MAHA RGB, MCL Original Operating Instructions

Page 1

MCL

Mobile Column Lift

Original Operating Instructions

BA491201-en

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Fehler! Verwenden Sie die Registerkarte 'Start', um Name dem Text zuzuweisen, der hier angezeigt werden soll.Fehler! Verwenden Sie die Registerkarte 'Start', um Name dem Text zuzuweisen, der hier angezeigt werden soll.Fehler! Verwenden Sie die Registerkarte 'Start', um Name dem Text zuzuweisen, der hier angezeigt werden soll.

Page 2

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Contents

1 Safety ...................................................................................................................... 4

1.1 Introduction ......................................................................................................................................... 4

1.2 Symbols .............................................................................................................................................. 4

1.3 Intended Use ....................................................................................................................................... 4

1.4 Inappropriate Use ................................................................................................................................ 4

1.5 Requirements on Operating and Service Personnel ............................................................................. 4

1.6 Safety Instructions for Commissioning ................................................................................................. 5

1.7 Safety Instructions for Operation ......................................................................................................... 5

1.8 Safety Instructions for Servicing ........................................................................................................... 5

1.9 What to Do in the Event of Defects or Malfunctions ............................................................................. 5

1.10 What to Do in the Event of an Accident ............................................................................................... 6

1.11 Safety Features ................................................................................................................................... 6

1.11.1 Locking Device .................................................................................................................................... 6

1.11.2 Braking Motor ..................................................................................................................................... 6

1.11.3 Thermal Overload Protection ............................................................................................................... 6

1.11.4 Safety Shutdown after Motor Overload ................................................................................................ 6

1.11.5 Warning and Information Labels .......................................................................................................... 6

2 Description ............................................................................................................... 7

2.1 Design and Operating Principle ........................................................................................................... 7

2.2 Specifications ...................................................................................................................................... 8

2.3 Sample Nameplate .............................................................................................................................. 9

2.4 Noise Emission .................................................................................................................................... 9

3 Operation ............................................................................................................... 10

3.1 Handling / Moving the Columns ........................................................................................................ 10

3.2 Initial Operation ................................................................................................................................. 11

3.3 Main Switch....................................................................................................................................... 11

3.4 Control Unit ....................................................................................................................................... 12

3.5 Positioning, Logging in and Interconnecting the Columns ................................................................. 14

3.6 Switching over to Group Mode .......................................................................................................... 15

3.7 Switching over to Single Mode .......................................................................................................... 15

3.8 Raising and Lowering ........................................................................................................................ 15

3.9 Shutdown .......................................................................................................................................... 16

3.10 Emergency-down Function, Mechanical ............................................................................................ 16

3.11 Transverse Beam for Semitrailers ...................................................................................................... 17

4 Maintenance .......................................................................................................... 18

4.1 Annual Inspection .............................................................................................................................. 18

4.2 Care Instructions ............................................................................................................................... 18

4.3 Spare Parts ....................................................................................................................................... 18

4.4 Maintenance by the Operator ............................................................................................................ 19

4.4.1 Checking the Load Nut for Wear ....................................................................................................... 19

BA491201-en

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4.4.2 Greasing the Load Nut ...................................................................................................................... 20

4.4.3 Greasing the Support Bearing of the Lifting Screw and the Moving Gear .......................................... 21

4.5 Setting the Hydraulic Jack ................................................................................................................. 22

5 Troubleshooting ..................................................................................................... 23

6 Service Lifetime ...................................................................................................... 24

7 Dismantling ............................................................................................................ 24

8 Disposal ................................................................................................................. 24

9 Contents of the Declaration of Conformity .............................................................. 24

10 Company Information ............................................................................................. 25

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BA491201-en

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Safety

1.1

Introduction

1.2

Symbols

1.3

Intended Use

1.4

Inappropriate Use

1.5

Requirements on Operating and Service Personnel

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Thoroughly read this manual before operating the equipment and comply with the instructions. Always display the manual in a conspicuous location.

Personal injury and property damage incurred due to non-compliance with these safety

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instructions are not covered by the product liability regulations.

Important safety instructions. Failure to comply with instructions could result in personal injury or property damage.

Important information.

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• This lift is to be used exclusively for the safe lifting of commercial and agricultural vehicles such

as trucks, buses, tractors etc. Observe the rated load capacity.

• The lift may not be modified without the express written consent of the manufacturer. In case of

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non-compliance the declaration of conformity becomes void.

