twin busch TW SA 42 U V2 User manual

TWIN BUSCH GMBH
Technical changes, errors and printing mistakes are reserved. V01_NK_418_EN

TWIN BUSCH GMBH
Technical changes, errors and printing mistakes are reserved. V01_NK_418_EN
IMPORTANT NOTES...................................................................................................................................... 2
SAFETY NOTES.............................................................................................................................................4
1. Operation of lifting platforms ......................................................................................................................4
2. Checking of the lifting platforms.................................................................................................................4
3. Important safety notices.............................................................................................................................5
4. Warning labels ...........................................................................................................................................6
5. Potential safety risks..................................................................................................................................7
6. Noise level .................................................................................................................................................8
PACKING, STORAGE AND TRANSPORTATION.........................................................................................9
1. The lift was dismantled into 3 parts for transportation................................................................................9
2. Storage ......................................................................................................................................................9
3. Lifting and handling....................................................................................................................................9
PRODUCT DESCRIPTIONS.........................................................................................................................10
1. General descriptions................................................................................................................................10
2. Construction of the lift ..............................................................................................................................10
3. Dimensions ..............................................................................................................................................11
4. Technical data..........................................................................................................................................12
INSTALLATION INSTRUCTIONS ................................................................................................................ 12
1. Preparations before installation................................................................................................................12
2. Installation attentions ...............................................................................................................................13
3. General Installation Steps........................................................................................................................14
4. Items to be checked after installation.......................................................................................................15
OPERATION INSTRUCTIONS ..................................................................................................................... 16
1. Precautions..............................................................................................................................................16
2. Descriptions of control panel....................................................................................................................16
3. Flow chart for operation ...........................................................................................................................17
4. Operation instructions..............................................................................................................................17
TROUBLE SHOOTING................................................................................................................................. 19
MAINTENANCE............................................................................................................................................20
ANNEX.......................................................................................................................................................... 21
Annex1, Floor Plan........................................................................................................................................21
Annex2, Electrical schemes and parts list.....................................................................................................24
Annex3, Hydraulic schemes and parts list.....................................................................................................29
Annex4, Pneumatic scheme and parts list ....................................................................................................33
Annex5, Mechanically exploded drawings and parts list ...............................................................................34

TWIN BUSCH GMBH
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SAFETY NOTES
1. Operation of lifting platforms
This lift is specially designed for lifting motor vehicles. Users are not allowedto use it for any other purposes. The applicable
national regulations, l a w s and directives must be observed.
Only users aged 18 or above who have been instructed on how to operate the lifting platform and have proven their ability to do
so to the owner are to be entrusted w i t h unsupervised operation of lifting platforms. The task of operating the lifting platforms
must be granted in writing.
Before loading a vehicle onto the lifting platform, users should study the original operation instructions and familiarize
themselves with the operating procedures in several trial runs.
2. Checking of the lifting platforms
Checks are to be based on the following directives and regulations:
●Basicprinciplesfor testinglifting platforms
●Thebasicsafetyrequirements stipulatedinthe directive2006/42/EC
●Harmonized European standards
●Theapplicableaccidentpreventionregulations
The checks are to be organized by the user of the lifting platform. The user is responsible for appointing an expert or qualified
person to perform checking.
The user bears special responsibility if employees of the company are appointed as experts or qualified persons.
2.1. Scope ofchecking
Regular checking essentially involves performing a visual inspection and a functional test. This includes checking the condition
of the components and equipment, checking that the safety systems are complete and functioning properly and that the
inspection log book is completely filled in. The scope of exceptional checking depends on the nature and extent of any structural
modification or repair work.
2.2. Regular checking
After initial commissioning, lifting platforms are to be checked by a qualified person at intervals of not longer than one year.
A qualified person is somebody w i t h the training and experience required to possess sufficient knowledge of lifting platforms
and w h o is sufficiently familiar w i t h the pertinent national regulations, accident prevention regulations and generally
acknowledged rules of engineering to be able to assess the safe operating condition of lifting platforms.
2.3. Exceptional checking
Lifting platforms w i t h a lift height of more than 2 meters and lifting platforms intended for use w i t h people standing under the load
bearing elements of the load are to be checked by an expert prior or reuse following structural modifications and major repairs to
load bearing components.

