Bishamon TORTOISE III Operation manual

Operation and Service Manual
for
Model BSC3200KU
Sugiyasu Corporation
Feb. 2011

Warning
Inthismanual,「Danger」,「Warning」,「Caution」aredefinedandspecified
asbelow.NoticeofWarningsareveryimportantforsafeoperations.
Astheseareveryimportanttoprotectoperatorsfromaccidentresultingin
injuryordeath,ordamagetoproperties,makecertaintounderstandthemfully
beforeoperatinglift.
・・・・・Incorrectoperationmayimminentlyresultin
 seriousinjuryordeathoftheoperator.

・・・・・Incorrectoperationmayresultinseriousinjuryor
 deathoftheoperator

・・・・・Incorrectoperationmayresultininjuryanddamage
 toproperty.Thepossibilityofoccuranceof
 dangerislowerthan" Warning" articles.
Preface
Beforeoperatingthelift,READandbefamiliarwiththisoperationmanual.
IncorrectoperationbynotREADingandnotbeingfamiliarwiththeoperationmanual
mayresultinnotonlypoorperformingoftheliftfunctionsbutalsothefallingofthe
vehiclesandaccidentofinjuryordeath.

Thecontentsofthemanualmaydifferifthepurchasedliftismodified.
Contactyoursupplierifthecontentsofthemanualhasanyunclearstatements,
error,omissionandincorrectcollating.

Danger
Warning
Caution

Contents
 1) ObjectsoftheLift………………………………………… 1
 2) Danger,Warning,Caution…………………………… 1〜4
 3) LocationsoftheLabels………………………………… 5
 4) ComponentsoftheLift…………………………………5〜7
 5) Circuit………………………………………………………… 8
 6) Systems……………………………………………………… 9
 7) SafetyDevice……………………………………………… 10
 8) Pre-OperationChecks…………………………………… 11
 9) OperationInstruction……………………………… 12〜13
10) CleanUpafterServiceWork…………………………… 14
11) RegularInspection……………………………………… 14
12) TroubleShooting…………………………………… 15〜16
13) Specifications………………………………………… 16〜17
14) Warranty…………………………………………………… 18
15) AfterService……………………………………………… 19
16) Installationandrelocation…………………………… 19
Page

ー1ー
1
2
ObjectsoftheLift
Danger,Warning,Caution
Thisliftisdesignedformotorvehicleservicing(excludingoneboxvehicleandtruck
typevehicle).
CautionforSafety
2-1 GeneralSafetyRulestobeobserved
2-2 CautionsinOperation
1Readandbefamiliarwiththeoperationmanualbeforeoperating.
2Onlytrainedoperatorsareallowedtousethislift.
3Makecertaintoperformdailyinspectionsandregularmaintenanceinaccordance
withtheinstructionsofoperationmanual.
4Ifyoususpectthatthereisanymalfunction,donotoperateliftandcontactyour
supplierforcheck.
5Thisliftisdesignedformotorvehicleservicing.DONOTuseforanyother
purposes.
6Donotremoveanylabelsanddonotmodify.
Astheseareveryimportanttoprotectoperatorsfromaccidentresultingin
injuryanddeath,anddamagetoproperties,makecertaintounderstand
fullybeforeoperatinglift.
Themeaningofthemark(symbol)usedbehindpicturesareasbelow.
Thespecifiedactthatshouldnotbeconducted.
Thespecifiedactthatshouldbeconducted.
WarningandCautionthatispossibletooccurduetoincorrectoperation.
Whenliftisoperating,DONOTgetundervehicle.
DONOTallowotherstogetundervehicle.
IFTHEVEHICLESTARTSTOFALLFROMLIFT,Moveaway
quickly.
DONOTATTEMPTTOSUPPORTVEHICLE.
※Itmayresultinseriousinjuryordeath.
※Itmayresultinseriousinjuryordeath.
READandbefamiliarwiththeoperationmanualforthislift.
Theimportantwarningsaredescribed.
Ignoringthewarningsmayresultinseriousaccidents.
Warning
Danger

ー2ー
Vehiclemustbepositionedevenly.DONOTliftoffset
vehicle.
DONOTliftvehiclebyoneendorbyonesideonly.
Whenliftingvehicle,besurethatcenterofthegravity
remainswithindesignatedYellowrange.
DONOTswing,shakeorpushtheraisedvehicle.
DONOTlowertheliftwhileanystandorsupportisin
positionundervehicle.DONOTuse"Down"motionofliftfor
anyotherpurposeexceptlowering(ex.forputtingoffparts).
CAUTION!
Removingcomponentsmayaltercenterofgravityand
causevehicletofall.
DONOTuseliftunlessyouhavebeentrainedinitsoperation.

