Owners Manual-1 - Beacon Industries, Inc.
Contents
1. Check for unusual noise See Trouble Shooting B Yearly inspection Oil in reservoir should be changed at least once a year or sooner if the oil darkens or becomes gritty Presence of water is indicated if the oil turns milky C Winter Summer Maintenance Change the oil as per Oil Viscosity Recommendations depending on the ambient temperatures prevailing in your area Some Tips to the Operator 1 Always load the Lift properly centering the load on the platform as much as possible 2 Never use the Lift if it is in need of repairs or in the case of a malfunction 3 Notify your maintenance personnel in case you notice anything out of the ordinary such as binding odd pump noises etc 4 Do not continue to depress the UP control if the Lift is not raising You can permanently damage the motor or pump by doing so 5 Important Do not load the unit when in mobile position or attempt to move while loaded 6 For proper operation of the unit make sure ground is level and horizon tal Oil Viscosity Recommendations Best performance can be obtained by utilizing ISO Vg grade 32 46 oil with a viscosity range between 150 250 SUS at 100 F 32 54 cST a 40 C Minimum viscosity at operating temperature is 60 SUS 10cSt Maximum start up viscosity at minimum ambient temperature of hydraulic oil is 150 F 65 C Oil should be non corrosive have maximum anti wear properties rust and oxidation treatment2. and be non foaming Recommended list of oils for an ambient temperature range of 10 F to 100 F 23 C to 38 C are as follows 1 Amoco Oil Co 2 Cities Service Oil Co Rycon Oil No 32 46 Citgo AW Hyd Oil 32 46 Citgo All Temp Hyd Oil 3 Chevron USA Chevron EP Hyd Oil 32 46 4 Fina Oil Co Fina AW 32 46 Fina Automatic Transmission Fluid Dexon II 5 Gulf Oil Corporation Gulf Harmony 32 AW 32 46 6 Mobil Oil Corporation DTE 15 24 25 Mobile Fluid 300 transmission Fluid Sentinel SH 10 Hydraulic Oil Tellus Hyd Oil 32 46 Tellus T Hyd Oil 32 46 Rando Oil Hd 32 46 XCell AW 46 200 7 Sentinel Lubricants Corp 8 Shell Oil Corp 9 Texaco Inc 10 Union 76 Notes 1 Do Not Use Brake Fluid 2 All BTAD s requiring oil by BEACON will be supplied with AW 46 200 Hydraulic oil 3 BEACON strongly recommends the use of an oil immersion heater when units are mounted outside or when ambient temperature is ex pected to fall below 40 F 4 In case an oil heater is used on your lift refer to temperature settings given under oil immersion heater section in Options Options Attachments and Accessories Some of the more common options and attachments are given below A Oil Immersion Heater An oil immersion heater with thermostat control specs 250 Watts 115v 208 240V 1 PH 60H2 is available as an optional accessory BEA CON strongly recommends the use of this accessory when uni
3. Tread Bridge Length Steel Hinged Bridge AA Plate with Safety Chains X T AC Bridge Width Platform Width Reservoir Motor Pump Valves and Electric Control Box Ramp Width Safety Tread Steel Hinged Approach Ramp with Safety Chains Not Shown in Bottom View Ramp Length Removable Safety Handrail with Midrail and Toeboard Power Unit Cover Safety Chain Assembly with Snap Hooks at with Removable One End 4 Supplied Front and Rear Panels Not Shown in Top View 15ft Power Cord with 3 or 4 Prong Twist Lock Plug Depending on Voltage and Phase Steel Treadplate Platform Assembly Weather Proof Up Down Push Button Station with 10 Coil Cord Not Shown in Top ven TT RA Hydraulic Cylinder Gor huang Upper Travel on Model Limit Switch Structural Tubing Scissor Leg Assembly Automatic Flip Up Flip Down Portability Wheel Assembly Crowned Poly Rollers Lift Plate A _ Standard Maintenance Safety NM l Detachable Angle 2 Supplied i Dolly Jack s i Assembly to be NN Used for Moving V 2 Lift Only When Empty Base Frame Assembly 6 Dia Crowned Poly Wheels Standard Vertical Travel Height Ground Mus Be Horizontal and Level Min Ground Lowered Clearance Base Length Figure 2E Figure 1 Figure 2 Typical Layout if BTAD Series Alternate Transfer with Standard Transfer Arrangement Arrangements Portability Feature The BTAD Series is a p
4. actual 115 volts at the power cord plug during full load operation Improperly sized wiring at the customer plant will lead to overheating of motors and constant overload tripping due to high ampere draw The standard 1 1 2 HP power unit uses an intermittent duty rated super torque motor Make sure that frequency of operation does not exceed one full lift every 4 minutes This is to avoid overheating of motors Please note that motor operates only on UP cycle DOWN cycle is by gravity In high frequency operations or faster speeds consult factory for use of power units with continuous duty rated motors 460V Q H2 Q o x1Q 9 X2 24V Figure 9A Transformer Connections on 3 Phase Power Supply H1 H3 H2 WI TUN X 24V X1 X2 X1 Figure 10A Transformer Connections on 1 Phase Power Supply Low Voltage High Voltage T4 5 Note To Reverse the Rotation e 1 1 I of a Three Phase Motor Inter 99 s Ww Pm S change any 2 of the 3 power 5 r v T Wan leads to the motor Line Line T6 T5 T4 T6 T Motor Connections Figure 9B 3 Phase Motor Connections Note To Reverse the Rotation i i of a Single Phase Motor In Electrolytic Capacitor terchange 5 and 6 T 02 E1 01 02 5 T Line 2 Line 2 Oil Capacitor High Voltage Low Voltage Figure 10B Motor Connections for 112 HP 1PH 60Hz Elect