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A n expert is somebody w i t h the training and experience required to possess specialist knowledge of lifting platforms and w h o
is sufficiently familiar w i t h the pertinent national w o r k safety regulations, accident prevention regulations and generally
acknowledged rules of engineering to be able to check and give an expert option on lifting platforms.
3. Important safety notices
Recommend for indoor use only, DO not expose the lift to rain, snow or excessive moisture.
Onlyuse thislift on asurface that isstable, l e v e l and dryand not slippery, and capable ofsustaining t h e load. Do not
install the liftonany asphalt surface.
3.2. R e a d andunderstandall safety warnings before operating thelift.
3.3. Donot l e a v e thecontrolswhiletheliftisstillinmotion.
3.4. Keep hands and feet a w a y fromany moving parts.Keep feet clearof the lift whenlowering.
3.5. Only these properly trained personnelcanoperate the lift.
3.6. Do not w e a r unfit clothessuchas large clothesw i t h flounces,tires,etc, whichcouldbe caughtbymovingparts of the lift.
3.7. T o preventevitableincidents, surroundingareas of the lift must be tidy and with nothing unconcerned.
3.8. Theliftissimplydesignedtolifttheentirebodyofvehicles,w i t h itsmaximumweightwithintheliftingc a p a c i t y .
3.9. A l w a y s insurethe safetylocksareengaged beforeany attempt tow o r k near or under the vehicle. Neverremovesafety
related componentsfrom the lift.Do not useif safetyrelated components are damaged or missing.
3.10. Do not rockthe vehiclewhile onthe lift or removeany heavy componentfromvehiclethat maycauseexcessive weightshift.
3.11. Check at any timethe parts of the lift toensure the agility of movingparts and the performanceof synchronization. Ensure
regular maintenance and if anything abnormal occurs,stopusingthe lift immediately and contactour dealers for help.
3.12. L o w e r thelifttoitslowestpositionanddoremembertocutoffthep o w e r sourcewhenservicefinishes.
3.13. Donotmodifyanypartsoftheliftwithoutmanufacturer’sadvice.
3.14. Iftheliftisgoingtobeleftunusedforalongtime,usersarerequiredto:
a.Disconnectthep o w e r ;
b. Emptytheoiltank;
c.Lubricatethemovingpartsw i t h grease.
WARNING：the warnings, cautions and instructions discussed in this instruction manual cannot c o v e r all possible
conditions and situations that may occur. It must be understood by the operator that common sense and caution are
factors which cannot be built into this product, but must be supplied by the operator.
Attention: For environment protection, please dispose the disused oil in a proper way.

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4. Warning labels
AllsafetywarningLabelsareclearlydepictedonthe lifttoensurethattheoperatorisawareofandavoidthedangers
ofusingtheliftinanincorrectmanner.Thelabelsmustbekeptcleanandtheyhavetobereplacedifdetachedor
damaged. Please read carefully the meaning of eachlabel and memories them for future operation

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5. Potential safety risks
5.1. Mainsvoltage
Insulation damage and other faults may result in accessible components being live
Safety measures:
•Onlyeverusethep o w e r cordprovidedoratestedpowercord.
•Replacew i r e s with damagedinsulation.
•Donotopentheoperatingunit.
5.2. Riskofinjury,dangerofcrushing
In the event of excessivevehicle weight, incorrect mounting of the vehicle or on removing heavy
object, there is arisk of the vehicle falling off the lifting platform or tipping up.
Safety measures:
•Theliftingplatformisonlyevertobeemployedfortheintendedpurpose.
•Carefully studyand heed all the information given in Section1.4.
•Observethe w a r n i n g noticesforoperation.
1.6 Noise level
Noise emitted during operating the lift should be less than 70dB. For y o u r health consideration, it is suggested to place a noise
detector in your working area.

