MAHA RGE UNI TRAM Operating Instructions Manual

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RGE UNI TRAM

Mobile Column Lift

Original Operating Instructions

BA491701-en

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Contents

1 Safety ...................................................................................................................... 5

1.1 Introduction ......................................................................................................................................... 5

1.2 Symbols .............................................................................................................................................. 5

1.3 Intended Use ....................................................................................................................................... 5

1.4 Inappropriate Use ................................................................................................................................ 5

1.5 Safety Instructions for Commissioning ................................................................................................. 5

1.6 Safety Instructions for Operation ......................................................................................................... 5

1.7 Safety Instructions for Servicing ........................................................................................................... 6

1.8 What to Do in the Event of Defects or Malfunctions ............................................................................. 6

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

1.10 Safety Features ................................................................................................................................... 7

1.10.1 Locking Device .................................................................................................................................... 7

1.10.2 Braking Motor ..................................................................................................................................... 7

1.10.3 Phase Sequence Relay........................................................................................................................ 7

1.10.4 Thermal Overload Protection ............................................................................................................... 7

1.10.5 Safety Shutdown after Motor Overload ................................................................................................ 7

1.10.6 Warning and Information Labels .......................................................................................................... 7

2 Description ............................................................................................................... 8

2.1 General Information ............................................................................................................................. 8

2.2 Noise Emission .................................................................................................................................... 8

2.3 Specifications ...................................................................................................................................... 8

2.4 Sample Nameplate .............................................................................................................................. 9

3 Installation .............................................................................................................. 10

4 Operation ............................................................................................................... 11

4.1 Requirements on the Operator .......................................................................................................... 11

4.2 Handling / Moving the Columns ........................................................................................................ 11

4.3 Lift Positioning ................................................................................................................................... 12

4.4 Controls ............................................................................................................................................ 14

4.5 Main Switch ...................................................................................................................................... 15

4.6 Emergency Stop................................................................................................................................ 15

4.7 Operating Modes .............................................................................................................................. 15

4.7.1 Automatic Mode ................................................................................................................................ 15

4.7.2 Single Mode ...................................................................................................................................... 16

4.7.3 Group Mode ...................................................................................................................................... 17

4.7.4 Cable Remote Control ....................................................................................................................... 17

4.8 Emergency-down Function, Mechanical ............................................................................................ 18

4.9 Operation with more than 6 Columns ................................................................................................ 19

4.10 Load Acknowledge Switch (Optional) ................................................................................................ 20

5 Maintenance .......................................................................................................... 21

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5.1 Annual Inspection .............................................................................................................................. 21

5.2 Care Instructions ............................................................................................................................... 21

5.3 Spare Parts ....................................................................................................................................... 21

5.4 Maintenance by the Operator ............................................................................................................ 22

5.4.1 Recirculating Ball Nut ........................................................................................................................ 22

5.4.2 Options ............................................................................................................................................. 23

5.5 Setting the Hydraulic Jack ................................................................................................................. 24

5.6 Display Codes ................................................................................................................................... 25

6 Service Lifetime ...................................................................................................... 27

7 Dismantling ............................................................................................................ 27

8 Disposal ................................................................................................................. 27

9 Contents of the Declaration of Conformity .............................................................. 27

10 Company Information ............................................................................................. 28

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Safety

1.1

Introduction

1.2

Symbols

1.3

Intended Use

1.4

Inappropriate Use

1.5

Safety Instructions for Commissioning

1.6

Safety Instructions for Operation

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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 rail vehicles. Observe the rated load

capacity.

• The lift shall 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

• 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.

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• 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.

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1.7

Safety Instructions for Servicing

1.8

What to Do in the Event of Defects or Malfunctions

1.9

What to Do in the Event of an Accident

• 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.

• 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.

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

superstructure, support or lower the lift immediately.

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

• 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.