5. drawn on the motor name plate or as shown in Fig 9 and 10 Recommended Motor Lubrication Lubricant Consistency 3 Cyprina 3 or comparable Lithium Grease Intermittent Duty and Normal Continuous Duty grease once a year High Ambient moist or dirty Continuous Duty grease twice a year 3 Push Button Control Station The standard push button control station supplied with the Lift is weath erproof pendent with UP and DN momentary contact dead man type push button There is a mechanical interlock provided internally i e when one button is depressed the other is mechanically held open 4 Down Solenoid The cartridge type Down Solenoid valve discussed in the Hydraulic Section uses a 24V 60Hz coil requiring 40VA Removal of coil is accom plished by removal of the top nut without disturbing the hydraulic system 13 Cylinder Repair Kit Consists of Items Marked by an Asterisk Figure 8 Sectional View of Hydraulic Cylinder See Figure 7 for details 5 Twist Lock Plug The twist lock plug supplied with the 15 foot power cord on the unit con forms to the following specifications Customer to supply or make provi sions for mating receptacles NEMA Configuration NEMA Configuration of Power Supply of Twist Lock Plug Mating Receptacle by by ECOA Purchaser 208 230V 3PH 60Hz L15 20R 460V 3PH 60Hz L16 20P L16 20R 115V 1PH 60Hz L 5 30P L 5 30R 230V 1PH 60Hz L 6 15P L 6 15R 6 Wi
6. 7 Adapter BHOS P412 02 Adapter a eos Paor os JReducer 14 L5 L5 3 fs BHOS P402 03 BHOS P109 0220 Hose Assembly A NPT x 22 Long s BHYD 41 03 EN o BHOS P422 15 Elbow tt tj BHOS P350 08 08 HoseFiting Stragnt Et t t BHOS P404 05 NppeseNPT Sif BHOS P201 08 180 Suction Hose 1 2 I D x 18 Lg 11 1 1 BHOS P351 08 08 ElbowFiting 1 1 1 BHYD 43 02 Suction Filter o S t j BHOS P404 05 Nippes SSS 1 31 t 16 BHLD P720 Elow Control Vave30 GPM tt 1 1 BHOS P419 01 Ebow 0 0 0 0 0 1 1 tj el BHLD P719 Solenoid Valve Ref Part of Item 83 rs Hos Pasoos resa Ner Hos pa34 03 cross sa wer 1 1 1 1 BELC P126 09 Electric Motor 11 2HP 4 P 280 115 V 1 PH eOHz BELC P126 07 Electric Motor 11 2 1 HP208230 460v3PH eOHz tt BMS35291 6 1 420 UNC HHMBx3 4tg 9 9 j BMS353384a fJaoiw 1 0 e9 ep ej s BMS35690 402 t420UNCHexNut eo eope j BHOS P107 0340 Hose Assembly 3 8 NPT x 34 Long BHYD 44 02 E BELC P105 10 Cable Connector CS 80 Power Supply j BELC P10 amp 15 Cable Connector Pd Power Supply EH BELC P105 14 EN BELC P115 11 Control Box 115V
7. Box for Units Fitted with Assembly for UP DN Circuits Warning Bell and Flashing Red Light Figure 19C Details of Optional Electrical Figure 19D Control Box for Units Fitted with Warning Bell Details of Optional Electrical Control Bell to Sound 2 Seconds on Start of Box for Units Fitted with UP and Down Cycles Flashing Red Light Observation 1 Lift does not raise but pump is running or humming 2 Lift raises too slowly 3 Motor labors or heats excessively O09 Q2 9 e Trouble Shooting Possible Cause Motor rotation may be reversed Motor may be single phasing humming voltage at motor terminals mao be too low to run pump at existing load Hose or hydraulic line is leaking Oil level in resevoir is low Load exceeds capacity requirements Relief valve is bypassing the oil back into the tank Suction filter is clogged starving pump Suction line may be leaking air due to loose fittings Filter Breather cap on tank may be clogged Down Valve may be energized by faulty wiring or stuck open Hydraulic pump may be inoperative Foreign material stuck in Down Solenoid causing some oil to bypass back into tank Foreign material clogging suction filter breather cap pressure line filter or a pinched hose Low Motor voltage Lift overloaded Oil is too thick for proper operation Lift operates with a shuddering vibration Pump is inoperative Voltage may be low I
8. Connector 1 0 only Butt Connector 3 0 only A 7 p XY Y 7 E ALLS SSNS 3 Cylinder Repair Kit Consists of Items Marked by an Asterisk Figure 17 Sectional View of Hydraulic Cylinder Assembly CYL A2805 5650 Piston Rod Retainer Ring Quad Ring o CYL M0006 228 Back Up Ring CYL Mooo1 228 CCT Ring S 8 CYL B3405 6138 Barrel Assembly Weldment 9 CYLPOO01 tt Piston 235 29 U 10 MS3217 1137 1 j RetanngRing 0 1 i HYD 31 16 1 DowySed tT 12 HDW P9 0406 ButonHeadScrewv 0 O 1 13 CYL A2801 RK Cyl Repair Kit Consists of items 3 4 6 7 11 amp 12 Aa 2 2 2 tem PartNumber Description Qty e 2 BHLT P709 2 E 4 o BHLT P709 10 CheckValveSeat t 8 BHLT P709 12 Check Valve Screwbody 9 BHLT P709 13 Check Valve Pug t 10 BHLT 709 14 ORing Of Consists of items 12 through 16 13 BMS3393 30 ORing Of 5 CYL MO001 014 JjORing Jt hy Suction Port Figure 18 Cross Sectional View of Hydraulic Pump with Internal Valves used on 1 HP Power Units IH1H2 HS HA LI T nae is 1213141516 Uitetsfapsfet7 sts fiopifiaiish afi sii Figure 19A Figure 19B Details of Optional Details of Standard Electrical Control Box Electrical Control