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PACKING, STORAGE AND TRANSPORTATION
Packing,lifting,handling,transportingoperationsmustbeperformedonlybyexperiencedpersonnelwith appropriate knowledgeof
the lift and after reading this manual.
1. The lift was dismantled into 3 parts for transportation
Name
Packed
by
Dimension
Weight
Quantit
y
Control cabinet
Wooden case
510*480*1300
84KG
1
Power side platform
Carton with wooden base
5100*700*360
1550KG
1
The secondary platform
Carton with wooden base
5100*700*360
1550KG
1
Ramp
Bubble film
1300*680*250
106KG
1
2. Storage
The packs must be kept in a covered and protected area in a temperature range 0f -10°to +40°. They must not be exposed to
direct sunlight, rain or water.
Stacking the packs
We advise against stacking because the packs are not designed for this type of storage. The narrow base, heavy weight and
large size of the packs make stacking difficult and potentially dangerous.
If stacking is unavoidable, use all appropriate precautions:
-never stack to more than 2 meters in height.
-never make stacks of single packs. A l w a y s stack pairs of packs in a cross pattern so that the base is bigger and the resulting
stack is more stable. Once the stack is complete, restrain it using straps, ropes or other suitable methods.
A maximum of t w o packs can be stacked on lorries, in containers, and inr a i l w a y wagons, on condition that the packs are
strapped together and restrained to stop them falling.
3. Lifting and handling
The packs can be lifted and transported only by using a fork lifter. The center of gravity and lashing points are marked on the
packaging. Never attempt to hoist or transport the unit using lifting slings.
Opening the packs
When the lift is delivered make sure that it has not been damaged during transportation and that all the parts specified on the
packing list are present.
Packs must be opened adopting all the precautions required to avoid injury to persons (keep at a safe distance when cutting
the straps) or damage to parts of the machine (be careful that no parts are dropped w h i l e you are opening the packing)
Take special care with the hydraulic power unit, the control panel and the platform cylinder.

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PRODUCT DESCRIPTIONS
1. General descriptions
This model is surface mounted and is mainly composed by lifting platforms, base plates, oil cylinders and a set of operation unit.
The gear pump works when p o w e r supply is connected and meanwhile oil in the pump pushes upwards the pistons of oil
cylinders. Thus, scissor brackets of the lift rise accordingly. The mechanical lock w i l l automatically engaged incase of failure of
hydraulic system.
Besides, designs like 24V working voltage of control box and limit switch, low-height alarming buzzer, anti-surge valves, etc
have fully considered your personal security.
2. Construction of the lift

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3. Dimensions

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4. Technical data
Rated capacity
4000KG
8818,49 Lbs
Full raised height
1900mm
74.80 in
Full lowered height
180mm
7.08 in
Full raised time (with rated load)
≤55s
Full lowered time (with rated load)
≤55s
Hydraulic working pressure ( Bar )
200 Bar
2900,75 PSI
Pneumatic working pressure (Bar)
6-8 Bar
87-116 PSI
Rated capacity of the secondary lift
4000KG
8818,49 Lbs
Full raised height of the secondary lift
450mm
17,71 in
Oil tank volume
18L
4,75 Imp.gal

