TERRY Melody 2 hydraulic MK2 Installation Manual

Hide thumbs

Table Of Contents

Table of Contents

Quick Links

Installation Manual

Melody 2 MKII Platform Lift

Ref. ED20400f Date: 03/04/2012

Original instructions

Table of Contents

Need help?

Do you have a question about the Melody 2 hydraulic MK2 and is the answer not in the manual?

Questions and answers

Summary of Contents for TERRY Melody 2 hydraulic MK2

Page 1 Installation Manual Melody 2 MKII Platform Lift Ref. ED20400f Date: 03/04/2012 Original instructions...
Page 2: Table Of Contents
Melody 2 hydraulic MK2 Installation Manual - Issue f Contents Safe Working Weights of Main Parts / Assemblies Health & Safety Compliance Fitting safety scotch Power Pack Isolate Switch Powerpack / Circuit Box and Cable Runs Installing Melody 2 Hydraulic Lift...
Page 3: Safe Working
Data Sheets for all hazardous substances used in the manufacture, installation and use of this equipment are available at www.terrylifts.co.uk  CDM Regulations - Terry Group Limited hereby certifies that the dismantling and disposal of this equipment can be achieved by reversing the installation...
Page 4: Fitting Safety Scotch
Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES Fitting safety scotch Working under the Lift – ALWAYS FIT THE SAFETY SCOTCH IMPORTANT Before any work is carried out underneath the lift, the safety scotch must be fitted to the LH Gate Post as indicated below.
Page 5: Power Pack Isolate Switch
Melody 2 Hydraulic MK2 Installation Manual - Issue f Power Pack Isolate Switch In order to safely work on the lift and to perform a manual lowering operation, a Lift Isolate switch has been provided. This switch isolates the 12V power to the lifts carriage and disables the use of the call stations, re-levelling system and gates when turned off.
Page 6: Powerpack / Circuit Box And Cable Runs
Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES Powerpack / Circuit Box and Cable Runs Ref. ED20102c Fit the hydraulic powerpack in a suitable location using 2 x 10mm Rawl bolts. Fit the electrical control box as close to the powerpack as possible. Use the mounting brackets supplied.
Page 7: Installing Melody 2 Hydraulic Lift
Melody 2 Hydraulic MK2 Installation Manual - Issue f Installing Melody 2 Hydraulic Lift NOTES Ref. ED20129e 23/08/2011 Specialist tools required  22mm SDS drill bit  Chain splitter  Pin punch  Metal cutting circular saw Arrival on site...
Page 8 Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES 2. Upper Level Plinth  Follow the diagram below to fix the upper level plinth. 22mm Diameter holes Ensure the jig is pushed hard against the lifting face Drill through two small ﬁ xing...
Page 9 Melody 2 Hydraulic MK2 Installation Manual - Issue f 4. Cutting of the Main Uprights and Lower Guides NOTES Use a jigsaw or metal cutting saw to cut uprights and guides. Ensure burs are removed and treat cuts before ﬁ tting as follows: Seal all exposed edges using a touch-up can.
Page 10 Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES Guides  Cut the calculated length off the lower LH and RH Guides.  Take the off- cut from the lower left hand guide and copy the outline of the ram cut-out onto to remaining guide. Either use a jigsaw or metal cutting saw to create the guide cut-out.
Page 11 Melody 2 Hydraulic MK2 Installation Manual - Issue f  Offer the left hand upper guide/upright assembly to the upper level plinth and secure using an M12x110mm bolt. Once fitted, ensure a 40mm gap exists between the base plate and the bottom of the upright. This is to allow the trailing cables to exit the upright.
Page 12 Melody 2 Hydraulic MK2 Installation Manual - Issue f 8. Ram  Carry the ram from the van (2 people) and locate between the pins on the left side of the base plate. Ensure the head of the ram and the bleed points are facing the correct way.
Page 13 Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES  Important! Ensure both guides are in good contact with the base plate and that the baseplate is level in both directions.  Ensure the right hand guide is perfectly vertical in both directions by moving the baseplate accordingly.
Page 14 Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES Remove the gate beak bracket assembly and move the correct set of inserts to ensure the bracket aligns with the gate. Drop the gate over the gate pivoit pin (Lubricating the pin first).
Page 15 Melody 2 Hydraulic MK2 Installation Manual - Issue f 14. Ram Head Assembly NOTES The method for fixing the new ‘ram-to-carriage bracket’ into position is very similar to the previous method; Take the lift to its upmost position and undo one of...
Page 16 Melody 2 Hydraulic MK2 Installation Manual - Issue f  Lay out the chain drive assembly ensuring that no dirt or grit gets in the links, and attach the Anti Creep unit as detailed above. The chains now need to be cut to length.
Page 17 Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES clowns feet Fix the backpillar and roller Top plate of backpillar on Orientation of the roller inside of carriage (thick side of hub faces outwards) The beak bracket on the carriage is now a ﬂ oating beak There is no need to adjust the lock beak when the gate is ﬁ...
