Nussbaum TOP LIFT TSK 12000 DJ User manual

Operating manual | Inspection book
Including spare parts list
Version: USA
Manual date: 05.05.2020
TOP LIFT TSK 12000 DJ
TOP LIFT 2.50 TTKAS DG
Serial No.:

Operating Manual and Inspection Book
TOP LIFT TSK 12000 DJ
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Contents
1 General informations............................................................................................................ 4
1.1 Lift purpose ...................................................................................................................... 4
1.2 Liability.............................................................................................................................. 4
1.3 Owner/Employer responsibilities................................................................................... 4
1.4 Lift operator responsibilities ........................................................................................... 5
1.5 Safety regulations........................................................................................................... 6
1.6 Safety devices................................................................................................................. 7
1.7 Safety labels affixed to lift ............................................................................................. 8
1.8 Protocols ........................................................................................................................ 10
1.9 Set up and test the lift.................................................................................................. 10
2. Lift master forms ................................................................................................................. 13
2.1 Manufacturer ................................................................................................................ 13
2.2 Purpose .......................................................................................................................... 13
2.3 Changes to the design / construction ...................................................................... 13
2.4 Changing the assembly location............................................................................... 13
3. Technical information........................................................................................................ 14
3.1 Technical data.............................................................................................................. 14
3.2 Data sheet.............................................................................................................. 15
3.3 Hydraulic plan........................................................................................................ 18
3.4 Pneumatic plan..................................................................................................... 20
3.5 Electrical circuit diagram ..................................................................................... 21
4. Installation ..................................................................................................................... 26
5. Operating instructions ................................................................................................. 28
5.1 Lifting the vehicle.......................................................................................................... 28
5.2 Lowering the vehicle.................................................................................................... 29
6. Behaviour in cases of error ............................................................................................... 30
6.1 Moving onto an obstacle............................................................................................ 30
6.2 Emergency discharge with stand unit and safety latch......................................... 30
7. Maintenance and care of the lift.................................................................................... 33
7.1 Lift maintenance plan ................................................................................................. 34
7.2 Cleaning the lift............................................................................................................. 38
8. Assembly and commissioning.......................................................................................... 38
8.1 Set up guidelines .......................................................................................................... 38
8.2 Assembly of the lift........................................................................................................ 39
8.3 Commissioning............................................................................................................. 39
9. Safety inspection................................................................................................................ 40
9.1 Single safety inspection before commissioning ....................................................... 41
9.2 Regular safety inspection and maintenance .......................................................... 42
9.3 Exceptional safety inspection..................................................................................... 50
10. Spare part list.................................................................................................................... 51

Operating Manual and Inspection Book
TOP LIFT TSK 12000 DJ
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1 General informations
Important safety instructions –Save these instructions
1.1 Lift purpose
Nussbaum lifting systems are the result of over 35 years’ experience in the automotive
lifting industry. The high quality and superior concept ensures reliability, a long Lift life-
time, and a strong economic business solution for your automotive lifting needs.
The TSK 12000 is a hydraulic symmetric In-Ground Lift with a lifting capacity of 12000
pounds.
The Lift features a powerful integrated power unit and hard-chromed cylinders. The
maximum load distribution is 3000 lbs per arm.
1.2 Liability
To avoid unnecessary damage, injury or death, read all operating instructions care-
fully. Nussbaum is not liable for any damages, injuries, or deaths resulting from misuse
of the Lift. The user carries the risk alone.
There will be no guarantee or liability for incidents involving injuries, death, or damage
to equipment if these incidents are the result of one or more of the following:
•Inappropriate use of the Lift to include: Inappropriate installation, operation, and
maintenance of the Lift.
•Use of the Lift while security devices are inoperative, not working properly, or are
installed incorrectly.
•Failure to follow the operating instructions regarding transport, storage, installation,
initiation, operation, and maintenance of the Lift.
•Unauthorized changes to the design and operation of the Lift.
•Wrong or incorrect maintenance practice.
•Catastrophes, acts of God, or external reasons.
•Nussbaum Lifts are warranted with the use of Nussbaum original or replacement
parts. Use only replacement parts approved by the original equipment manufac-
turer or parts meeting original manufacturer specifications. Use of unauthorized
parts may void the warranty. For parts, call Nussbaum at 1-704-864-2470.
•It should be recognized that any piece of equipment can be dangerous when
operated improperly.
1.3 Owner/Employer responsibilities
Automotive lift institute safety requirements for operation, inspection and maintenance
(ANSI/ALI ALOIM)
The Owner/Employer shall insure that lift operators are qualified and that they are
trained in the safe use and operation of the lift: ALI/SM 10-1 safety manual; ALI/ST-17 ;
ANSI/ALI ALOIM-2008 (R2013), American National Standard for Automotive Lifts-Safety
Requirement for Operation, Inspection and Maintenance; ALI/WL Series, ALI Uniform
Warning Label Decals/Placards; and in
case of frame engaging lifts, ALI/LP-GUIDE, Vehicle Lifting Points/Quick Reference
Guide for Frame Engaging Lifts and SAE J2184, Vehicle Lifting Points for Service Garage
Lifting.