※Incorrectoperationmayresultinaccident.
KEEPHANDSFREEfromliftandvehiclewhenoperating
lift.
Warning
※Whenremovingpartsorwithvibration,itmayresultinfalling
ofthevehicle.
※Whenremovingpartsorwithvibration,itmayresultinfalling
ofthevehicle.
※Whenremovingpartsorwithvibration,itmayresultinfalling
ofthevehicle.
※Supportercontactmaycomeoffanditmayresultinthe
fallingofthevehicle.
※Supportercontactmaycomeoffanditmayresultinthe
fallingofthevehicle.
※Itmayresultinpinchinghandsorseriousinjury.
※Itmayresultinfallingofthevehicleanddamagetothe
vehicle

ー3ー
ELECTRICALHAZARD!
DONOTopencontrolboxorremovecoverplateswithout
isolatingelectricalsupply.
MAKESUREtoDRAINAIRFilterRegulatorbeforestarting
operation.
DONOTmodifythisliftunderanycircumstances.
Warning
※Itmayresultinseriousaccident.
※Itmayresultinelectricshock.
※Ifwaterdropgoesinsideofaircircuit,liftmaynotwork
properly.
Itmayresultinpersonalinjuryorproperydamagingaccident.
Push
Up
KEEPFEETFREEfromliftandvehiclewhenoperatinglift.
※Itmayresultinpinchingfeetorseriousinjury.

ー4ー
※Alwaysmaintainliftinaccordancewithoperationmanual.

DONOTUSETHISLIFTATALLIFREPAIRSARE
REQUIREDORIFYOUSUSPECTANYMALFUNCTION.
Caution
Regularinspectionsandroutinemaintenanceareessentialforthesafeoperationof
thislift.
Theproceduresaredetailedintheoperationmanualandtheymustbeadheredto.
Youmustkeepawrittenrecordofinspectionsandrepairsthatincludesthedateof
inspection/repairandthenameoftheinspector/repaireranddetailsofworkdone.
DailyInspectionstobeperformedeachdaybeforefirstoperation.
※Raiseandlowerliftwithoutaloadandcheckforanyabnormality.
※Checkforoilorairleakage.
※Checkairpressureregulatorforcorrectpressure0.7MPa.
DONOTUSEwithhigherairpressure,oritmaybreakAirSwitchingValve.
※Airsupplytofilter/regulatormustnotexceed1.0MPa.
※Checkforcorrectoperationofelectricalcontrols.
※Checkthatsafetydevicesarewellfunctioning.
Pre-OperationChecks
※Onlytrainedoperatorsareallowedtousethislift.Keepothersawayfromliftand
controls.
※Thisliftisdesignedformotorvehicleservicing.DONOTuseforotherpurposes.
※Liftcapacityis3,200kg.DONOTattempttoliftheavierloads.
※Totalloadforbothleftandrightsidesmustbewithin3,200Kgs.
※PositionDrive-onPlatesundercorrectvehicleliftingpoints.Ifvehicleliftingpoints
cannotbepositivelyidentifiedthenconsultvehiclemanufacturer'smanual.DO
NOTliftvehicleifyouareindoubtonthem.
※DONOToperateliftifsafetydevicesarenotfunctioning.
※Checkconditionofrubbersupporters.Keepthemcleanandfreeofoilandgrease.
WhenLiftingandLowering
※PAYATTENTION. Observetheliftoperationatalltimes.
※StopliftingafterDrive-onPlateshavemadefirmcontactwithvehicleandcheck
Drive-onPlateslocationsandsecurity.
※DONOTuseanyothersupportingsbutstandardSideSillBlockbetween
Drive-onPlatesandliftingpoints.
※DONOTliftloadedvehicles.Theymaybeunbalanced.
※DONOTliftvehicleswithpassengersinside.
※Makesurethatsafetyhooksareengagedbeforegettingundervehicle.
※DONOTlowerliftbeforeclearingareaofpersonsandobjects.
※Ifvehicleshouldtiltduringliftingorloweringoperations;
Lowerliftandhold'Down'buttonfor5〜10seconds.
Iftiltincreaseswhenloweringthencontactsupplieranddonotuselift.
※Makesureliftisfullyloweredbeforeenteringorleavingvehicle.
※Ifliftwillnotlower,Raiseliftandthenlower.
※Whenloweringliftwithadjustableplate,
(a)Stoploweringwhenliftisfreeofvehicle
(b)RemoveSideSillBlockandreturnDrive-onPlatestoclosedposition
(c)Lowerlifttofloor
Generally
※DONOTmodifythisliftinanyway.
※Thisliftisnotweatherproofandisnottobeusedoutdoorsorforvehiclewashing.
※Becautiousatalltimes.Donotoperateliftifyoususpectthatthereisany
malfunction.
Maintenance