Any use other than described is inappropriate, for example:

• Climbing on the lift supports

• Transporting persons on the lift supports

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• Usage as mobile work platform or for other lifting operations

All persons employed in the operation, maintenance, installation, removal and disposal of the device must

• be at least 18 years old,

• be trained and instructed in writing,

• have read and understood this manual

• be on record as having been instructed in safety guidelines.

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1.6

Safety Instructions for Commissioning

1.7

Safety Instructions for Operation

1.8

Safety Instructions for Servicing

1.9

What to Do in the Event of Defects or Malfunctions

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• Use the lift on a hard, level surface only.

• The standard lift version may not be installed and commissioned in the vicinity of explosives or

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flammable liquids.

• Read the detailed operating manual.

• Lift operation by trained personnel over 18 years only.

• Do not exceed the rated load capacity per column as indicated on the lift nameplate.

• Ensure an unobstructed movement of lift and vehicle.

• After raising the vehicle briefly, stop and check the lift supports for secure contact with the

vehicle.

• Closely watch lift and vehicle during raising and lowering cycles.

• The working area which cannot be overviewed by the operator should be monitored by a

second person.

• When operating the lift in single or group mode, make sure the vehicle is not tilted.

• Do not allow anyone to stay in lift area during raising and lowering cycles.

• Do not allow anyone to climb on lift or inside raised vehicle.

• Keep lift and vehicle free of tools and parts.

• When using the lift outdoors, lower the vehicle and stop operation when the wind velocity

exceeds 6 m/s.

• Push the support forks completely under the wheels or lift points of the vehicle to be raised.

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• Do not drive over or pinch electrical cables.

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• Service work may be done by authorized service technicians only.

• Turn off and padlock the main switch before doing any repair, maintenance or setup work.

• Disconnect the mains plug before opening the control box.

• Work on the electrical equipment may be done by service technicians or certified electricians

only.

• Ensure that ecologically harmful substances are disposed of only in accordance with the

appropriate regulations.

• Do not use high pressure or steam jet cleaners. Use of caustic cleaning agents may damage

the lift.

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• Do not replace or override the lift safety devices.

• In case of defects or malfunctions such as uncontrolled lift movement or deformation of the

superstructure, support or lower the lift immediately.

• Turn off the main switch and secure it against unauthorized usage. Contact service.

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1.10

What to Do in the Event of an Accident

1.11

Safety Features

1.11.1

Locking Device

1.11.2

Braking Motor

1.11.3

Thermal Overload Protection

1.11.4

Safety Shutdown after Motor Overload

≥ 15 %

1.11.5

Warning and Information Labels

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• The injured person is to be removed from the danger area. Find out where dressing and

bandages are kept. Seek first-aid.

• Provide first-aid (stop bleeding, immobilise injured limbs), report the accident and seal off the

accident site.

• Immediately report any accident to your supervisor. Make sure a record is kept of every

occasion first-aid is provided, e.g. in an accident book.

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• Remain calm and answer any questions that may arise.

The locking device serves to prevent inadvertent lowering motions caused by gear, load nut or lifting screw failure. The carriage is blocked by safety wedge (1) and counterwedge (2).

The motors are equipped with AC spring pressure brakes. Once the motors are switched off, the brakes prevent any further movements.

Overload protection via electronically monitored thermoswitches.

The motor load is permanently monitored by the control PCB. If an overload of system will switch off automatically. In this case the lift cannot be raised any more, but it can be normally lowered to bottom position.

Do not change or remove the warning and information labels. Order replacement for defective

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BA491201-en

labels.

occurs, the

Page 7

Description

2.1

Design and Operating Principle

Complete System

Column

Control

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•

The complete system of the Mobile Column Lift consists of individual columns, which can be interconnected (e.g. 4, 6, 8 columns) and used to raise commercial vehicles. A maximum number of 8 columns per lift system can be logically interconnected.

A maximum number of 8 lift systems can be operated parallel, with information exchange on different radio channels.

The complete system can be operated from each individual column. The columns interact via radio communication, with each lift system using its own channel.

•

The columns are mechanically designed for engaging the wheels of commercial vehicles. They are all identical and interchangeable from system to system. Power supply is effected via a standard three-phase connection.