9. Scissor Dock Lift BTAD Portable Loading Dock Installation Operation and Service Manual BEACONA BEACON INDUSTRIES INC 12300 Old Tesson Rd St Louis MO 63128 2247 USA OFFICE 314 487 7600 FAX 314 487 0100 www beacontechnology com General Information The BTAD series of Lifts have been primarily designed for loading dock applications The most important advantages of BEACON Scissor Dock Lifts is that they are infinitely adjustable The installation of this Lift provides full flexibility allowing you to load and unload at any truck bed elevation All BTAD models are similar in design but differ in capacity and platform sizes This manual is intended to familiarize you with installation operation and service procedures Model Number and Capacities The model number serial number and capacities are stamped on the nameplate Please remember to include these numbers in any correspon dence with your dealer or the factory Loading The load capacity rating as stamped on the nameplate of your Lift des ignates the net capacity assuming uniformly distributed load This capacity must never be exceeded as permanent damage may result The relief valve has been preset to raise the indicated capacity plus an overload Lowering loads exceeding the rated capacity can result in excessive wear or damage to the Lift Axle Load Ratings The maximum axle loads that the Lift is designed to take over its sides and ends is stamped on the
10. cosity Recommendations Cylinder may be binding Align correctly See 1 k Lower the Lift Remove the Solenoid Valve and clean it See Hydraulic Section Correct as necessary See also 1 g i See 1 c See 1 f Refer to Oil Viscosity Recommendations Observation Spongy or Jerky Lift operation Do not a Air trapped in cylinders confuse spongy op eration with small surges caused by foreign material on Lift wheel roller plate Lift lowers too slowly when loaded 6 Liftlowers too quickly 7 Liftraises then lowers slowly 8 Lift has raised but does not lower Trouble Shooting Possible Cause Air trapped cylinders Oil starvation Down Valve filter clogged Pinched tube or hose Oil too thick Foreign material in Flow Control Valve Binding cylinders Foreign material in Velocity Fuse Leaking hoses cracked fittings Check valve stuck open The combination of a stuck Check Valve and open Solenoid Valve will cause excessive speeds Foreign material stuck in Flow Control Valve In this case Lift lowers initially at a normal rate then speeds up as the platform descends Down Solenoid Valve may be incorrectly wired or is stuck open due to dirt Check Valve may be stuck open Check for leaking hoses fittings pipes Cylinder packings may be worn or dam aged Blown electrical fuse Incorrect Down Solenoid Valve wiring Down Solenoid Valve is stuck Faulty Dow
11. econds by adjusting the knob on the timer relay located inside the control box Locate it in front of a door Place it on top of a low dock Position it in front of a raised dock Trans A Dok has Unlimited Application Posibilities To Stabilize Place Dolly Jack Tow Bar at the rear lift plate and raise Roller catch automatically releases lowering the unit onto the base from BTAD is now ready for operation To Relocate Position Dolly Jack Tow Bar under the rear lift plate raise The Flip up Flip down Wheels will automatically lower and lock in mobile position Then place tow bar under front lift plate and move to next location Important Do not load BTAD when in the mobile position or attempt to move while loaded Figure 5 Portability Feature Hydraulic Circuit see Figure 6 When the operator wants to raise the platform he depresses the UP control This starts the electric motor Item 3 which runs the hydraulic pump Item 2 Oil from the reservoir is sucked in through the suction filter Item 1 and into the pump The oil flows through the check valve and the flow control valves Item 9 before entering the cylinders Item 7 The function of the check valve is to allow the oil to flow in one direction i e towards the cylinders It also prevents the flow of oil back into the pump circuit when the pump stops running This holds the oil in the cylinders and maintains the desired elevation If the load is exc
12. essive and the UP button is still depressed pressure will build up in the circuit between the pump and the cylinders This forces the ball or poppet in the relief valve to unseat and the pump output returns into the reservoir through the same suction hose When the operator desires to lower the Lift he depresses the DN Down control This energizes the down solenoid valve Item 4 The pop pet in the solenoid valve is unseated and oil now returns from the cylinders through micronic filter Item 6 the flow control valve Item 5 the return filter which is a part of the solenoid valve the solenoid valve return suc tion hose and into the reservoir The flow control valve controls the down Speed of the lift It is preset and cannot be changed Releasing the DN control will de energize the solenoid closing the valve poppet This prevents the oil from returning to the reservoir and the cylinders will stop retracting The Lift is now maintained at that particular elevation There is a Velocity Fuse Item 8 at the base of each cylinder In the event of a hydraulic hose failure the platform lowers at a fast rate As Soon as the descent speed exceeds the preset speed the Velocity Fuse will shut off the oil flow and the platform will remain stationary until pres sure is reapplied This safety feature reduces the possibility of accidental personal injury or damage to the Lift Solenoid Valve The solenoid valve is of cartr