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INSTALLATION INSTRUCTIONS
1. Preparations before installation
Space requirements.
Refer to 3.3 for the dimensions of the lift. There must also be a clearance of at least 1 meter between the lifting platform and
fixed elements (e.g. wall) in all lifting positions. There must be sufficient space at the ends of the lifting platform for driving
vehicles on and off.
To stop vehicles colliding with the ceiling, it is advisable to fit an overhead light barrier in low ceiling buildings.
1.1. Foundations and connections
The user must have the following work performed before erecting the lift.
●Constructionof the foundation following consultationw i t h themanufacturer’s customerservice or anauthorizedserviceagent.
●Routingofthewiringtotheinstallationlocation.Theusermustprovidefuseprotectionfortheconnection.
●Routing of thecompressedair connectiontothe installationlocation.The user must installa service unit upstream
of the connection.
Refer also to the corresponding information in the commissioning instructions.
1.3. Foundations preparations
Please refer to Annex1 for floor dimensions.

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4. Toolsandequipmentsneededforinstallation
Tool Name
Specification
Qty
Electrical driller
With Ø16 and Ø18 driller.
1
Open spanner
Ø17-19mm
2
Adjustable spanner
bigger than Ø30mm
1
Cross socket screw driver
PH2
1
Quick spanner handle adapter/ Ratchet
1
Socket spanner
D24mm
1
Leveling device
1
Hammer
10 pounds
1
Truck lift
Capacity more than 2500KG
1
Lifting string
Capacity, 1000KG
2
Lifting string
Capacity, 2000KG
1
Torque spanner
MD400
1
5. Checking parts
Unfold the package and check if any parts missed as per the following list. Do not hesitate to contact us in case any parts
missed, but if you do not contact us and insist installing upon the lack of some parts, w e as w e l l as our dealers w i l l not bear
any responsibility for this and will charge for any parts subsequently demanded by the buyer.
S/N
Name
Specification
Qty
1
Lifting platform
6604
2
2
Expansion bolt
M16*120
16
3
Control cabinet
/
1
4
Drive-on ramp
6604V2-A9
2
5
Protective cover A(L=2200)
6604V2-A13
1
6
Protective cover B(L=1000)
6604V2-A14
1
7
Protective cover C(L=1000)
6604V2-A15
1
8
Protective cover D(L=1000)
6604V2-A16
1
9
Cross socket cap head tapping screw
ST4.8*35
20
10
Plastic expansion tube
M10*40
20
11
Cross socket cap head screw
M6*12
4
12
Hex nut
M6
4
13
Flat washer
M6
4

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2. Installation attentions
Jointsof oil hose and wiring mustbe firmlyconnectedinorder toavoidleakageof oil hoseand loosenessof electrical wires.
All bolts shouldbe firmlyscrewedup

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Donotplaceanyvehicleontheliftinthecaseoftrialrunning.
3. General Installation Steps
Step1: Choose installation site.
Use a fork lift to place the machine at installation site as required. See Annex 1 for space requirements on the installation site.
Step 2: Connect hydraulic oil hoses.
Connect the oil hose as per the scheme for oil hose connection. (This step is very important and it is quite necessary to
understand the diagram of oil hose connection before operation)
Step 3: Connect pneumatic hoses.
Connect the pneumatic release system by the scheme of pneumatic hose connection.
Step 4: Connect electrical wires.
Refer to the electrical connection scheme. Connect the power supply and the quick connecters for limit switch.
Step 5: Fill with hydraulic oil.
ONLY C L E A N A N D FRESH OIL
ONLY
Attention: Lift must be fully lowered before changing or adding hydraulic oil
Normally it needs 22 liters of hydraulic oil.
Initially, fill the tank full w i t h about 18L of hydraulic oil . Run the main and the secondary lift for several cyclesand add another
4L into the tank.
Note：As running speed of the lift is mainly decided by the density hydraulic oil, w e suggest using NO.46 hydraulic oil w h e n
average
Temperature of the location is above 18 degree Celsius and using NO.32 hydraulic oil when temperature is below 18 degree
Celsius.
Step 6: Leveling
Check the connection of the hydraulic and electrical system before leveling operation
Review operation instructions and get familiar with lift controls by running the lift through a few cycles before leveling operation.
Leveling platforms of the main lift
1) Turnonthemainpowers w i t c h andturntheselectionswitchSA2tothemainliftandSA1to“Leveling”status.Turnthet w o
handlesof leveling valvetothe following status.
2) Push theUP button toraise theplatforms tothe maxheight and then l o w e r tothe minimum height. Repeat this for 3 cycles. Pay
attention topush the UP button very slightly and slowly whenthe platforms almost reach tothe max height. Afterthat, engage the
mechanical safety locks and push DOWN I and DOWN II to completely lower the platforms. This step may needs pretty long time
as there remainedairintheoilcylindersandnoloadontheplatforms.
3) Repeat the cyclesof step2for two or three times. Turn off the t w o leveling valvesw h e n platforms are fully lowered.Turn the t w o
handles tothe following status.