ー5ー
3LocationoftheLabels
4ComponentsoftheLift
①「CenterofGravity」Label
②Capacitylabel
③CautionLabel
④Danger/WarningLabel
BSC3200KU
SlidingSupporter
SlidingSupporter
ControlBox
AirFilterRegulator
PushButtonswitch
Built-InHyd.Unit
Cylinder
SlideCover
LoweringStopDevice
ThelengthofSlidingSupportercanbeadjustedbetween1320〜1870mm
PullthePullingGripforsliding.
PullingGrip
SlidingPart
whenfolded whenslidingout

ー6ー
MakesuretodrainAirFilterRegulatorbeforestartingoperation.
Ifwaterdropgoesinsideofaircircuit,liftmaynotworkproperly,andmay
resultinpersonalinjuryorpropertydamagingaccident.
Warning
Supplydryair.Ifnot,liftwouldbebroken.
Caution
MakesuretocheckifthepressureatGaugeis0.5MPabeforestarting
operation.
Ifthepressureislowerthan0.5MPa,liftmaynotworkproperly.
Ifthepressureismorethan0.5MPa,itmaydamageAirSwitchingValve.
Caution
(AirFilterRegulator)
AirFilterRegulatoradjuststhesuppliedairpressure
(0.7-1.0MPa)downtoappropriatepressure(0.5MPa).
Italsofiltersthewaterintheair.
PressureGageindicatesairpressureadjustedbytheRegulator.
〈OperationMethod〉
◎Checkiftheairpressuresuppliedtothe
Regulatorismorethan0.7MPa.
◎LoosenTopScrewfirst.ThenwatchGuageand
adjustairpressureto0.7MPabyturning
AdjustingKnob.
 turnright:pressureUP
 turnleft:pressureDOWN
◎FixTopScrewafteradjustingtheairpressure.
〈Howtodrain〉
PushupDrainvalve.Watercomesoutduring
thevalveispushedup.

ー7ー
ItmaycauseaseriousaccidentifyouoperatePushButtonControlSwitch
carelessly,withoutbeingsureaboutsafetyaroundLiftandvehicle.
Warning
(PushButtonControlSwitch)
(SideSillBlock)
PushButtonControlSwitchisaswitchtoraiseandlowerDrive-onPlate.
・Bypushing"UP"button,Drive-onPlategoesup.
Byreleasingthebutton,theplatestops.

・BypushingDOWNbutton,Drive-onPlategoesdown.
Byreleasingthebutton,theplatestops.
SideSillBlockisusedforprotectingsidesillofvehicleswhenliftingupvehiclesby
Drive-onPlate.