•

Each column is equipped with a control unit made up of the following components:

• Operating panel with display

• Microprocessor

• Pulse generators and sensors

• Watchdog monitoring

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• Radio transmitter / receiver

• Drive unit

• Emergency stop switch

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2.2

Specifications

MCL/RGB

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MCL / RGB

2.3

Sample Nameplate

2.4

Noise Emission

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Load capacity per column 5500 kg

Full travel 1750 mm

Raising / Lowering time 150 s

Tyre diameter 900…1250 mm

Fuse protection per column 5 A

Motor power 2.2 kW

Protective system IP 54

Supply voltage 3~ 380/220 V; 50 Hz

Net weight per column 400 kg

Surface load 0.3 N/mm2

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The properties indicated apply to lifts running at operating temperature. Specifications are subject to change without notice.

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MOBILE COLUMN LIFT Ser.No. / Date of Production: *** Project: *** Type: *** Charging Voltage: *** Operating Voltage: *** Net weight per column: *** Load capacity per column: *** System of Protection: *** WEEE Reg. No. ***

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The sound pressure level is lower than 70 dB(A) in the working area of the operator.

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Operation

3.1

Handling / Moving the Columns

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Screw a lifting-eye bolt M16 into the tap hole on the motor plate of the column. Insert a chain or strap through the ring and lift the column using a hoist or forklift.

Close hydraulic valve by putting valve lever in position 3. Pump with handle to raise the moving gear. Move column to desired position. To lower the moving gear, open the hydraulic valve by putting the valve lever in position 1. The column is ready for operation.

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Position 2 is the neutral position.

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3.2

Initial Operation

3.3

Main Switch

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Place the receiving antennae in an upright position before operating the columns.

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The main switch is used as emergency switch. In case of emergency turn it to position 0.

• Main switch in position 0: Power supply is interrupted

• Main switch in position 1: Lift is ready for operation

• When in position 0, the main switch can be protected against tampering

by means of a padlock.

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3.4

Control Unit

A LED Display: Operating Status

B Button: Raise

C Button: Lower

D LED Display: Number of Columns

E Button: Open/Close Column Unit

F LED Display: Column Unit

G LED Display: Channel Number

H Button: Select Channel Number

I LED Display: Operating Mode

J Button: Select Operating Mode

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Red, yellow and green LEDs indicate the operating status. See also section "Troubleshooting".

When button is pushed, lift raises until button is released or upper end position is reached.

When button is pushed, lift lowers until button is released or lower end position is reached.

Number of LEDs represents number of columns in a column unit. Flashing LED indicates next

free column number in an open column unit.

Use this button to open a closed column unit or to close an open unit.

LED lighting up indicates that the column unit is closed. LED also lights up when operating

mode is changed (see below).

LED lighting up indicates current channel number.

Use this button to switch on to the next available channel. Occupied channels are skipped,

channel 10 is followed by channel 1 and so on.

Current operating mode is indicated by LED.

Use this button to switch on to the next mode. "Single" (one column), "Auto" (all columns of a

column unit) and "Group" (several columns) can be selected.

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3.5

Positioning, Logging in and Interconnecting the Columns

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1 Push the support forks completely under the wheels or lift points of the vehicle to be raised.

Use the lift on a hard, level surface only.

2 Connect all columns to be used with the power supply.

It is possible to plug in either each column separately or a combination of not more than four columns.

3 Turn the main switch to position 1.  LED "Auto" flashes.

4 Select the transmission channel. All columns

belonging to the same unit must be set to the same channel.

5 Confirm using the operating mode button.  LED "Auto" lights up permanently.

6 Repeat the procedure for all columns.  Number of columns within the unit is displayed.

Before closing the unit check the number of logged-in columns. After closing verify that it corresponds with the number of columns appearing on the display.

7 Once all columns are logged in, close the unit using button

"0/1".

 LED "Column unit" lights up, lift is ready for operation.

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BA491201-en

Page 15

3.6

Switching over to Group Mode

3.7

Switching over to Single Mode

3.8

Raising and Lowering

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1 Switch to Group mode using the operating

mode button on the desired columns.

 LED "Group" lights up permanently.

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1 Switch to Single mode using the operating

mode button on the desired column.

 LED "Single" lights up permanently.

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• Before operating the lift, check that the number of

columns appearing on the display corresponds to the number of columns actually logged in.

• All columns belonging to the same unit must be set

to the same channel.

• If the unit is opened there may be interference

problems with other transmission channels.

• When operating the lift in Single or Group mode,

make sure the vehicle is not tilted. Otherwise the vehicle may fall off the lift!

1 Press "Raise" or "Lower" button.  Lift stops once button is released or end position is reached.

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BA491201-en

Page 16

3.9

Shutdown

3.10

Emergency-down Function, Mechanical

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1 Before shutting down the lift, open the

column unit using button "0/1".  LED "Column unit" goes off. 2 Turn main switch to position 0.

