5.) Integrity of the retaining rings on all rollers and on all pivot point pins.
6.) The integrity of the frame anchor bolts, and for cracks in the concrete around them.
7.) Proper functioning of any hand- or foot-operated mechanisms.
8.) Damage or deformity of the bridge plates (including the hinge) and the handrails.
9.) Unusual noises or movement during operation.
10.) All the information, safety, and warning labels being in place and in good condition.
11.) The need to clean off dirt and debris.
12.)Grease all pivot points.
(C) Yearly inspection
The oil should be changed if the oil darkens, becomes gritty, or turns a milky color (indicating the presence of
water). Replace with an anti-wear hydraulic oil with a viscosity grade of 150 SUS at 100°F, (ISO 32 at 40°C). Ex: AW
32 or HO 150 hydraulic oil, or a non-synthetic transmission fluid. You may use a synthetic transmission fluid if you flush
the system with the synthetic fluid before filling the reservoir.
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OPERATION INSTRUCTIONS – BWL-100
The Occupational Safety and Health Administration (OSHA) incorporated Commercial Standard CS202-56 into its
mass of regulation [29 CFR 1910.6(j)(1)], which instituted design and performance requirements on Dock Leveling
Devices. However, the Dept. of Commerce (DoC) withdrew CS202-56 in 1980 and replaced it with ANSI MH30.1-2000.
The DoC also recommends ANSI MH29.1 as a source of instructions about industrial scissor lift operation. MH29.1 is
the appropriate choice in this case, because our BWL-100 series of products are industrial scissor tables.
Safe operation is the responsibility of the operator according to ANSI MH29.1, Section 5. In addition to
the instructions that appear in this manual, ALL end-users of this product should refer to ANSI MH29.1 for information
regarding owner/operator responsibilities for safe operation, care, and maintenance. To reduce the likelihood that
personal injuries might occur as a result of using this product, each person who might install, use, or maintain this
product must understand and follow these recommendations:
Do not exceed the maximum rated load (capacity). Permanent damage to the lift or injury to personnel could
result from exceeding the listed capacity.
Keep all personnel clear of the scissor dock when it is in operation.
Never use the scissor dock if any damage or unusual noise is observed, if it is in need of repairs, or if it seems to
be malfunctioning. Notify your supervisor or maintenance personnel if you notice anything out of the ordinary.
Check the operation of the perimeter pinch point guards daily. Do not use the lift if the aluminum frame bars of
the guard are bent or if the circuit does not function.
DO NOT use the lift unless all labels are readable. Contact Beacon for replacement labels as necessary.
The standard model scissor dock is suitable for use indoors or outdoors in most industrial and commercial
locations. It is intended to be used to raise and lower material handlers such as fork trucks and pallet jacks to allow
freight to be loaded and unloaded from semi trailers.
Keep all personnel clear of the lift when it is in operation. Be certain no part of any person or object is under
any part of the lift before lowering the platform.
Loading:
The load rating, in pounds, is shown on the machine dataplate located on the bevel of the bridge plate end of the
platform. It indicates the net capacity of the scissor dock with a static load that is centered and evenly distributed on
the platform.
oConsult ANSI MH29.1, Section 3 for loading definitions.
When not fully lowered, the lift’s maximum single axle load is roughly 65% of the rated capacity for side loading, and
75% for end loading. The actual axle capacities (The hydraulic hose and bridge plates are at the lift’s “ends.”)
In the fully lowered position, cross-traffic loads must not exceed two times the platform’s load rating.
Do not exceed a rate of two feet per second when moving loads across the platform.
Note:Ancillary equipment reduces the maximum rated load of the dock scissor lift. If you or a third party adds after-
market features to the scissor lift, you must recalculate the maximum rated load. To do so, subtract the total weight
of all equipment added to the scissor dock from the maximum rated load (capacity).
Operation:
Inspect the perimeter pinch point guards’ operation daily.
Caution: Always carefully watch the platform and any load on it when the lift is in operation.
The scissor dock is furnished with a constant-pressure (dead-man style) pushbutton control on a coil cord.
oPressing the “UP” pushbutton will turn on the power unit to raise the platform. The platform will raise only
while the control is pressed. Upon releasing the control, the platform will stop and hold its position.
oPressing the “DOWN” pushbutton will energize the lowering valve to allow the platform to descend by gravity
(the motor does not run). Releasing the control button, or the operation of the pinch point guard, will stop the
platform movement and the unit will hold its position.
To lower the platform in the event of a malfunction or power outage, remove the power unit cover and locate
the colored, knurled knob on the end of the lowering valve. Be certain there are no obstructions or personnel under
the lift! Push the knob in, twist the knob counterclockwise 180°, and release it. When the platform has been
lowered, push the knob in again, twist the knob clockwise 180°, and release it.
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