13. iPH 60Hz CT 1 tt BELC P115 09 EH BELC Pi15 10 Control Box 460v 3PH 60Hz 1 1 29 BELC P105 14 twz CabeConectr esee Quality Required e e e e x lt x lt s a a Em eee tmm EIE BELC P105 24 Lock Nut 1 2 BELC P107 02 Push Button Staton t t t 9 BTAD P9308 AlminumBracket 3 t t Cable Connector 3 4 Hub fort only Cd LS Cable Connector 3 4 Hub A for 30 only dedede 3 4 Nut 4 4 26 BELC P105 14 Cable Connector s s 9 jBL 133 Decal 230V sPH 60Hz dL 2 2 BL 3137 Decal 208v 3PH 60Hz 2 jBL 36 Decal 230V PH ieOHz dL 2 2 2 BELC P03 5 10 10_ ForkConnector__ dT 6 6 BL 132 Decal Lower Supply BELC P112 04 4 BELC P101 06 Twist Lock Plug for 230V 1 PH 60Hz only L6 15P L5 30P Twist Lock Plug for 208 230V 3PH 60Hz only L15 20P Twist Lock Plug for 460V 3PH 60Hz only L16 20P Power Cord amp Motor Leads 10 AWG 3 Type SO Cord x 280 Lg Single Phase P U only Power Cord amp Motor Leads 1 14 4 Type SO Cord x 280 Lg 8 Phase P U only Solenoid amp Limit Switch Leads 1 16 2 SO Cord x 15 Lg Decal Oil Hose Clip Gear Pump 2 gom 3600 RPM BELC P101 07 Coil Cord 16 4 AWG 10 Ext BELC P101 08 90 Connector for single phase capacitor only Butt
14. idge construction and is virtually mainte nance free If there is a faulty operation check Trouble Shooting Section To clean the cartridge valve follow this procedure 1 Use a sharp blunt object and push poppet in from the bottom to open the valve 2 Repeat several times while valve is immersed in kerosene Blow dry Do Not Immerse The Coil 3 Inspect 0 rings and the teflon extrusion washer 4 Reinstall The valve should be tightened to approximately 30 ft Ibs Hydraulic Reservoir Capacity Integral Reservoir Capacity is as follows a 6 wide models 3 3 4 gallons approx b 8 wide models 5 gallons approx Quantity may be 2 or 3 Depending on Capacity and Mode Key 1 Suction Filter 2 Hydraulic Pump with built in check Relief and Solenoid Valves item 4 3 Electric Motor 4 Down Solenoid Valve with Filter 5 Down Flow Control Valve 6 25 Micron High Pressure Filter 7 Hydraulic Cylinders 8 Velocity Fuse 9 Up Flow Control Valves Figure 6 Hydraulic Schematic Down Solenoid Valve Assembly Pressure Port Check Valve Sub Assembly Relief Valve Sub Assembly Suction Port Figure 7 Cross Sectionel view of Hydraulic Pump Instructions for Repacking Hydraulic Cylinders General points to note Leakage of hydraulic cylinders after a period of time is expected and is a normal maintenance function Weepage is the small amount of oil that accumulates arou
15. ller Roller Pin Roller Pin Pin Axle Pin Assembly Decal Maintenance Safety Bar Decal Power Supply Decal CAUTION WIRING for 115V only Decal Remove Shipping Bolts ECOA Logo Decal Danger Keep out Decal Lifting Cap Decal Caution All Loads must Be Centered Black and Yellow Safety Stripe min 22 max 26 Name Plate Transport Roller Assembly Reference Axle Pin Reference Caster Assembly 6 Diameter Poly Reference Axle Pin Reference Bushing Reference Retainer Washer Reference Flat Washer Reference Hex Soc F H Screw Reference Qty Required BTAD XX 606 1 ee ee ee Ca ce Oe eae Ge 2E DERE eN VANOANNANARNYNANHOANA orar or d d UV NNNANN Bt VONWMANNATAGZNAANANAKRAAA BTAD XX 608 1 a GA E nkocE GE mk xk BAM au o0 BPRRwWOAOHWOANARARAO ets re A DM pH Oe VANOANNANAZYNANHYINA Prot or tt RIDQIDIDOSIDID A i i OW BTAD XX 806 1 4o EC eA mE Gnk mE ge gm m SRBaanas of o owaPRRwaoawanana a au m m NMANOANNANAZNYNANHOFANAAAAANAAAANDYNNANND ROWU e N 1 e lao 66000000 08 D OOQOQODOHOG Figure 16A General Layout of Power Unit for 2 Cylinder Models 5 um OO Toe OT i4 006 O a OO 900 0000 Figure 16B General Layout of Power Unit for 3 Cylinder Models Trans A Dok Parts List Quality Required TAD XX 606 BHOS P413 3
16. ls the Up Limit Switch will be actuated This shuts off the power to the motor When in this condition depressing the UP button will have no effect The platform will remain stationary at this elevation Always remember that the motor runs only when the UP button is de pressed and the Down Solenoid Valve is energized only when the DOWN button is depressed mm p ee ee pue Depp ms eee umm Number Ends or Slides Width E EE E Speed f p m Cyinders Weight BTAD 30 606 3000s 1500s 72 72 pve 2 2500bs Ei AF D m mm Rum MER SE Me m EUN M RE 05 L eTApsoen soodies e mom pos rs oe os e 2 a BTAD 60 606 6000ls sooows v2 s s ev o v2 2 2550s BTAD 30608 3000s 1500s 72 90 ss con 5 Jim 3 7O0bs OV Or Or KaLa Kan ayo BTAD 40 608 4000 Ibs 2000Ibs _ 72 o s s c s5 vuv 3 2725 tbs stap so60a 000s zxoms 7 sw s os oon 5 wwe a zm BTAD 60 608 6000 1s s000ibs _ 72 o sss oc 5 r 3 e0bs BTAD 30 906 3000s 1500s o 77 s sv ec 5 r 3 sobs BTAD 40 806 4000Ibs 2000s oe 77 gt sv c 5 vv 3 sobs Lenao sosos sone 000s ae ms perf om L5 re 3 9 emnes sons ope ae me 8 19 L5 rel 3s 899 JaJa aa afjajajaja o a Note For Models BTAD XX 806 only the overall width is 19 instead of 11 Platform Length Safety
