Trolley IW1 - Chariot roulant industriel GYS - Free user manual and instructions

USER MANUAL Trolley IW1 GYS

GENERAL INSTRUCTIONS This user’s manual includes operating instructions for your device and safety warnings for your protection. Please read it carefully before rst use and keep it for future reference. Do not use this machine if any parts are missing or damaged. This product must not be modied in any way. Fasteners that are over- or under-torqued and susceptible to breakage, loosening or separation can lead to serious accidents. Unsecured components can become projectiles. Assemblies that require a specic torque should be checked with a dynamometer. If the markings indicating the rated load, working pressure or warning signs are illegible or missing, they must be replaced. Operators and maintenance personnel must be physically capable of supporting the load, weight and power of the connected equipment and must be able to perform the work. This equipment is intended for professional use only. PERSONAL SAFETY Wear safety shoes to avoid an accident in the event of falling parts or during the machine’s assembly. Wear protective gloves to limit the risks associated with vibration exposure. Repeated movement and exposure to vibrations can be harmful to both the hands and arms. In the event of numbness, itching, pain or discolouration of the skin, stop using the device and consult a doctor. Wear ear protection. Prolonged exposure to the operating noise of an air tool can result in permanent hearing loss. WORKING ENVIRONMENT Slips, trips or falls are a major cause of serious injury or death. Look out for loose cables on the oor. Always use the tool at a safe distance from people and objects in or around the work area. The impact-wrench support is intended for indoor use, in a well-lit environment on a at oor.

DESCRIPTION OF THE IMPACT-WRENCH SUPPORT

The impact-wrench support is a user-friendly tool that makes it easier to use impact wrenches for heavy good vehicles. It allows an operator to support the impact wrench’s weight and torque as well as some of the vibrations when the de- vice is used on a heavy goods vehicle. It enables the user to move around the vehicle easily and to hold the equipment rmly in its working position thanks to its brake. It balances a wide range of weights and can be tted with an ination device and a silencer. It is ideal for working on all types of HGV tyres and also oers better access to the underbody. COMPONENT PARTS The impact-wrench support consists of numerous parts. The positioning of these component parts is shown on the fol- lowing pages. Contact the manufacturer, GYS, for more information about the part numbers. ASSEMBLY

Cable ties made from black polypropylene (PP) (4.8 mm x 295 mm)

Castor wheels with central brake (D125 mm)

93437 Clevis joint and inter-arm support 2 93438 Clevis with stop arm No. 1 2 93439 Fixing plate No. 1 2 93440 Fixing plate No. 2 2 93451 Impact-wrench cord attachment 1 93474 Front casing 1 93871 Bolt-storage unit 1 93872 Seat 1

93909 Column top 1 93908 Seat base 1 93887 Spacer between column and seat 2 93877 First arm 1

Stainless steel cable (L200 mm) with two rings (D24 mm)

2- Loosen the screw between the connecting rod and the hexagonal

bar to be able to slide the bar to one side without taking it out comple- tely (Torx Allen key [T30]).

3- Insert the castor wheel into the plate, then pass the bar through the

wheel cavity until it protrudes through.

4- Position the four wheel screws without tightening them (screws

[M8x16], Allen key [H6]).

5- Insert the other wheel in the opposite plate then replace the hexa-

gonal bar and tighten the screw between the connecting rod and the bar (tapped hole, Torx Allen key [T30] and a mallet if necessary).

6- Insert the four M8x16 wheel screws and tighten them all (Allen key

1- Place the wheels on the two front plates.

2- Position the eight wheel screws and tighten them

1- Apply the brakes and position the column (the brake will remain

applied for the product’s entire assembly procedure).

2- Insert the two lock nuts (M8) and tighten them to prevent the

column from closing and to keep it straight (spanner or 13 mm socket spanner).21 TROLLEY IW1

1- Position the lower-rear casing so that the top part of it is behind the

upper-rear housing, lining up the screw holes (see pictures).

2- Position and tighten the four screws (M6x10) (Torx Allen key [T30]).

Indice: jonathanb Etabli par: MECANIQUE 18/09/2019 Torx oval-head screw (M5x9) with captive washer x4 Screw (M6x10) x6 Flat-head screws (M5x12) x4 Straightening bar handle (M8x10 H81) x1 Column top x1 Front casing x1 Spacer between column and seat x2 Tapped plate for stop screws x1 Torx Allen key (T25 and T30)

1- Holding the column’s shaft in place, rotate the mechanism clockwise

to wind the chain onto the pulley, then position the tapped plate for stop screws inside the casing unit attached to the right-hand side of the column (see pictures).