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Authorized personnel only! Do not restart the lift before the error has been remedied.

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In case of power failure or defects the lift can be lowered manually. The lift may only be lowered, not raised.

1 Remove the fan cowl from the motor. 2 Screw a hex head cap screw M8x10 into the thread inside the motor shaft. 3 Place a suitable socket on the screw and turn it in clockwise direction using a hand drill, until

the carriage has lowered approx. 50 mm. 4 Intermittently lower the columns in increments of approx. 50 mm, until the lift is in bottom

position. 5 After the error has been remedied, perform an emergency-down to reinitialize the control, or

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contact your service representative.

BA491201-en

Page 17

3.11

Transverse Beam for Semitrailers

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A Support plate with location hole for central pivot of semitrailer B Lift points for support forks 1 Position transverse beam under central pivot (C) of semitrailer. 2 Lower semitrailer until central pivot is approx. 20 mm above support plate (A).

Do not load the rollers of the transverse beam with the weight of the semitrailer. 3 Check for alignment of central pivot and location hole. Adjust if required. 4 Position the columns.

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5 Raise the semitrailer being sure the central pivot engages the location hole.

BA491201-en

Page 18

Maintenance

4.1

Annual Inspection

12 (twelve) months

4.2

Care Instructions

4.3

Spare Parts

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Danger! Electric shock hazard! Before doing any maintenance work, turn off the main switch and protect it against tampering.

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• The maintenance interval prescribed by the manufacturer is

This maintenance interval refers to normal workshop usage. If the equipment is used more

frequently or under severe operating conditions (e.g. outdoors), the interval must be reduced

accordingly.

• Maintenance work shall be done only by authorized and trained service technicians provided by

the manufacturer, licensed dealers or service partners.

• In case of non-compliance the manufacturer's warranty becomes void.

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• Periodically clean the equipment and treat it with a care product.

• Repair damage to the paintwork immediately to prevent corrosion.

• Usage of caustic cleaning agents or high pressure and steam jet cleaners may lead to

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equipment damage.

Regular care and maintenance is the key condition for functionality and long life expectancy of the equipment!

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To ensure safe and reliable operation, only use original spare parts supplied by the equipment

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manufacturer.

BA491201-en

Page 19

4.4

Maintenance by the Operator

4.4.1

Checking the Load Nut for Wear

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

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Shut down and lock the lift until the worn-out load nut has been replaced.

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Maintenance interval: 12 months

1 Lower the carriage to bottom position. 2 Remove the cap plug from the inspection window (arrow). 3 Check the clearance between check screw (A) and safety nut (B). New load nuts have a

clearance of approx. 2 mm. If no clearance can be detected, the load nut is worn out and must

be replaced together with the safety nut.

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4 At completion of wear check reinstall the cap plugs.

The correct setting of the clearance between wear check screw and safety nut is imperative for proper functionality and safety of the lifting screw and load nut system. If the clearance is not set properly when installing the new load nut, the wear and tear on the load nut can no longer be reliably checked. In this case, the safe operation of the lift can no longer be guaranteed.

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BA491201-en

Page 20

4.4.2

Greasing the Load Nut

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

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1 Lower the carriage to bottom position. 2 Remove the cap plug from the lubricating window (arrow). 3 Grease the load nut through the lubricating nipple using a grease gun. 4 Run the lift through a full raising and lowering cycle to distribute the grease evenly on the lifting

screw. 5 Repeat the lubrication procedure twice or three times. 6 At completion of lubrication reinstall the cap plugs.

Maintenance interval: 6 months

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BA491201-en

Page 21

4.4.3

Greasing the Support Bearing of the Lifting Screw and the Moving Gear

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

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1 Remove the lifting screw cover. 2 Lubricate the support bearing through the

lubricating nipple (large opening, arrow) using

a grease gun. 3 After lubricating reinstall the lifting screw

cover.

Maintenance interval: 6 months

• Periodically oil the rollers of the moving gear.

If they are equipped with lubricating nipples, lubricate using a grease gun.

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BA491201-en

Page 22

4.5

Setting the Hydraulic Jack

A: Setting the Lowering Speed

Threaded Pin





Lowering Speed





B: Setting the Responsiveness of the Automatic Lowering Function

Adjusting Screw





Responsiveness





A B

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Note that the jack must be mounted to the column when making any settings.