17. ly damage the internal stem Do not remove the Solenoid Valve from the Pump Body as the unit will come down at a dangerous speed Remove and replace Raise Lift and remove the safety bar or whatever object is blocking the down travel then press the down button See 2 f To unlock repressurize the hydraulic system Put maintenance safety bar in place and unscrew Bleeder plug Item 136 fig 8 from cylinder This will relieve the pressure inside the cylinder After the platform drops by a few inches reset the Lim Switch to cut off motor a 60 Raised Height
18. n Solenoid Coil Maintenance safety bar or some other object blocking down travel Binding cylinders In case of excessive down speeds the Velocity Fuse will become operative and shut off oil flow from the cylinders thus the platform will remain stationary Check if the Limit Switch is inoperative and the platform has raised all the way so that the inter nal cylinder stops are in operation If stops are in operation velocity fuses have been locked up Remedy Bleed oylinders by lowering Lift fully and hold DN button for 20 30 seconds more Raise Lift and repeat procedure several times Bleed cylinders also by loosening bleeder screws until a steady stream of oil comes out See 1 e 9 h i Remove Solenoid Valve and clean filter Correct as necessary In case of pipe check for obstruction in line See Oil Viscosity Recommendations for your ambient temperatures Lower the Lift remove Flow Control Valve and clean See Hydraulic Section See 2 f Remove and clean Correct as necessary Remove Check Valve and clean it See Hydraulic Section Remove Flow Control Valve and clean it See 2 a Remove and clean See Hydraulic Sec tion Correct as necessary Replace packings See Cylinder Repair procedure Check and replace Correct as necessary See Wiring Dia gram Lightly tap down the Solenoid Coil body to seat it properly Do not hit hard as it will permanent
19. n off the electrical power at the disconnect or ciruit breaker to prevent accidental operation while you are repairing the unit Switch should be tagged or locked in off position to prevent accidental operation 4 Remove the cylinder s from the unit by removal of the cylinder holding plate and hardware Figure 15 Items 25 26 27 28 and the cylinder rod pin at the base Figure 15 Items 21 22 23 and hoses 5 Clamp the cylinder assembly in a vise 6 Figure 8 shows the sectional view of the hydraulic cylinder Replace seals accordingly 7 Mountthe cylinders back in position by installing item 28 Figure 15 The mounting hardware should be left slightly loose 8 Extend the piston rod and install the cylinder rod pin washer and retaining ring Figure 15 Items 21 22 23 9 Raise and lower the platform after removing the maintenance safety angle so that the cylinder aligns itself Now tighten the cylinder mounting plate bolts Figure 15 Item 25 e aa TET TER o LE LILLE RS 3 MMS SS NS SSSA g Barrel Weldment Assembly Piston Retaining Ring Dowty Seal Screw 2 Retaining Ring 3 Quad Ring 4 Backup Ring 5 Gland 6 Backup Ring Electrical Components Given below are the various electrical components used on the Lift A brief explanation of each is also given 1 Control Box The control box comes pre wired from the factory Specifications Magnetic Starter 24 V AC Coil Thermal ove
20. nameplate Suggestions and Criticism BEACON is a company which puts great stress on constructive ideas or criticism Your suggestions as end users of BEACON equipment may result in research and development which will enable us to produce an even better product We would appreciate hearing your ideas Receiving Instructions Every BTAD Portable Loading Dock is thoroughly tested and inspected prior to shipment However it is possible that the unit may incur damage during transit Remove all packing and strapping material and inspect for damage IF DAMAGE IS EVIDENT FILE A CLAIM WITH THE CARRIER IMMEDIATELY Also check the platform size type of power unit etc to see that the unit is correct for the intended application General Layout Transfer Arrangements and Specifications Figure 1 shows a general layout for a typical BTAD series with the stan dard transfer arrangement Figure 2 shows some of the alternate transfer arrangements Figure 3 gives an idea of different application possibilities The major specifications of the BTAD Series are listed below according to model numbers Installation 1 Remove all steel strapping and the wooden skid The unit comes with four 4 eye bolts fitted on the platform See Figure 15 Item 16 These are to be used for lifting the unit with a crane or fork truck 2 Remove the 2 shipping bolts Figure 15 Item 18 and 20 3 The weather proof UP DN Push button Station with 10 coil cord a