2- Hold it in place with two screws (M6x10) (Torx Allen key [T30]).

3- Position the four Torx oval-head screws (M5x9) with captive washer

on the column, then insert the front casing by passing the screw heads through the small holes.

4- Place the casing against the column and slide it down. When it is

fully down, tighten the four screws (M5x9) with captive washers (Torx Allen key [T25]).

5- Place the spacers between the column and the seat with the

spacers’ tapped holes facing downwards. Tighten the at-head screws (M5x12) to hold the spacers in place (Torx Allen key [T25]).

6- Position the column top and hold it in place with the four screws

(M6x10) (Torx Allen key [T30]).

7- Screw the handle into the casing on the right-hand side of the

column. Assembling the seat Torx oval-head screw (M6x10) x8 Crosshead countersunk-head wood screw (M3x10) x4 Torx Allen key (T30)

1- Place the pad on a clean, at surface with the bottom facing up.

2- Turn the seat upside down as well and attach it to the cushion,

making sure that it is properly aligned with the cushion (sides and front aligned with the seat’s metal base).

3- Insert the seat bottom into the seat and secure it with the 4 M6 x 10

screws. (Torx key T30)22 TROLLEY IW1

1- Insert the axial rod’s small pin into the impact-wrench connector

and then into the impact-wrench plate. Firmly tighten the nut (M12x1) (Sleeve [19 mm] and clamping the ball joint if necessary). Pay atten- tion to the alignment of the impact-wrench’s screw holes.

2- Slide the ball-joint bellows onto the axial rod’s large pin until it

reaches the smooth part.

3- Position the hexagonal lock nut (M14x1.5) onto the rod.

4- Put the tongued washer on tot axial rod with the fold going up in the

opposite direction to the nut (see pictures). Then, screw the axial rod into the second welding arm by positioning the tongued washer’s fold into the arm’s slot.

5- Firmly tighten the nut (M14x1.5) onto the tongued washer (22 mm

6- Fold the tongued washer as shown in the picture using a mallet and

1- Replace the two hollow hexagonal nuts on the front of the FRL with

standard nuts (M5) (max. tightening cut [4 N.m], Allen key [H5], at spanner [8 mm]).

2- Place the four hexagonal M/F spacers (M5x8x12) over the standard

nuts (front and rear) and tighten them to the same torque (4 N.m), (at spanner [8 mm]).

3- Position the FRL casing onto the hexagonal M/F spacers (M5x8x12)

at the front and then hold it with two lock nuts (at spanner [8 mm]).

4- Insert the screw (M8x95) into the FRL casing, the hexagonal M/F

spacers (D8.2x12, L40) and the FRL plate. Then, x the FRL plate onto the hexagonal M/F spacers (M5x8x12) with two lock nuts (M5), (at spanner [8 mm]).

5- Insert the hexagonal socket plug with seal (G1/4) into the outlet

under the FRL (Allen key [H6]). It is possible to replace the plug with a specic tting that allows the outlet to be used for ination or other purposes.

6- Fit the two hexagonal M/F spacing sleeves (M5x8x12) to the FRL

1- Place the seat’s hooks into the notches on the tray, then push the

seat towards the column.

2- Attach the seat to the column by tightening the two screws (M6x10)

which go through the bottom of the seat and screw into the spacers between the column and the seat.

3- Position the two remaining screws for attaching the seat into the

folds inside the seat (on the tray).24 TROLLEY IW1

Arm assembly Montage bras Hexagonal-head screw (M16x110x38) Socket-head screw (M8x95) x2Lock nut (M16) x1Lock nut (M8) x2Clevis joint and inter-arm support (engraved 1) x2Fixing plate No. 1 (engraved 1) x2Assembled arm x1Allen key (H6)Socket spanner (13 mm) x1 Socket spanner (24 mm) x1