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1.10

Safety Features

1.10.1

Locking Device

1.10.2

Braking Motor

1.10.3

Phase Sequence Relay

1.10.4

Thermal Overload Protection

1.10.5

Safety Shutdown after Motor Overload

≥ 15 %

1.10.6

Warning and Information Labels

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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.

The phase sequence relay in the power supply unit ensures safe and independent operation.

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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labels.

occurs, the

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Description

2.1

General Information

2.2

Noise Emission

2.3

Specifications

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The mobile column lifts of the RGE series are produced as wheel engaging or universal lifts. Depending on the version, the lift system consists of 2 or 4 columns and can be expanded to 6 columns in the standard version. The lift can be expanded up to 12 columns when using a special power supply unit.

All components are easily accessible under the lifted vehicle due to a generous maximum lifting height of 1750 mm. An extended lifting height of 2400 mm is optionally available.

The lift is a mobile unit whereby the columns can be substituted with stands when vehicles are to

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be worked on for a longer period of time. The lifting columns are free to be used on other vehicles.

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

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Load capacity per column 7500 kg

Lifting height (standard) 1750 mm

Raising/Lowering time * 113 s

Raising speed 0.92 m/min

Motor power 1.5 kW

System of protection IP 54

Supply voltage 3~ 380/220 V; 50 Hz

Net weight per column w/o support * 452 kg Surface load 0.5 N/mm

* Applies to standard lifting height of 1750 mm. Raising/Lowering time and Net weight differ from

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the above figures when lift is equipped with special lifting height.

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

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2.4

Sample Nameplate

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Mobile Lifting System Ser. No. / Date of Production: *** Project: *** Type: *** Supply Voltage: *** Frequency: *** Rated Current: *** Fuse Protection: *** Load Capacity per Column: *** System of Protection: *** WEEE-Reg.-No. ***

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Installation

all

270 Nm

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Example of a simple load support. The design of other supports may differ considerably depending on the application requirements.

The support must be connected to the carriage using are needed:

6 Bolts M16x60-12.9 MAHA # 22 0912 16060 1 6 Washers M16 300 HV MAHA # 22 0125 16 2

Tightening torque:

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six thread holes. The following fasteners

Page 11

Operation

4.1

Requirements on the Operator

4.2

Handling / Moving the Columns

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All persons employed in the operation, maintenance, installation, removal and disposal of the plant 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 intructed in safety guidelines.

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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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4.3

Lift Positioning

Connection Diagram

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Control Unit

Connecting Cable

Dummy Plug

Mains Plug

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Power Supply Unit

Input Terminal

Output Terminal

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

• Apply the parking brake after positioning the vehicle.

• Push the support forks completely under the wheels/lift points of the vehicle.

• Attach the power supply unit (V) to the control unit (B) of the column closest to the mains

• Interconnect the columns using connecting cables (1) between input terminals (E) and output

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Do not drive over or pinch electrical cables.

socket.

terminals (A). Connect a dummy plug or the remote control (2) to the output terminal of the last column.

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Secure the connecting cable plugs using the safety clamps. The plugs and terminals are coded.

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• Connect the mains plug (3) of the master column with the 400 V mains socket. Recheck the

electrical connections.

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• Once the main switch is turned on, the lift is ready for operation.

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4.4

Controls

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Power Supply Unit

Main Switch

LED Display Indicates operating and error states.

Selector Button (on Control Unit) Use this button to select between: Automatic / Single / Group mode

Seven-Segment Display (on Control Unit) Indicates operating and error codes.

RAISE Button (on Control Unit) Press and hold this button to raise the lift. Lift stops once button is released or upward travel stop is reached.

LOWER Button (on Control Unit) Press and hold this button to lower the lift. Lift stops once button is released or downward travel stop is reached.

Emergency Stop Button (on Control Unit) In case of emergency press this button to disconnect the lift from the mains supply. Pull out the button to make the lift ready for operation.