The lowering valve is located on the right-hand side of the cylinder. To set the lowering speed, adjust the threaded pin using an Allen key while holding the lock nut firmly with an open-end wrench. Check for correct setting by carefully lowering the jack.

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BA491201-en

OPEN

INCREASE

REDUCE

The automatic lowering valve is located on the left-hand side of the cylinder. Remove the screw plug using an Allen key, then insert a flat-tip screwdriver to set the adjusting screw. Soak up leaking fluid with a rag. Reinstall the screw plug.

OPEN

REDUCE

INCREASE

Page 23

Troubleshooting

Indication (Status LEDs)

Diagnosis

Remedy

FLASH

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Red

Yellow Green

OFF OFF OFF

OFF OFF Sensor error Contact service.

OFF Load nut failure detected. Contact service.

OFF

If no other LEDs are ON: Emergency-stop actuated.

If other LEDs are ON: Radio interference (e.g. Channel, Mode…). Possible cause: Devices in the vicinity transmitting on the 433 MHz band (such as garage door opener, radio set…).

Lift is not yet referenced, when a new column with new control is being connected after final assembly.

Level difference between columns too great.

Lift has contacted obstruction or floor.

Enable emergency-stop button.

Wait until radio interference has stopped.

Lower lift with emergencydown function.

Raise lift until yellow LED goes off.

and lift stops while lowering. Upper sensor maladjusted. Contact service.

OFF

and lift stops while raising. Upper sensor maladjusted. Contact service.

OFF OFF Hardware error occurred.

OFF OFF

and lift stops during operation.

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OFF

Lift overloaded.

Sluggish operation. Possible causes: Long standing under load, insufficient lubrication…

Supply network too "weak". Voltage drops when lift is started, motor does not reach working speed.

Voltage drop in supply network.

Error occurred (Watchdog).

Rated load capacity exceeded. Lowering still possible.

Release button, try again. Contact service if required.

If error repeats, have network inspected.

Interrupt voltage for 5 sec. If error persists, contact service.

If error repeats, have network inspected.

Turn off main switch and turn on again after approx. 5 sec. If error repeats, contact service.

BA491201-en

Page 24

Service Lifetime

Dismantling

Disposal

Contents of the Declaration of Conformity

MAHA Maschinenbau Haldenwang GmbH & Co. KG

Typ: Designation: Directives: Standards:

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In its standard version, this product is designed for 22,000 load cycles based on EN 1493. The maximum period of normal use in relation to the possible product life expectancy shall be

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evaluated and scheduled by a qualified person during the annual safety inspection.

Decommissioning and dismantling of the equipment may be done only by specially authorized and

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trained personnel provided by the manufacturer, licensed dealers or service partners.

If you want to dispose of the equipment, please contact your MAHA dealer or the following address, indicating equipment type, date of purchase and serial number:

MAHA Maschinenbau Haldenwang GmbH & Co. KG Hoyen 20 87490 Haldenwang Germany

Phone: +49 (0) 8374 585 0 Fax: +49 (0) 8374 585 500

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Email: altgeraete@maha.de

Alternatively, you may take the equipment to a specialised waste management plant to ensure that

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all components and operating liquids are properly disposed of.

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herewith declares as a manufacturer its sole responsibility to ensure that the product named hereafter meets the safety and health regulations both in design and construction required by the EC directives stated below. This declaration becomes void if any change is made to the product that was not discussed and

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approved by named company beforehand.

MCL / RGB

Mobile Column Lift; Rated Load Capacity per Column 5500 kg

2006/42/EC; 2014/30/EU

EN 1493; EN 60204-1

BA491201-en

Page 25

10 Company Information

Legal notice based on ISO 16016: The reproduction, distribution and utilization of this document as well as the communication of its contents to others without explicit authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.

The contents of this edition have been checked with great care. However, errors cannot be fully excluded. Subject to technical change without notice.

Document

Document No.: BA491201-en Approval Date: 2016-07-19

Manufacturer

MAHA Maschinenbau Haldenwang GmbH & Co. KG Hoyen 20 87490 Haldenwang Germany

Phone: +49 8374 585 0 Fax: +49 8374 585 590 Mail: maha@maha.de Web: http://www.maha.de

Service

MAHA SERVICE CENTER AutomoTec GmbH Maybachstraße 8 87437 Kempten Germany

Phone: +49 8374 585 100 Fax: +49 8374 585 491 Mail: service@automo-tec.com Web: www.automo-tec.com

BA491201-en