1- Insert the anged bearings into the holes on the shaft close to where it meets the column, then grease the inside of the bearings, the plastic and metal faces as well as the shaft’s connecting pins at the top of the column with neutral grease.2- Grease and insert the hexagonal-head screws (M16x110x38) into the clevis joint (1), through the bearings on the shaft at the top of the column and the other clevis joint (1) in this order (see pictures). Then, position the lock nut (M16) without tightening it. (by hand). Pay attention to the direction of the clevis joints ensuring the holes are all aligned. The shaft’s pins at the top of the column must be in the clevis joint’s bean-shaped holes. 3- Insert the screwws (M8x95) into the upper clevis joint (1), the plate (1), then the arm, the other plate (1) and the lower clevis joint (1).4- Firmly tighten the lock nuts (M8) onto the screws (M8x95) (socket spanner [13 mm] and Allen key [H6]). Firmly tighten the nut (M16) onto the screw (M16), then loosen the nut with a 1/8 turn (socket spanner [24 mm]).FRL assembly ±0.3 Tolérances générales Description Jusqu'à 1000Jusqu'à 400Jusqu'à 120Jusqu'à 30Jusqu'à 6Jusqu'à 3 Mécanique ±0.05 ±0.05 ±0.1 ±0.15 ±0.2ISO 2768-F Plan de Contrôle Casser les angles: 0.2 x0.2 Montage client Tournage: Ra 1.6 19/11/2019

1- Ax the socket box with the two screws (M5x9) with washers

(Torx Allen key [T25]). Assembling the hoses Montage tuyau Montage Goupilles Pipe (D12x19 L1760) x1 Cable ties made from black polypro- pylene (PP) (4.8 mm x 295 mm) x2 Single-ear hose clamp (19.5 mm) x1 Pincers

1- Thread the hose from the FRL outlet, then push the hose into the

fsingle-ear hose clamp (19.5 mm) tting (pincers). Be careful not to cut the hose.

2- Attach the hose to the arm and/or the impact-wrench cord attach-

ment using the cable ties made from black polypropylene. Assembling the pins Montage tuyau Montage Goupilles Stainless steel cable (L200 mm) with two rings (D24 mm) x2 L-shaped rod (L101 mm x D55 mm) x2 Torx Allen key (T30) Flat spanner (10 mm)

1- Mount the cables on clevises with pins and then position them in

1- Lock the arm by inserting the pins.

2- Adjust the balancing eort to the minimum setting using the clam-

ping screw located under the seat.

3- Insert four of the screws (M6x30) into the impact wrench’s handle

and in the impact-wrench connector (corner plate), then tighten the screws with the four lock nuts (M6) (Torx Allen key [T30], at spanner [10 mm]).

4- Fit the male-hose adaptor into impact-wrench’s air inlet and tighten

it (at spanner [26 mm]).

5- Hold the impact-wrench support in place by aligning the moun-

ting-bolt holes on the impact wrench’s handle with the impact-wrench plate’s holes, found under the ball joint. Then, ax the impact wrench by tightening the four screws (M6x30) that pass through the impact- wrench support and the impact-wrench plate (Torx Allen key [T30]). It is recommended that two people be present to undertake this operation.

6- Connect the hose to the impact-wrench support and secure it with

the single-ear hose clamp (pincers). Be careful not to cut the hose. USAGE SPRING TENSION The impact-wrench support trolley is equipped with a spring that balances the weight of the impact wrench. To increase the balancing force (to further raise the impact wrench), simply turn the adjusting screw under the seat clockwise using a ratchet spanner and a spark plug socket (21 mm). Moving in the opposite direction will relax the spring and reduce the balancing force (to further lower the impact wrench). The system does becomes slightly unbalanced when the arm is moved back towards oneself (the impact wrench tends to move upwards), so it is advisable to adjust the balancing so as to limit the force with which the wrench moves upwards (ideally being balanced gently). Be careful not to knock the adjusting screw as this will damage it and may prevent it from working. PIN The impact-wrench support trolley is equipped with pins to prevent the arm from opening when the product is moved or during storage. Simply close the arm and position the pins in the appropriate position in the clevis pins. During use, it is recommended to place them in the rst arm’s tube holes.27 TROLLEY IW1

BRAKE The impact-wrench support trolley is equipped with a synchronised hand brake that acts on each of the two rear wheels. It is operated by pulling up the handle on the left when sitting on the seat. It is deactivated by lowering this handle. AIR TREATMENT The impact-wrench support trolley comes with a lter, regulator and lubricator unit (FRL). It is recommended to connect it to a specic air network with half-inch (1.27 cm) connections enabling an increased air ow. The recommended operating air pressure is 6 to 6.5 bar (0.6 to 0.65 MPa). The maximum pressure is 10 bars. It is possible to add a quarter-inch (6 mm) quick connector between the lter regulator and the lubricator to connect a pump or any other pneumatic accessory. A silencer and/or coalescing lter can be tted to the machine to separate any oil from the impact wench’s returning airow; this recycles the used oil and avoids oil mist in the return airow or the impact wrench’s air outlet.