5
ー8ー
Circuit
AirCircuit
ElectricCircuit
HydraulicCircuit
MC :MagnetSwitch
PB1 :PushButtonSwitchforraisingLift
PB2 :PushButtonSwitchforlowering
Lift
SOL :AirSolenoidValveforloweringLift
SOL2:LoweringValve
LS1 :LimitSwitch
200V〜400V
0V

6
ー9ー
Systems
TortoiseLift(NSCseries)liftsupDrive-onPlateswithDoubleScissorsLink,using
HydraulicCylinderworkedbyElectricHydraulicPump.
BothsidesofDrive-onPlatessynchronizeingoingupanddownastheyare
connectedbySynchronizingBar.
(LiftingSystem)
(LoweringSystem)
Whenpushing"UP"button,Motorworks.PumprotatesandsendsoilintoCylinders.
Whenreleasingthebutton,motorstops.CheckValvespreventoilfromcoming
backfromCylinders.AndCylindersstayatthatheightlevel.
Whenpushing"DOWN"button,AirSwitchingValveworks.TheAirSwitchingValve
sendsairintoHookReleasingCylinders,andtheCylindersreleaseLoweringStop
Hooks.
WhenbothsidesofLoweringStopHooksarecompletelyreleased,LimitSwitchfor
HookReleaseSensingelectrifiesLowringValve.
TheLoweringValveopensthereforeandCylindersstartlowering.
-TolowerDrive-onPlatesincaseofemergency(ex.apowercut)-
PulloutHookReleasingCylinderbyhand.KeepingHooksreleased,loosenslowly
Hand
ControlLoweringValvewithL-shapehookwhichwassupplied.
LimitswitchforHookReleaseSensing
7(0.7MPa)

ー10ー
7SafetyDevice
LoweringStop
Hook
Theyareinstalledateachcylinderto
preventliftfromfallingincaseofoil
leakingandbreakageofhydraulihose
etc.
However,pleasenotethatthereisno
LoweringStopHookbelowapprox.
500mmfrombottom.
FuseValve
(ShutOffValve)
Itisinstalledateachcylinder.
Itwouldshutofftheoilflowincase
suddenflowofoilfromcylinderdueto
thebreakageofhydrauliccircuitetc.
ReliefValve
Incaseofbelow,itwouldworkto
preventliftfrombreak
a.liftingheavierloadthanlift'scapacity
b.liftisreachingthetop
c.pressureinhydrauliclineincreases
duetothetroubleforanyreason
Itisinstalledinsideofgearpump.
ThermalRelay
Itwouldsensetheexcessiveelectric
currentandshutoffthethecircuitand
protectelectriccomponents.
ItisinstalledatmagneticSwitch.

8
ー11ー
Pre-OperationChecks
Pointtobechecked
LiftUnit
LiftUnit
HydraulicCircuit
HydraulicUnit
AirCircuit
LoweringStopDevice
InsidePit
Visualand
hearing
Visual
Visualand
touching
Visualand
touching
Hearing
Visual
Visual
Tighteningor
Contactsupplier
Tighteningor
Contactsupplier
Removeforeign
objects
Contactsupplier
Contactsupplier
Contactsupplier
Contactsupplier
Doesliftriseandlower
smoothlywithoutnoise?
Anydamage,strain?

Anyoilleakfromcylinder,
hyd.unit,pipingetc?
Anynoisefromhyd.unitin
liftingandlowering?
Anyairleakfromhookrelease
cylinder,airpiping?
LoweringStopHookswork
properly?DotheHooksget
releasedinloweringoperation?
Andkeep"IN"positionotherwise.
AnyforeignobjectsinPit?
CheckItems CheckMethod
Actionifproblem
isfounfd
PerformthePre-OperationChecksbeforeoperationeveryday.
Thischeckmustbedonewithoutload.
MakesuretoadjustAirFilterRegulator
everydaybeforeoperation.
Ifnot,Unitmaynotworkproperlyandcouldbe
broken.
Checkifairpressureis0.7MPaatGageofAir
FilterRegulator.
Ifthepressureislessthan0.7MPa,Drive-on
Platesmaynotlowercorrectly.
Cautions
(HowtoDrain)
PushupDrainValve.Watercomesoutwithair
duringthevalvepushedup.
onAirFilterRegulator