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4) Turn SA1 to normal working status and push UP button to check the synchronization. (Normally, the two platforms are not
synchronizedtill this step).
5) Ifnotbeingsynchronizedand oneplatformrisesfasterthantheother,openthelevelingvalvethatcontrolstheslowerplatformand
turn SA1 toleveling status,pushthe UP button slightlyuntil both platforms are at the sameheight. Closethe levelingvalve.
6) TurnSA1tonormal workingstatusandcheckthesynchronization.
7) IFstill not being synchronized, repeat step4 tostep6 until both platforms are synchronized.
Leveling platforms of the secondary lift (central jack)
1)T u r n SA2oncontrolpaneltoJACKandturnSA1tolevelingstatus.
2)PressUPbuttonuntilbothplatformofthejackgoutmosttoptobleedairinthecylinders.
3)PressDOWNI, until jacksl o w e r tothe lowestposition.
PRESS UP BUTTON TO CHECK. THE JACKS SHOULD BE SYNCHRONIZED BY THIS STEP.
Repeat the above leveling steps until synchronization reached.
4. Items to be checked after installation.
S/N
Check items
YES
NO
1
Are two platforms adjusted with the same level?
2
Are oil hose tightly connected?
3
Are all electric connections correct?
4
Are valves of the pump unit oil tight?

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OPERATION INSTRUCTIONS
5.1 Precautions
1. Checkallthejointsofoilhose.Onlywhenthereisnoleakage,theliftcanstartwork.
2. The lift, if its safetydevicemalfunctions,shallnot be used.
3. Itshallnot lift or l o w e r an automobile if its centerof gravityis not positionedmidway of the runways.Failure todo somaycause
damage toproperty and personnel.
4. O p e r a t o r s and personnelconcernedshouldstandinasafetyarea duringliftingand l o w e r i n g process.
5. When the platforms are raised to the desired height, switchoff the power to prevent any w r o n g operation done by
unconcerned people.
6. Make sure the safety lock of the lift is engaged before start working under the vehicle and no people under the vehicle
during lifting and lowering process.
2. Descriptions of control panel
POS.
Name
Function
FA
Alarm buzzer
Safety warning
SB1
UP button
Control the rising movement
SB3
DOWN button
Control the initial lowering movement
SB4
DOWN button
Control the final lowering movement
SB2
LOCK button
Engage the safety locks
SB
Emergency stop
Stop power in emergency cases
HL
Power indicator
Show if power is on
QS
Main switch
Power on /off
SA1
Selection switch
Control working or leveling condition
SA2
Selection switch
Main lift or secondary lift