21. ncorrect wiring Oil starvation causes pump to bind High internal heat is developed if this occurs pump may be permanently damaged Binding cylinders Oil may be too thick e 02o Remedy See arrow on pump to check correct rota tion Change motor rotation per notes in Electrical Section If Lift has been running properly for some time then it is possible that plant wiring has been changed and the motor is now running reversed Check wiring and overloads fuses etc to ascertain that all 3 phase lines are present at the motor Measure voltage at motor terminals or as near as possible while pump is running under load If voltage is sufficient check for inadequate or incorrect wiring as this can starve the motor Correct as necessary Correct as necessary Add oil Do not change Relief Valve setting Instead reduce the load to rated capacity Remove and clean Check fittings Remove and clean Remove Solenoid Valve check and clean See Hydraulic Section Disconnect hydraulic line at power unit Put hose end in a large container and run pump again If no output check motor rotation as per 1 a above Check also the pump motor coupling which may be defective and correct as necessary If pump is worn replace with a new pump Lower the Lift Remove the Solenoid Valve and clean it See Hydraulic Section Correct as necessary See also 1 g i See 1 c See 1 f Refer to Oil Vis
22. nd a detachable disconnect plug is packed separately in a small box Make Sure you have received the same Attach the plug to the receptacle provided on the side of the power unit housing See Figure 1 for actual position 4 The unit is supplied completely prewired along with a 15 long power cord and a twist lock plug The twist lock plug will have 3 or 4 prongs depending on the power supply for which the BTAD is wired A decal indicating the Power Supply is stuck on the side of the power unit housing where the power cord comes out of it Read the voltage and phase and check if you have the same power supply source Please refer to the Electrical Section in this manual for the correct mating receptacle required to be purchased and installed by the purchaser of our equipment Now attach the power plug and turn ON the electrical power at the fused disconnect switch if provided at your end The lift is now ready for initial testing 5 Press UP button The unit will elevate On releasing the UP button the platform will remain stationary Press the DN button The platform will descend 6 Raise and lower unit several times for the full stroke Check leakages which may occur due to hydraulic connections loosened during ship ment 7 Raise the unit to the top and insert the 2 Maintenance Service Angles in position See Figure 1 for location Lower the unit until the bottom rollers touch the Maintenance Safety Angle No
23. nd the piston rod and gland assembly in normal use After a period of time the accu mulation increases to the point where it spills over the flange of the gland and runs down the barrel This is normal for single acting cylinders and it does not indicate a need for a change of packings Wipe off the excess oil occasionally Weepage should not be confused with leakage Leakage is oil that is bypassing a worn or cut seal When Lift does not maintain a raised position for a period of time approx 1 2 1hour it is an indication of a leak These symptoms require a seal replacement Normally when one cylinder is repacked the other cylinders should also be repacked since when one seal wears out the other is close to wearing out Caution As is well known dirt and foreign material are the worst enemies of hydraulic systems and hence precautions should be taken to prevent contamination of the system through open f fittings pipes or disassembled components In the event of accidental contamination flush pipes and hoses with clean oil and wash components with a cleaning solvent Failure to do so may cause serious damage to seals and machined surfaces Procedure 1 Raise the Lift insert the Maintenance Safety Bars as shown in Fig 1 2 After the Maintenance Safety Bars are in position lower the Lift Keep the DN control depressed for about 15 20 seconds after the down ward travel ceases This relieves pressure from the system 3 Tur