Page 18 Melody 2 Hydraulic MK2 Installation Manual - Issue f 17. Attaching the Carriage to the Chain Drive Assembly  Remove the 3 x M12 bolts from the front of the chain assembly and keep safe.  Position the carriage so its base butts up to the bottom of the chain drive assembly.
Page 19 Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES The below diagrams show the location of each switch within the control mechanism Complete Control Control Mechanism Mechanism Assembly Switch Assembly Plunger 1) Creep Switch 2) Latch Switch Control Mechanism...
Page 20 Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES Secure the anti-creep support bracket in place using the M6 x 30 CSK Screw (CB066) + M6 Washer (CW005) & M6 Nyloc (CN002) Secure top of brace with single countersunk...
Page 21 Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES It is very important that the safety switches in the Anti Creep Assembly are the correct distance away from the 60x60 box sections to ensure safe operation. A new feature has been added to the back end of the ﬂ...
Page 22 Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES Carriage Cable Connections  Run the cables neatly from the bottom right and left sides of the car back to the lift control panel. Make sure the cables are run under the platform in the cut-outs formed in the main floor assembly.
Page 23 25. Radio Isolate Programming Instructions  The Radio Isolate Reciever has been developed to provide an easily programmable timer for use across the range of Terry lifting Products. The unit is located externally to the lift and connects into the powerpack unit.
Page 24 Melody 2 Hydraulic MK2 Installation Manual - Issue f Details Of CE1724 Radio Kit The kit consists of a CE1724 Issue B receiver and a CE1725 transmitter fob. The receiver has a 1 amp fuse ﬁ tted to the Red supply wire. Flying Lead connections are coded thus; Red +V supply, Black OV supply, White &...
Page 25 Melody 2 Hydraulic MK2 Installation Manual - Issue f Programming Key fobs must be ‘Learnt’ by the receiver module. To carry out this process SW1 must be pressed for a minimum of 1 second, but no longer than 10 seconds. The Key fob to be ‘learnt’ is then pressed;...
Page 26: Wiring
Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES Wiring ED20112F 13/05/2010 General Information The CE1466 board provides the main controller unit for the Melody Hydraulic Lift and is located in an IP65 rated Painted Steel Box installed externally from the lifting platform.
Page 27 Melody 2 Hydraulic MK2 Installation Manual - Issue f System Diagnosis NOTES Battery Connectivity In the Control Box check the battery voltage with respect to the Earth Terminal located on the lower left Hand side of the control unit. This should be approximately 13.6 V DC.
Page 28 Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES Gate Lock and Light Timer The Gate Lock timer is set manually on site so that the customer has ample time to exit the platform before the gate should re-lock. Typically this timer should be set to four seconds.
Page 29: Diagnostic Flow Charts
Melody 2 Hydraulic MK2 Installation Manual - Issue f Diagnostic Flow Charts Power Supply The following flow chart highlights the route of the power ciruit of the lift. hdK &h^ d Z KZ Z^d > ZZ/ ' &/E >...
Page 30 Melody 2 Hydraulic MK2 Installation Manual - Issue f Emergency circuit The following flow chart highlights the route of the emergency ciruit of the lift. Numbers shown refer to test point on the ciruit diagrams on pages 30 and 31 of this document. All Emergency cct wires are...
Page 31 Melody 2 Hydraulic MK2 Installation Manual - Issue f Up Hold The following flow chart highlights the route of the Up Hold ciruit of the lift. Numbers shown refer to test point on the ciruit diagrams on pages 30 and 31 of this document.
Page 32 Melody 2 Hydraulic MK2 Installation Manual - Issue f Down Hold The following flow chart highlights the route of the Down Hold ciruit of the lift. Numbers shown refer to test point on the ciruit diagrams on pages 30 and 31 of this document.
Page 33 Melody 2 Hydraulic MK2 Installation Manual - Issue f Door Enable Circuit The following flow chart highlights the route of the Door Enable Circuit. The timer controlling the door locks originates from the same timer. Letters relate to check poins on pages 31& 32.
Page 34: Wiring Diagrams
Melody 2 Hydraulic MK2 Installation Manual - Issue f Wiring Diagrams...
Page 35 Melody 2 Hydraulic MK2 Installation Manual - Issue f FIG.3 CARRIAGE WIRING...
Page 36 Melody 2 Hydraulic MK2 Installation Manual - Issue f FIG.4 CONTROL SYSTEM COMPLETE WIRING...
Page 37 Melody 2 Hydraulic MK2 Installation Manual - Issue f FIG 5 Interface Panel Layout L) - CALL STATIONS O) - DOOR LOCKS & PRESSURE SW R) -TRAILING CABLES D) - CALL STATION DOOR BUTTONS See page 33 for full wiring details...