ー12ー
OperationInstructions
9
〈ProcessinServicingVehicle〉
1.VehicleEntry
2.SetUpLiftingPoint
Cautions
・Whenvehicleenters,Drive-onPlatesmustbefullylowered.
・LocatevehiclesothatCGofthevehicleandliftcenterwouldbeinthesame
spot.Thenvehiclewouldbestable.
Caution
Supportvehiclesonliftingpointswhichisdesignatedbyvehiclemanufacturers
whenliftingthemup.Donotliftupveheclesonotherpoints,orvehiclescouldbe
deformedorbroken.
DONOTliftvehicleifyouareindoubtonitsCGposition.
CG=CenterofGravity
VehiclemustbepositionedevenlysothatCGofthevehicleandliftcenterwouldbe
inthesamespotaccordingtothevehiclemodels.
TolocateCGofthevehicle,refertotheservicemanualofthevehicleorcontact
vehiclemanufacturer.
・PutSideSillBlocksbetweenDrive-onPlatesandliftingpointsofvehicle.
(AdjustableDrive-onPlateType)
・First,liftupDrive-onPlatesuntiltheycompeletelycomeoutfromtheground.
ThenslidethePlateandputSideSillBlockbetweenDrive-onPlatesandlifting
pointsofvehicle.
Vehicle
Entry Setup
Lifting
Point Lifting Lowering Vehicle
Exit

ー13ー
Waring
Donotliftupanyloadwhichisheavierthanlift'sCapacity.
Lift could be broken.
Make sure there is no one and nothing around lift before operation,or it could result in serious
accident.
Danger
Donotgoundervehicleduringoperation.
Ifnot,itmayresultinpersonalinjuryaccident.
Caution
MakesurethatDrive-onPlatesarefullylowerdbeforevehicleexit.
Ifnot,itmayresultindamagingvehicleandLift.
3.Lifting
5.VehicleExit
4.Lowering
1Push"UP"buttonswitchandliftupDrive-onPlates.Stoptheoperationjust
beforeSideSillBlockstouchliftingpointsofvehicle.Thencheckagainifthe
Blocksarepositionedunderliftingpoints.
2Ifnot,adjustthemtoproperposition.
3Iftheyare,liftupDrive-onPlatesuntiltiresofvehiclecomeofffromtheground
(about2-3cm).
4Swingvehicleupanddowngentlyandslowlyinordertocheckifvehicleiswell-
balanced.Ifso,liftvehicleuptotheheightforwork.
5Release"UP"buttonimmediatelywhenDrive-onPlatesreachmax.height.
・Push"DOWN"button.ThenLoweringStopHookgetreleasedandDrive-onPlates
lower.Whenyoustoppushingthebutton,Drive-onPlatesstayinthatheightlevel,
andLoweringStopHooksgethookedinLoweringStopRacks.
・IfLoweringStopHooksdonotgetreleasedbecausetheyaredeeplyhookedin,lift
upthePlatesalittleandpush"DOWN"buttonagain.
1IncasethatAdjustableDrive-onPlatesareextended,stoploweringoncewhen
tiresofvehiclereachthegroundandthePlatesleaveofffromvehicle.
2RemoveSideSillBlocksandreturnthePlatestominimumlengths.
3RestartloweringthePlatesagaintothebottom.
Makesurethatthereisnotoolsorotherobjectsundervehicleandinsideofpit
beforevehicleexit.

ー14ー
10
CleanUpAfterServiceWork
11
RegularInspection
Checkconditionofrubbersupportersafterservicework.
Keepthemcleanandfreeofoilandgrease.
Ifanyabnormalityisfound,contactyoursupplier.
Forsafety,turnoffthecircuitbreaker.
Period
EveryMonth
Every3Months
Every12Months
Parts
Bolts,Screw
&Nutsetc.
AirCircuit
LoweringStop
Device
OilTank
ControlBox
Pipeline,Air
Hoseandparts
aroundthem
ScissorsLink
andDrive-on
Plates
Base
Lubricatethepartsandpointsshownonpage16.
Hyd.Cylinder
SideSillBlock SideSillBlock crack,deforming
OilTankand
Synchronizing
Cylinder
※Replaceoilin3monthsafterinstallation,thenreplaceeveryyear
Looseness
Joint,AirTube,
AirPressureEquipment
MovementoftheSafety
HookReleaseCylinder
Electriccomponents
(MagnetSwitch,Relay
etc)
Wearofbearings
RotationofRoller
LinkandDrive-onPlates
SuctionFilter
Joint
PipeLine,Hyd.AndAirHoses
OilLeak
NaturalLowering
Oil
Oilvolume
LoosenessofAnchorBolt
LevelAdjustment
Tightening
anyleakofdrainorairinsideof
thecircuit
movement,dirtatcontact
point,crack
anyleakofoilorair⇒tightening
anycrack,oilleakage⇒replaceparts
smoothmovementoftheparts
clog
leakfromdustseal,joint
Liftupvehicleandcheckthe
lowering(≦1mm/5Minutes)
loosenessatbearing
offsetweratrollers
crack,twist,damage,distortion
Oilconditions
tighteningandadjustinglevel
Itemstobeinspected InspectionMethod
Esso UnipowerSQ32,XL32
Shell TelusOil32,K32,W-ROil32
Mobil MobilDTE24
QualityofHyd.Oilisveryimportantfortheperfomanceofthegearpumpusedfor
theliftandtherecommendableoilareasbeloworequivalent.
Viscosity-ISOVG32OilVolume-13litters
〈HydraulicOil〉