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The Owner/Employer shall establish procedures to periodically inspect the lift in ac-
cordance with the lift manufacturer’s instructions or ANSI/ALI ALOIM- 2000, American
National Standard for Automotive Lifts-Safety Requirements for Operation, Inspection
and Maintenance; and the employer shall insure that the lift inspectors are qualified
and that they are adequately trained in the inspection of the lift.
The Owner/Employer shall establish procedures to periodically maintain the lift in ac-
cordance with the lift manufacturer’s instructions or ANSI/ALI ALOIM-2000, American
National Standard for Automotive Lifts-Safety Requirements for Operation,
Inspection and Maintenance; and the employer shall insure that the lift maintenance
personnel are qualified and that they are adequately trained in the maintenance of
the lift.
The Owner/Employer shall maintain the periodic inspection and maintenance records
recommended by the manufacturer or ANSI/ALI ALOIM-2008 (R2013), American Na-
tional Standard for Automotive Lifts-Safety Requirements for Operation, Inspection
and Maintenance.
The Owner/Employer shall display the lift manufacturer’s operating instructions; :
ALI/SM 10-1, safety manual; ALI/ST-17; ANSI/ALI ALOIM-2008 (R2013), American Na-
tional Standard for Automotive Lifts-Safety Requirement for Operation, Inspection and
Maintenance; ALI/WL Series, ALI Uniform Warning Label Decals/Placards; and in case
of frame engaging lifts, ALI/LP-GUIDE, Vehicle Lifting Points/Quick Reference Guide for
Frame Engaging Lifts; in a conspicuous location in the lift area convenient to the op-
erator.
Additional owner/employer responsibilities
•Shall require that Personal Protective Equipment (PPE) be used according to the
appropriate regulations.
•Shall display the “Safety Regulations” and adhere to them closely.
•Shall ensure that all safety- and danger signs on and around the Lift are observed
and followed!
•Shall follow the specified time intervals between the recommended inspection
and maintenance procedures and tests.
•Shall use only spare parts that comply with the technical requirements specified
by the manufacturer.
•Shall ensure that loose screws, nuts, and bolts are firmly tightened after mainte-
nance.
•Shall not modify the Lift without written consent of Nussbaum.
•Shall ensure that these instructions are maintained and available to all personnel
that install, use or maintain the lift. This document contains important information
about installation, operation, and maintenance of the automotive Lift. Any
changes to the installation and or location of the automotive Lift must be docu-
mented.
1.4 Lift operator responsibilities
•Shall read and understand all safety and warning instructions in the manual or af-
fixed to the lift.
•Shall be trained to operate and use the TSK 12000 DJ Lift for its designed use.
•Shall be familiar with accident prevention and basic labor safety regulations.
•Shall not allow unauthorized personnel to operate the Lift.