SAFETY DURING USE AND TRAVEL

Be aware the risk of electric shocks when bringing the impact wrench back towards yourself. Set a balancing force that is just sucient. Always lock the arm in place with the pins when moving the device. Do not sit on the impact-wrench support trolley to avoid opening the arm and increasing the risk of electric shocks. Take particular care when passing through doorways, over electrical wires or other objects on the ground. Handles must be gripped in a way that prevents you from hitting your hands on objects protruding from the wall, shelves or other objects.

INSERTING AND CHANGING THE IMPACT-WRENCH SUPPORT

The user is responsible for the correct installation or replacement of the impact-wrench support. As described in the section ‘Assembling the impact-wrench’. Always use a chock behind the rear wheels when installing/changing the impact-wrench support. Always secure the arm with locking pins when tting/changing the impact-wrench support. Always set the balancing force to the minimum when tting/changing the impact-wrench support. The impact-wrench support must always be securely fastened to the impact-wrench plate to prevent the impact wrench from falling. It is recommended that two people carry out this operation. The impact-wrench support’s maximum load must not exceed 20 kg. MAINTENANCE In order for the impact-wrench support trolley to work at its best, it is important to carry out regular maintenance following the instructions below. The maintenance interval is dened according to normal use with a daily use of eight hours. For more intensive use, the maintenance should be carried out more frequently.28 TROLLEY IW1

- Check parts for cracks or points of wear and tear. - Check the tightness of bolts and screws. See section ‘ASSEMBLY PROCEDURE’ for instructions on how to tighten torques. - Check the condition of the arm’s articulated parts. Add a suitable grease (neutral grease) to moving parts (arm joints). - Check that the castor wheels are working properly. Grease the bearings. Check that the rubber surfaces are in good condition. - Check the condition of the lter (remove dust if necessary). Bleed the lter. - Check that the air regulator is working properly. - Check the oil level in the lubricator. After assembly/disassembly, the impact-wrench attachments tted to the plate must be checked, as well as the tapped plate attachments for the stop screws. Available in the sections entitled ‘Assembling the impact-wrench’ and ‘Assembling the column’. MAINTENANCE Dusting can be done with an compressed-air blower before cleaning. Wash the impact-wrench support trolley with a product suitable for painted steel surfaces. Follow the product’s cleaning instructions. Dry the wrench-holder support with a cloth after cleaning. Never use a high-pressure sprayer as this can damage the paintwork. TROUBLESHOOTING The impact-wrench support trolley is designed for eective and safe use provided that the maintenance instructions have been followed. However, if you do encounter any operating problems, here is some advice. If problems persist, contact the repairer or the manufacturer. If the arm doesn’t move or has diculty moving: - Check that all parts of the arm are present, check the ‘ASSEMBLY PROCEDURE’ section. - Check that the xing screws are tightened to the correct torque and that the moving parts (arm joints) are properly lubricated, see section entitled ‘ MAINTENANCE’. If the impact-wrench support trolley makes a strange noise: - Check that the impact-wrench support trolley’s component parts are correctly mounted, see ‘ASSEMBLY PROCEDURE’ section. - See section entitled ‘MAINTENANCE’. TECHNICAL SPECIFICATIONS Balancing capacity (impact wrench attachments) 70 Kg Product's height From 1 to 20 kg Product's width 95 cm Product's depth 85 cm Connection to the air network 86 cm Minimum airow rate ½'' (1.27 cm) 10 bar max. (built-in regulator) Recommended pressure, 6 to 6.5 bar Can be connected in ¼'' (6 mm) 10 bar max. (will lower the impact wrench's performance) Débit d’air minimum Depending on the impact wrench Lubrication Recommended oil: ISO 22 (ISO 32 will work) Adjust according to the manufacturer's recommendations Impact-wrench holding connector and handle Berne key (from 36 mm to 44 mm) Adjusting the balance Ratchet spanner with spark plug socket (21 mm) (not supplied) Storage temperature 0°C à 60°C Operating temperature 5°C à 50°C29 TROLLEY IW1

WARRANTY The impact-wrench support is covered by warranty for two years starting from the date of shipment. The warranty covers defects in the hardware and/or manufacturing. This warranty is only valid if the maintenance has been carried out according to the instructions in this user manual. The warranty does not cover periodic maintenance, calibration or regular adjustments. Labor costs related to such actions are not covered. Incidents considered to be misuse or abuse may void the warranty.

DISASSEMBLY AND RECYCLING

To disassemble the impact-wrench support, refer to the section entitled ASSEMBLY PROCEDURE and reverse the order of the instructions. The impact-wrench support must be disposed of in accordance with the current environmental and disposal guidelines of the country in which it is located.

DECLARATION OF CONFORMITY