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3. Flow chart for operation

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4. Operation instructions
To avoid personal injury and/or property damage, permit only trained personnel to operate the lift. After reviewing these
instructions, get familiar w i t h lift controls by running the lift through a few cycles before loading vehicle on lift. A l w a y s lift the
vehicle using both platforms. Never raise just one end, one corner or one side of vehicle.
The normal users are not allowed to open the door of control cabinet. Option switches in the control cabinet need to
be turned to ‘working’ before using the lift to raise vehicles .
Using the Main Lift
Raising
1. Drive and park the vehicle m i d w a y between t w o platforms. Make sure the vehicle is correctly positioned and secured against
rolling.
2. T u r n theoptionalswitchonthecontrolpanelto“MainL i f t ” .
3. Pushthe“UP”buttononthecontrolpaneltoliftthevehicleabithigherfromthegroundandcheckagainifthevehicleisinasafe
position.
4. Havingraisedthevehicletotheheight needed,pushthe“SafetyLock”buttontoensurethemechanicalsafetylockis
engaged.Press the“EmergencyStop”andcheckagainthestabilitybeforeperformingmaintenanceorrepairwork.
Lowering
1. Switchon.
2. Push ”DOWNI”buttontol o w e r thelift.Firstly,theliftw i l l automaticallyrisetodisengagethemechanicallocks.Thentheliftl o w e r s .
It will stoplowering w h e n clearancebetween the platforms and the ground reachesto600mm.
3. Push“DOWNII”buttontocontinuel o w e r i n g theplatforms. Alarmingbuzzw i l l beheard.
Using the Auxiliary
lift Raising
1. Turn the optional switchon the controlpanel to“Auxiliarylift”.
2. Placerubber pads under thepick-up points of vehicle.When itis necessarytousethe platformextensions,press“UP”
button toraise platformsofthejackabitovertheplatformsofmainliftandpullouttheextensions.
3. Press“UP”buttonandcheckagainiftherubberpadsaredirectlyunderthepick-uppointsofthevehicle,w h e n theyarevery
closeto the vehicle’schassis.
4. Keeponpushing”UP”buttonuntilreachestothedesiredheight.Fullriseofthejackis450mmovertheplatformofmainlift.
Lowering
Attention: incase the platform extensions ofthe auxiliary liftare used, the operator needs to pushthe
extension in afterthefourwheelsofvehiclelayonthemainplatforms.
1. Turn the optional s w i t c h onthe controlpanel to“Auxiliarylift”.
2. Push“DOWNI”buttononthecontrolpaneltolowerthe
jack. 3.Take away rubber pads.
The lift lowered
PressDOWNIIwhen
platforms stoploweringata
distanceof 600mmabove
ground

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TROUBLE SHOOTING
ATTENTION: If the trouble could not be fixed by yourself, please do not hesitate to contact us for help. We will offer our
service at the earliest time we can. By the way, your troubles will be judged and solved much faster if you could provide us
more details or pictures of the trouble.
TROUBLES
C A U S E
SOLUTION
Motor does not runand w i l l not
raise
The wire connection is loose.
Check and make a good
connection.
The motor is burnt
Replace it.
The limit switch is damaged or the wire connection is loose.
Connect it or adjust or replace the
limit switch.
Motor runs but will not raise
The motor run reversely.
Check the wire connection.
Overflow valve is loose or jammed.
Clean or adjust it.
The gear pump is damaged.
Replace it.
Oil level is too low.
Add oil.
The oil hose became loose or dropped off.
Tighten it.
The cushion valve became loose or jammed.
Clean or adjusts it.
Platforms go down slowly after
being raised
The oil hose leaks.
Check or replace it.
The oil cylinder is not tightened.
Replace the seal.
The single valve leaks.
Clean or replace it.
The overflow valve leaks.
Clean or replace it.
Electrical unloading valve leaks.
Clean or replace it.
Raising too slow
The oil filter is jammed.
Clean or replace it.
Oil level is too low.
Add oil.
Theoverflowvalveisnotadjustedtotheright position.
Adjust it.
The hydraulic oil is too hot (above 45°).
Change the oil.
The seal of the cylinder is abraded.
Replace the seal.
Lowering too slow
The throttle valve jammed.
Clean or replace.
The hydraulic oil is dirty.
Change the oil.
The anti-surge valve jammed.
Clean it.
The oil hose jammed.
Replace it.