24. ortable model Figure 1 shows the position of the lift plates A and B A more detailed view of these plates is shown in Figure 5 Moving or stabilizing the unit is achieved as follows To Move The Unit 8 Position dolly jack tow bar under the lift plate ZA and raise The flipup flip down wheels will automatically lower and lock in the mobile position b Now place dolly jack tow bar under lift place B the unit is now ready to be moved To Stabilize The Unit a Remove tow bar from under the lift plate B and position the same under lift plate ZA Raise The wheels will automatically raise b Lower dolly jack Caution Do not load the unit when in mobile position or attempt to move while loaded Routine Maintenance Raise the Lift and install the Maintenance Safety Bars before beginning any inspection or work on the unit A Monthly Inspections 1 Check oil level It should be 1 below top of the tank with Lift in fully lowered position Add as necessary See oil specifications 2 Check for oil leaks See Trouble Shooting Section and correct as neces sary ie Check roller bushings axle pin clevis and pivot points for wear 4 Check for worn or damaged hydraulic hoses or electrical cords Repair as necessary Check rollers for looseness and wear See Trouble Shooting Check retaining rings at all axles pivot points and clevis Never grease rollers or axles as they are lubricated for life o N Oo OC
25. ric Motor jui ss mer OL1 T1 Black 1 5 HP 208 230 460V 3PH 60Hz Fused Disconnect By Others Wall Outlet 24N by Others o 98 Black a White O mm 96 b a LE TEE Down Sol Control Box Station 4 Conductor Electrical Schematic For 208 230 460V 3PH 60Hz Fused Disconnect Plug at Source 15 Power Cord By Others Wall Outlet By Others Push Button 10 Ft Coil Cord Down Sol Control Box Station 4 Conductor Electrical Schematic For 230V 1PH 60Hz KEEN OOM oume E I Black White Motor 1 5 HP 115V 1PH 60Hz Fused Disconnect Plug at Source 15 Power Cord By Others Wall Outlet By Others Red wr a Green Ee Push Button 10 Ft Coil Cord Down Sol Control Box Station 4 Conductor Electrical Schematic For 115V 1PH 60Hz Service 208 230 460V 3PH 60 Hz Schematic with 208 230 460V 3PH 60Hz Power Supply for BTAD Units Fitted with Optional Flashing Red Lights Service 208 230 460V 3PH 60 Hz Fused n at Source Disconnect Wall Outlet by Others by Others Electrical Schematic with 208 230 460V 3PH 60Hz 2 Power Supply for Control Box BTAD Units Fitted with Optional Warning Bell Service 208 230 460V 3PH 60 Hz Lt I nJ f L2 S L3 4 L Fused plug at Source Disconnect Wall Outlet by Others by Others P774 208 230 460V 3PH 60Hz Power Supply for BTAD Units Fit
26. ring Diagram The standard power units come prewired for 1 1 2 HP 230V 1 PH 60Hz power supply unless otherwise stated in the order The wiring diagram for the standard and the more common options is shown in the figures 9A 9B 10A 10B and 11 A Diagram for the High or Low voltage connections on the motor and the transformer for three and single phase power supply is also shown which will facilitate field conversions The Diagrams are self explanatory 7 Wiring Size The standard 1 1 2 HP Power Unit uses an intermittent duty rated super torque motor A supertorque motor has the capabilities of producing torque greater than twice the nameplate rating on demand for short periods of time Thus it should be noted that ampere ratings mentioned under Electric Motors is for full load torque Under actual conditions the motors will draw higher current As a guide the following chart should be used for determining wire size of either the extension cord or the inter nal wiring for the power outlet at the customer s plant a 3 Phase Motors Voltage WireSize For Lengths Upto y O guage f150feet b 1 Phase Motors Voltage WireSize for Lengths Upto 1 8 guage 1 6 guage 11 dO guage dS feet po dB quage dS feet Note 1 For 115V 1PH 60Hz Power Supply For proper operation it is necessary to provide a separate 30 AMP circuit and adequate sized wiring to assure an
27. ription Base Frame Assembly includes 64 Leg Set Assembly includes 67 thru 71 Platform Assembly Standard Steel Ramp Assembly 30 x 60 Optional Aluminum Ramp Assembly 30 x 60 Standard Steel Bridge Assembly 18 x 60 Optional Aluminum Bridge Assembly 18 x 60 Dolly Jack Standard includes 65 and 66 Dolly Jack with Tow Bar Optional Equipment incl 65 amp 66 Handrail Assembly 44 c c Handrail Assembly 68 c c Handrail Assembly 92 c c Safety Maintenance Angles Rollers Roller Pins Bearings Retaining Rings Spacers Spacers Clevis Pin Weldment Washers Lifting Eyes 3 4 UNC x 5 Lg HHMB 1 2 UNC x 3 Lg HHMB 1 2 Washer 1 2 UNC x 11 2 Lg HHMB Cylinder Mounting Pin Retaining Ring Washer Cylinder Assembly Includes Item Nos 125 through 136 1 2 13 UNC HHMB x 21 4 Lg 1 2 Washer 1 2 13 UNC Hex Nuts Cylinder Mounting Plate Cylinder Gasket Cylinder Gasket Plate 1 4 20 UNC HHMB x 1 Lg 1 4 LW 1 4 20 UNC Hex Nut Cylinder Bellows Optional Equipment Only Bellows Clamps Optional Equipment Only Washer Safety Chain 68 Lg W 1 Snap hook Safety Chain 92 Lg W 1 Snap hook Ramp Plate Mounting Chain 56 Lg 3 4s 18 UNC x 11 4 Lg HHMB 5 16 Flat Washer Vie 18 UNC Hex Nut Bridge Plate Mounting Chain 50 Lg 1 4 16 UNC x 11 4 Lg Screw F H 3 4 16 UNC Nut Lock Dimpled Retaining Washer Flat Hd Screw 1 2 13 UNC x 11 2 Lg Leg Assembly Leg Ro