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Control Unit

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4.5

Main Switch

4.6

Emergency Stop

4.7

Operating Modes

4.7.1

Automatic Mode

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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

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In case of emergency push the emergency stop button to stop the lift movement immediately.

by means of a padlock.

To make the lift ready for operation, unlock the emergency stop button and switch off the lift briefly using the main switch.

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Select "Automatic mode" by pressing this button on each column. Activation of this operating mode is indicated by the letter A on the seven-

segment display.

Use these buttons on the control unit to raise or lower the lift.

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After switch-on the lift is in automatic mode.

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Page 16

4.7.2

Single Mode

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When operating the lift in Single mode, make sure the vehicle is not tilted. Otherwise the vehicle may fall off the lift!

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Select "Single mode" by pressing this button on the desired column.

Activation of this operating mode is indicated by the lit LED on the selector button and the letter S on the sevensegment display.

The columns not in Single mode are temporarily inoperative. This is indicated by the letter A flashing on the seven-segment display.

Use these buttons to raise or lower the lift. or

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The single mode can also be used for several columns simultaneously

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Height offsets between individual columns will be maintained after switch-over to automatic mode. The offset can be removed either – by equalizing the carriages in single mode or – by lowering all carriages to bottom position in automatic mode.

• Lift switches off once first carriage reaches upward travel stop.

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Page 17

4.7.3

Group Mode

4.7.4

Cable Remote Control

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When operating the lift in Group mode, make sure the vehicle is not tilted. Otherwise the vehicle may fall off the lift!

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Select "Group mode" by pressing and holding this button for approx. two

2 sec

seconds. Activation of this operating mode is

indicated by the lit LED on the selector button and the letter G on the sevensegment display.

The columns not in Group mode are temporarily inoperative. This is indicated by the letter A flashing on the seven-segment display.

Use these buttons to raise or lower the lift. or

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A remote control (model TCNA 10-2) is optionally available. The RAISE, LOWER and Emergency Stop buttons have the same functions as the corresponding

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buttons on the column control units.

Except for the emergency stop button, the remote control is not usable in single mode.

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Page 18

4.8

Emergency-down Function, Mechanical

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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.

Once the locking device is in engagement, manual lowering is no longer possible.

The following components are required for manual lowering:

A Lever at brake motor B Locking device

1 Pull or shake the safety wedge downward on each column. 2 First push onto the latch using a long screw driver, then additionally push the manual release

lever (in arrow direction). Intermittently lower the columns in increments of approx. 50 mm (2 in), until the lift is in bottom

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position.

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Page 19

4.9

Operation with more than 6 Columns

A B

D E

Branch 2 Branch 1

OUT

IN IN

OUT

OUT OUT

OUT

OUT OUT OUT

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Using the optionally available special control unit, the RGE lift can be operated with up to 12 columns – 2 column branches with 6 columns each.

Special control unit Control unit

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Connecting cable

Dummy plug or Cable remote control

Power cord with Mains plug

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Page 20

4.10

Load Acknowledge Switch (Optional)

Setup mode

Automatic mode

all

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Spring-loaded thrust pieces

Simple support plate

MAHA's mobile lifting systems for trams come standard with an electronic overload protection, which automatically detects overload occurring at any one column and subsequently shuts off the system.

In addition, load acknowledge switches are optionally available for tram lifts. Using these switches, correct load positioning at the lift supports can be easily monitored. Each column is positioned at the load and switches off as soon as the load properly contacts the support. When all columns have been positioned correctly at the load (Setup mode), the lift control switches over to regular operation (Automatic mode).

The load acknowledge switches can be used in combination with various supports such as simple support plates or prism supports.

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Prism support

Non-contact proximity switch

Load does not lie flat against support of this column. Display code is flashing.

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Load does lie flat against support of this column. Display code lighting permanently.

Load does lie flat against supports of columns. Lifting system is ready for operation.

Page 21

Maintenance

5.1

Annual Inspection

12 (twelve) months

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

5.2

Care Instructions

5.3

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.

•

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.