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Information of warning
Pay close attention to the danger and important information symbols shown below.
Carefully read all marked passages throughout this manual.
Danger! This sign indicates danger to life. Improper handling of the de
Scribed operation may cause serious injury or death.
Caution! This sign warns against possible damage to the automotive Lift or
other material defects in case of improper handling.
Attention! This sign indicates an important function or note.
1.5 Safety regulations
The Safety Regulations must be observed and strictly adhered to while working with
the automotive Lift. Read the safety regulations and the ANSI/ ALI ALOIM manual in-
cluded with the lift documentation carefully before working with the Lift!
Important safety instructions –read all instructions
•The total weight of the lifted vehicle must not exceed 12000 pounds.
•The automotive Lift must be in its lowest position, and the Lift Carry Arms must be
swung out before a vehicle can be driven into the Lift area.
•Total load must be distributed evenly on all arms.
•The Lift must not be installed in a hazardous location or in washing bays.
•The Lift must be checked by a service technician after initial installation and after
repairs or changes have been made to the Lift.
•The operating and maintenance instructions must be followed while working with
the Lift.
•Pre-check low clearance or specially equipped vehicles for ample clearance to
avoid damage to the vehicle and/or Lift.
•Only trained personnel are to operate the Lift.
•No one is to stand within the working area (danger area) during vehicle lifting and
lowering operations.
•No one is to occupy a vehicle during any phase of Lift operation.
•No one is to climb onto the automotive Lift when in a raised position.
•For unusual vehicles you may choose to instruct the user to contact Nussbaum for
lifting advice.
•The main electrical switch must be switched off and locked out or tagged out ac-
cording to OSHA Regulations before maintenance or repair work is performed on
the Lift.
•The operator must continue to observe the vehicle and Lift throughout the lifting or
lowering operation.
•Check the center of gravity of the vehicle if heavy parts, such as the engine are
removed.
•If heavy parts such as the engine must be removed, the center of gravity will
change. Secure the vehicle before removing parts to avoid the possibility of the
vehicle becoming insecure.
•Read all instructions before operating lift.
!

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•Care must be taken as burns may occur from touching hot parts.
•Do not operate the Lift with a damaged cord or if the Lift has been damaged –
until it has been examined by a qualified service person.
•To reduce the risk of fire, do not operate Lift in the vicinity of open containers of
flammable liquids (gasoline).
•Adequate ventilation should be provided when working on operating internal
combustion engines.
•Keep hair, loose clothing, fingers, and all parts of body away from moving parts.
•Use only as described in this manual. Use only manufacturer’s recommended at-
tachments.
•Always wear safety glasses. Everyday eyeglasses only have impact resistant lenses,
they are not safety glasses.
•The proper positioning of the carrier plate below the vehicle is to be checked again
after the vehicle has been raised slightly.
•After each set down of the vehicle, check the lifting arm positions below the fixture
points again and adjust as required.
•When disassembling heavy, consider any possible centre of mass shifts. The vehicle
is to be appropriately secured using suitable materials (e.g. tensioning belts,
beams, etc.) against falling.
•After design and maintenance on load bearing parts the lift must be inspected by
a technical expert.
•Vehicles may only be attached at fixture points approved by the vehicle manu-
facturer.
•The entire lifting and lowering process is to be continuously observed.
•Initial access to the lift is only permitted after the main switch has been turned off
and secured, and the operating lever is additionally secured against unauthorised
use.
Save these instructions!
1.6 Safety devices
Nussbaum has designed several saftety features into each Lift to ensure safe and effi-
cient operations under a variety of conditions. Warranties will be voided and danger-
ous working conditions exist if any of the listed devices are altered or disabled.
• Over-pressure valve
Hydraulic system fuse against over-pressure.
• Check valve
Secure the vehicle against unauthorised lowering.
• Main switch with curtain lock device
Fuse to prevent unauthorised use.
• Command / downstream system with latch
Secure against unauthorised lowering of the lift.
• Deadman controls
Lift movement stops when the operating lever is released.
• Lifting arm block
Secures the lifting arm against horizontal movement in a lifted condition.

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1.7 Safety labels affixed to lift
Read all labels and verify that all authorized users fully understand the meaning of
each caution /warning / safety instruction. Do not remove or deface safety labels
from the lift.

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1.8 Protocols
Technical documentation contains important information for safe operation and for
retaining functional safety of the lift.
•To verify lift set up, the assembly protocol form is to be completed, signed and
sent to the manufacturer.
•Forms are available in this inspection book for use in verifying single, regular and
extraordinary safety checks. Use the forms to document inspections and leave
the completed forms in the inspection book.
•The lift master forms must record changes to the construction or changes to set
up location.
1.9 Set up and test the lift
Safety relevant work on the lift and safety inspections may only be done by personnel
specifically trained to carry it out. They are designated in general and in this docu-
mentation as technical experts and specialists (competent people).
•Technical experts are people (freelance expert engineers, TÜV specialists) that
may inspect and assess due to their education and experience with lifts. They are
knowledgeable in the appropriate work safety and accident prevention regula-
tions.
•Specialists (competent people) are people who have sufficient knowledge and
experience with lifts and have participated in a special factory training by the lifts
manufacturer.