28. rload 3 pole Adjustable Transformer Primary 208 240 277 380 480V 50 60Hz Secondary 24V 0 100kVA Fuse in Secondary Circuit 4AMP Reset Automatic or Manual Enclosure NEMA 12 with 5 knockouts Motor Solenoid Limit Switch Push Button Control and Power Cord Overall Box Dimensions 12 x10 x5 In the case of a single phase unit the Adjustable Transformer has a primary voltage of 115 230V 60 Hz and a secondary voltage of 24V 0 100 KVA The control box is prewired for the power supply you have ordered In case it becomes necessary to convert from high to low voltage or vice versa reconnect the wires per diagram on the motor and transformer Also change overload protection to the proper value per motor chart see below 2 Electric Motor Install the power lines to conform to National Electrical Code NEC 430 22 and the local codes For reference the motor currents are listed below 1 1 2 HP 208 230 460V 3 Phase 60 Hertz 3450 RPM 2 minute intermit tent duty TENV Super Torque Motor VOLTAGE 208 230 460 Full Load Current Amps 5 3 4 8 2 4 b 1 1 2 HP 115 230V 1 Phase 6 Hertz 3450 RPM 2 minute intermittent duty TENV Super Torque Motor VOLTAGE 115 230 Full Load Current Amps 23 11 5 To reverse the direction of rotation of a 3 phase motor reverse any two of the 3 power leads to the motor On single phase motors see wiring diagram on motor In case wiring is done in the field connect the motor per wiring diagram
29. ted with Optional Warning Bell And Flashing Red Light DODOA QxX 9 q Figure 15 General Layout of BTAD Series Third Scissor Leg Details For Model BTAD xx 806 ONLY View from Dolly Jack End Item No AOI a 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 Part Number eK BHLD P533 30060 BTAD P5201 HLD P533 18060 BTAD P5001 BTAD P1751 BTAD P1758 BTAD P4101 48S BTAD P4101 72S BTAD P410196S BTAD P1401 BHLD P932 BHLD P913 BHLT P950 BHLT P972 BTAD P9303 BHLD P996 BTAD P9003 BHLT P970 BHLD P994 BMS35291 199 BMS35291 119 BMS27183 18 BMS35291 113 BTAD P9005 BWFC P108 BMS27183 27 BCYL A2805 5650 BMS35291 116 BMS35338 48 BMS35690 802 BTAD P9301 BTAD P9306 BTAD P9307 BMS35291 8 BMS35338 44 BMS35690 402 BTAD P9305 BMS35842 14 BHLT P971 BCHN P192 5 67SH BCHN P192 7 67SH BCHN P192 4 67 BMS35291 36 BMS27183 12 BMS35690 502 BCHN P192 4 17 BMS35239 119 BMS51922 170 BHLT P9101 BMS24667 76 BHLT P320 1 BHLT P2010 BHLT P9020 BHLT P9007 BTAD P9021 BHLT P9006 BTAD P9020 BL 121 BL 132 BL 129 BL 96 BL 155 BL 73 BL 97 BL 140 BHLD ST 2 L 71 BTAD P1671 BHLD P907 BCAS WA PY6 BTAD P9010 BHLT P953 BDSL P9064 BHLT P971 BMS24667 76 Figure 15 General Layout of BTAD Series Desc
30. ts are mounted outside and or when ambient temperature is expected to fall be low 40 F The heater has an adjustable thermostat control However care should be exercised by the customer in setting the temperature so that the viscosity of oil does not drop below 200 SUS at the elevated temperature This will ensure a trouble free running of the power unit Also customer should turn the heater off during the summer months of when the ambient temperature is above 65 F Caution Units equipped with an oil immersion heater should not exceed the following temperature settings Grade of Oil Oil Viscosity Max Allowable Temp Setting Used Rating of Oil Immersion Heater ISO Vg 46 250 SUS 100 F 110 F SAE 10 W 30 400 SUS 100 F 130 F SAE 40 750 SUS 100 F 150 F B Flashing Red Light A 24VDC flashing red light is available for added safety When the UP pushbutton is depressed the first time the light will start flashing and con tinue to flash indefinitely The platform may be raised lowered or remain stationary during this time To turn the light off depress the stop button located on the base of the flashing red light C Warning Bell A 24 VAC warning bell is available as an optional accessory for added safety The bell sounds for a few seconds on the start of the UP and DN cycles The length of time for the bell to sound is factory adjusted to 2 seconds However this timing can be easily varied from 1 to 10 s
31. w check the underside of the platform legs etc for any damage during shipment 8 Lower the platform after removing the maintenance safety angles Remove the front panel Check the oil level in the reservoir to ensure there have been no spillages during shipment Top off if necessary See Oil Viscosity Recommendations in this manual 9 Check the portability features as explained elsewhere in this manual 10 The unit is now ready for normal operation Operation The BTAD models are furnished with constant pressure dead man type push button controls Depressing the UP or RAISE control starts the motor see wiring diagram which in turn runs the hydraulic pump The cylinders begin to extend and the platform starts to raise The platform will rise as long as the UP control is depressed On releasing the control the platform ceases to rise and will remain at that particular elevation This is because the motor circuit is broken and the motor stops running On depressing the DOWN or LOWER control the Down Solenoid Valve is energized The cylinders start retracting as the oil returns to the reservoir and upon releasing the control the platform ceases to lower remaining at that particular elevation In the event that the Lift is overloaded the relief valve will open be cause of excessive pressure build up and oil will bypass into the reservoir When the Lift reaches a preset vertical travel 55 on standard mode
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