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Page 22

5.4

Maintenance by the Operator

5.4.1

Recirculating Ball Nut

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Twice a year grease the recirculating ball nut with 4…7 strokes from a grease gun. The lubricator is located at the recirculating ball nut inside the carriage.

To make the lubricator accessible, remove the screws (1 and 3). Then remove cover plate (4) and fastening strip of rubber cover (2). Fold down the rubber cover.

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Page 23

5.4.2

Options

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Recirculating ball nuts with outside lubricator (option) should be greased every six months with four to seven strokes from a grease gun.

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Carriage axles equipped with a lubricator (option) should be periodically greased using a grease gun.

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Page 24

5.5

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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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 25

5.6

Display Codes

Display Code

LED

Cause

Action

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Green

Yellow on

1 or

several

column(s)

Yellow on 1 column,

Green on all others

Red on

1 column

Normal operation, no errors.

Uncontrolled operation.

Bus line failure.

CAN bus without terminating resistor. Check terminating resistors of CAN bus

CAN controller out of step or defective. Turn the main switch off and on again.

Controller in sleep mode due to shortcircuit of CAN lines.

Safety switch triggered.

Carriage has made contact with obstacle.

Thermoswitch triggered.

Overheated motor. Lift stops and error message appears.

Normal operation.

Replace connecting cable.

in dummy plug and power supply unit, contact service.

If error persists, contact service.

Replace connecting cable. Contact service if necessary.

Switch column with error message to single mode. Raise carriage to unlock the safety wedge or remove obstacle.

Let the motor cool down. Check thermoswitch, motor and column. Acknowledge error with selector button on control panel. Red LED will go out and the lift is ready for operation.

Yellow on

all

columns

Red on all

columns

Red on all

columns

Insufficient speed / Overspeed.

Lift stops when irregular motor speed is detected.

Overloaded lift.

Maximum permissible load exceeded. Lower lift to bottom position.

Proximity switch defective.

Proximity switch defective due to shortcircuit or broken wire.

Release control element. The error is removed and the lift is ready for operation.

Acknowledge error with selector button on control panel.

Proximity switch must be replaced, contact service. Acknowledge error with selector button on control panel.

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Page 26

Display Code

LED

Cause

Action

Load

Red on all

columns

Red on all

columns

Red on all

columns

Red on 1 or several column(s)

Red on all

columns

Height difference between columns.

Maximum permissible height difference exceeded.

CAN bus error.

CAN bus connection was briefly interrupted.

Phase failure of supply system.

The lift stops and remains inoperative until power supply has been restored.

Phase failure of lift system.

Phase failure of lift system due to defective connecting cable.

Cyclic Redundancy Check error.

Hardware error occurred while data being read from or written to the EEPROM.

Turn the main switch off and on again. Zeroize the lift by lowering each column to bottom position in single mode. If error persists, contact service.

Turn the main switch off and on again. Lower lift to bottom position. Red LED will go out and the lift is ready for operation.

Remove phase failure.

Replace faulty connecting cable.

PCB must be replaced, contact service.

Load acknowledge switch triggered (Setup or Automatic mode).

Red on 1 or several column(s)

Display code flashing: Load does not lie flat against support of this column.

Display code lighting permanently: does lie flat against support of this column, but not against supports of all columns.

Load acknowledge switch triggered (Group or Single mode).

Red on

1 column

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Load does not lie flat against support. Turn main switch off and on again.

Properly position the column at the load.

Properly position the remaining columns at the load.

Properly position column at load, reselect operating mode if necessary. Lift is ready for operation.

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Page 27

Service Lifetime

Dismantling

Disposal

Contents of the Declaration of Conformity

MAHA Maschinenbau Haldenwang GmbH & Co. KG

Model: 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.

RGE UNI TRAM

Mobile Lifting System; Rated Load Capacity per Column 7500 kg

2006/42/EC; 2014/30/EU

EN 1493; EN 60204-1

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Page 28