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Set up protocol
After successful set up, complete this form fully, sign it, make a copy and send
the original to the manufacturer within a week. The copy remains in the inspec-
tion book.
Nussbaum Automotive Solutions, LP
1932 Jordache Court
Gastonia, NC 28052
Fax: [phone]
Email: [e-mail]
The lift with serial number............................. Was set up on (date) ........................
at (company name)....................................... in........................................................
checked for function and safety and put into operation.
The set up was done by the operating company / specialist
(score out the one that does not apply).
The operating company confirms proper lift set up, has read and will comply with
all information contained in this operating manual and inspection book, and will
keep this document accessible to trained operators at all times.
The specialist confirms proper lift set up, has read all information in this operating
manual and inspection book, and has transferred the documents to the operat-
ing company.
......................................... .................................................. ..................................
Date Name, operating company Operating company
& company stamp signature
......................................... .................................................. ..................................
Date Name, specialist Signature of specialist
Service partner:................................................................................................................
!

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Transfer protocol
The lift
with serial number..................................... was set up on .......................................
at (company name)................................. in........................................................
checked for function and safety and put into operation.
The following listed people (operators) were trained to handle the lift after it
was set up by a trained assembler of the manufacturer or a contract partner
(specialist).
(Date, name, signature, empty lines must have a scored out)
..................................... .................................................. .....................................
Date Name Signature
..................................... .................................................. .....................................
Date Name Signature
..................................... .................................................. .....................................
Date Name Signature
..................................... .................................................. .....................................
Date Name Signature
..................................... .................................................. .....................................
Date Name Signature
..................................... .................................................. .....................................
Date Name, specialist Signature of specialist
Service partner:................................................................................................................

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2. Lift master forms
2.1 Manufacturer
Otto Nussbaum GmbH & Co. KG
D-77694 Kehl, Germany
Tel.: [phone]
Fax: [phone]
www.nussbaumlifts.com
[e-mail]
2.2 Purpose
The Nussbaum lift TSK 12000 is for raising vehicles in normal workshop operations with
a total weight of 12000 lbs (5000 kg).
The set up of the standard lift is not permitted in explosion endangered work shops.
After construction and significant maintenance changes on load carrying parts, as
well as changing the installation location, the lift must be inspected afterwards by
a specialist who approves the changes. The lift is not set up for moving people.
2.3 Changes to the design / construction
Inspections by a technical expert are required before recommissioning (date,
type of change, technical expert signature).
................................................................................................................................................
................................................................................................................................................
Name, address of technical expert
.......................................................... ...................................................
Location, date Technical expert signature
2.4 Changing the assembly location
Inspections by a technical expert are required before recommissioning (date,
type of change, specialist signature)
................................................................................................................................................
Name, address of technical expert
.......................................................... ...................................................
Location, date Technical expert signature

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3. Technical information
3.1 Technical data
Load bearing capacity: 12.000 lbs (5000 kg)
Loading a lifting arm: A single load from only one lifting
arm may not happen
Lift time approx. 80 sec
Lowering time approx. 51 sec
Motor capacity 2 HP
Motor speed 3450 rpm
Operating pressure approx. 2200 psi (152 bar)
Pressure relief valve approx. 2350 psi (162 bar)
Oil volume approx. 4 GAL
Noise level 70 dB(A)
One-site connection 1 ~/N+PE, 230 V, 60 Hz
with maximum 25 Amp fuse

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3.2 Data sheet

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3.3 Hydraulic plan

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Hydraulic parts list
0.1
SPX 240
POWER UNIT
1.0
000jl31150-1x24V-SB15
Block
1.1
155211
PRESSURE RELIEF VALVE
1.2
982070
2/2 WAS SEAT VALVE
1.3
983700
NON RETURN VALVE
1.4
983629
FLOW CONTROL VALVE
1.5
975535
LOCKING SCREW
2.1
2.2
250TTKAS02100-30
250TTKAS02010
PLUNGERCYLINDER WITH RESTRICTOR 0.8 mm
RESTRICTOR D 1.7

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3.4 Pneumatic plan