12
ー15ー
TroubleShooting
Donotoperateliftifyoususpectthatthereisamalfunction.
Contactyoursupplier.
Symptom
〈Motordoesnotrotate〉
・ThermalRelayisdisconnected
・Contactingpointofmagnet
switchisburnt
・Powerissinglephase
・Electriccircuitiscutoff
〈Motorrotates〉
・Rolleratbottomoflinkisstuck
withforeignobjects
・Lackofoil
・SuctionFilterisclogged
・GearPumpdoesnottakeinoil
・Oilleakfrompressureoilpipe
・OilleakfromSealofCylinder
・LoweringStopHookisengaged
・Rolleratbottomoflinkisstuck
withforeignobjects
・ControlCableiscutorbecame
longer
・Airpressureisnotadjustedto
0.5MPa
・Thelowering≦0.5mm/5mitutes
iswithintolerances
・OilleakfromLoweringValve
・OilleakfromCheckValve
・OilleakfromSealofCylinder
・Oilleakfrompipelines
・HandControlLoweringValveis
loosen
・Lackoflubricationatbearing
・Wearoftherolleratlink
・LackofHyd.OilinCylinder
Solvetheproblemandthenreset
Solvetheproblemandthenreplace
magnetswitch
Checkthevoltageandsolvethe
problem
Repairthecutoff
Removeforeignobjects
Filltheoil
CleanorreplaceSuctionFilter
ReplaceGearPump
Tightenjointsorreplacetheparts
ReplacetheSeal
LiftupDrive-onPlatestorelease
Removeforeignobjects
AdjustorreplacetheCable
Checkifairsupplyismorethan
0.5MPaandadjustairpressureat
AirFilterRegulatorto0.5MPa
Contactsupplierifloweringismore
thantolerance
CleanuporreplacetheValve
Replaceseals
ReplacetheSeal
Findleakingspotandrepairthe
ShutofftheValvewithL-shape
Hookwhichisattached
Lubricate
Replaceroller
Filltheoilandliftuptotopwithoutload
Liftdoesnotrise
NaturalLowering
Liftdoesnotlower
Noise
PossibleCause Action

13
ー16ー
Specification
LubricationPoints
Lubricatethebelowpointswithgreaseeverymonth.
UpperShoeBearing
4points(Grease)
LowerShoeBearing
4points(DesignatedGrease)
Cylinder,UpperParts
2points(Grease)
Hook,ShaftParts
2points(Grease)
CenterShaft
8points(Grease)
Fulcrum
2points(Grease)
Fulcrum
2points(Grease)
Fulcrum
2points(Grease)
CylinderFulcrum
2points(Grease)
SupporterFulcrum
2points(Grease)
Note:Specificationscouldbechangedwithoutnotice.
Specification AdjustableDrive-onPlateType
Model
Capacity
ApplicableVehicle
VerticalTravel
Drive-onPlateSize
Power
Oil
OilVolume
3200(kg)
PassengerVehicleOnly
1800(mm)
3PH/200V/380/400/415/440V/50Hz/60Hz
※415V-50Hz 440V-60HzOnly
Motor 2.2kW4P/10min.Rating
Viscosity-ISOVG32
13(L)
BSC3200KU
(1320〜1870)L×470W(mm)
LowerShoeBearinghavetobelubricaredwithdesignatedgrease.
 :GreasewithMolbdenumincluded

ー17ー
BSC3200KU