Page 38 Melody 2 Hydraulic MK2 Installation Manual - Issue f CARRIAGE RESYNC TIMER TIMER MODE J - 3 MINUTES Carriage Resync Timer Operation When the lift arrives at and remains at the lower level and the gate is opened and closed the Carriage Resync Timer is activated.
Page 39 Melody 2 Hydraulic MK2 Installation Manual - Issue f CARRIAGE CREEP INTERFACE Creep Disable Creep CTL Relay CE1651 PCB...
Page 40 Melody 2 Hydraulic MK2 Installation Manual - Issue f POWER PACK CREEP INTERFACE VOLTAGE INVERTER CE1652...
Page 41: To Conduct An Insulation Resistance Test On The Safety Circuit
Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES To conduct an insulation resistance test on the safety circuit Ref. ED20121A The purpose of this test is to Megger all Up &, Down Hold, Emergency, and Door Enable Circuitry to the Carriage Platform...
Page 42 Melody 2 Hydraulic MK2 Installation Manual - Issue f...
Page 43: Installation Test Certifi Cate For Melody 2 Hyd Lift
Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES Installation Test Certiﬁ cate for Melody 2 Hyd Lift. Ref. ED20122d 25/05/2010 B.1. Description of installation: Lift reference:- Location:- Manufacturer:- Terry Group Ltd, Longridge Trading Estate, Knutsford, Cheshire. WA16 8PR...
Page 44 Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES B.2 Examinations and tests B.2.1 All lifts B.2.1.1 Earthing arrangements a) Is all metalwork that encloses live electrical conductors bonded to the main earthing terminal by protective conductors including the guides?
Page 45 Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES B.2.1.7 Enclosure interlocks Are all enclosure doors, gates or barriers ﬁ tted with interlocks? B.2.1.8 Clearances a) Are the lift way clearances adequate ? B.2.1.9 General a) Is a load plate ﬁ tted on the platform? B.2.2.2 Safety gear and breaking system (if ﬁ...
Page 46 Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES B.3 Basic safety system checks Check gate i/lock operation – interlock switch / magnetic proximity switch Check gate beaks are secure Check call station operation Check underpan safe edge operation Check carriage piller safety edge operation B.4 Exemptions...
Page 47: Trade Customer Feedback Questionnaire
Melody 2 Hydraulic MK2 Installation Manual - Issue f Terry Group Limited Head Office & Factory: Unit 1, Longridge Trading Estate, Knutsford, Cheshire, WA16 8PR tel: 0845 365 5366 fax: 0845 365 5367 email: sales@terrylifts.co.uk web: www.terrylifts.co.uk London Office: tel: 0845 365 5376 fax: 0845 365 5377...
Page 48 Melody 2 Hydraulic MK2 Installation Manual - Issue f...
Page 49: Declaration Of Conformity
Melody 2 Hydraulic MK2 Installation Manual - Issue f Declaration of Conformity NOTES Lift Type: MELODY 2 LIFT TERRY GROUP Ltd. declares that this lift fulﬁ ls all the relevant provisions of the following Directives: 2004/108/EEC EMC Specifications 2006/95/EEC Low Voltage Directive...
Page 50 Melody 2 Hydraulic MK2 Installation Manual - Issue f...
Page 51: Melody 2 Hyd. Lift Service Points
Melody 2 Hydraulic MK2 Installation Manual - Issue f MELODY 2 HYD. SERVICE & MAINTENANCE NOTES ref. ED20124d 03/04/2012 Dependent on frequency of use, this lifting platform should be serviced at least every 6 months. This service should be conducted by competent persons trained in the service and repair of the product.
Page 52 Melody 2 Hydraulic MK2 Installation Manual - Issue f NOTES BASIC SAFETY SYSTEM CHECKS Check gate interlock operation Ensure the gate only release at correct level Check gates stay locked during travel Check no operation with either gate open Check gate beaks are secure - Check tightness of both beaks and brackets...
Page 53: Melody 2 Hyd. Lift Master Defi Nition Of Basic Safety Items
Melody 2 Hydraulic MK2 Installation Manual - Issue f Melody 2 Hyd. Lift Master Deﬁ nition of Basic NOTES Safety Items Ref. ED20125b 26/02/2009 A. Check Gate Interlock Operation. Ensure the gates only release at correct level Check gates stay locked during travel Check no operation with either gate open B.
Page 54 Melody 2 Hydraulic MK2 Installation Manual - Issue f...
Page 55: Melody 2 Hyd 900 X 1400 Platform Details
Melody 2 Hydraulic MK2 Installation Manual - Issue f...
Page 56: Melody 2 Hyd 1100 X 1400 Platform Details
Melody 2 Hydraulic MK2 Installation Manual - Issue f...
Page 57: Lift Disassembly/Safe Disposal Of Hazardous Materials
Melody 2 Hydraulic MK2 Installation Manual - Issue f Lift Disassembly/Safe Disposal of Hazardous NOTES Materials This lift must be disassembled by a competent person who has been fully trained in the installation of this lift and is qualiﬁ ed to provide safe disconnection of the lift to the mains terminal.
Page 58: Bulletins
Melody 2 Hydraulic MK2 Installation Manual - Issue f ED20431 23/08/2011 Bulletins...
Page 59: Melody 2 Plinth - No Pins (Xb00160B)
Melody 2 Hydraulic MK2 Installation Manual - Issue f...
Page 60 Melody 2 Hydraulic MK2 Installation Manual - Issue f...

TERRY Melody 2 hydraulic MK2 Installation Manual

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for TERRY Melody 2 hydraulic MK2

Summary of Contents for TERRY Melody 2 hydraulic MK2

Table of Contents