AUTOPSTENHOJ Masterlift 2.35 Combi Manual de usuario

Manual no.: 9000195GB

Date: 10.07.2019

ALWAYS KEEP

operating instructions

ready to hand on the

unit

Read the operating

instructions before

working with the

unit

Masterlift

2.35 Combi / "Check-in"

Installation instructions

(TRANSLATED VERSION)

Sandkampstr. 90

D – 48432 Rheine

Tel.: + 49 5971/860202

E-mail: info@autopstenhoj.com

Internet.: www.autopstenhoj.com

Index: g

Before

taking into operation

check system compo-

nents, control, emer-

gency stop and safety

equipment for conditi-

on, damage and

correct function!

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Masterlift 2.35 Combi / "Check-in"

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Masterlift 2.35 Combi / "Check-in"

9000195GB

Table of contents

1 General............................................................................................................................................... 5

1.1 Information for the installation instruction............................................................................................ 5

1.2 Explanation of symbols ....................................................................................................................... 5

1.3 Liability and warranty .......................................................................................................................... 6

1.4 Copyright protection ............................................................................................................................ 6

2. Safety ................................................................................................................................................. 7

2.1 General ............................................................................................................................................... 7

2.2 Work safety ......................................................................................................................................... 7

2.3 Personal safety equipment.................................................................................................................. 7

2.4 Behavior in case of danger or accidents............................................................................................. 8

2.4.1 Preventative Measures ....................................................................................................................... 8

2.4.2 If the worst comes to the worst: Do the right things! ........................................................................... 8

3 Technical data ................................................................................................................................... 9

3.1 General function of Masterlift Combi................................................................................................... 9

3.2 General function of Masterlift Combi "Check-in" ............................................................................... 10

3.3 Connected loads ............................................................................................................................... 11

3.3.1 PLC control unit................................................................................................................................. 11

3.3.2 Motor ................................................................................................................................................. 11

3.3.3 Operating values............................................................................................................................... 11

3.3.4 Hydraulic system............................................................................................................................... 12

3.4 Weights ............................................................................................................................................. 12

3.5 Name plate........................................................................................................................................ 12

3.6 Requirements of the place of Installation.......................................................................................... 13

4 Installation of the lifting unit .......................................................................................................... 14

4.1 Overview of components Masterlift Combi........................................................................................ 14

4.2 Overview of components Masterlift Combi "Check-in"...................................................................... 15

4.3 Placing, aligning and concreting the steel cassette .......................................................................... 16

4.4 Installation of the hydraulic components........................................................................................... 17

4.4.1 Installation of hydraulic cylinders Masterlift Combi .......................................................................... 17

4.4.2 Installation of hydraulic cylinders Masterlift Combi "Check-in........................................................... 18

4.4.3 Installation of preassembled cylinders .............................................................................................. 19

4.4.4 Installation of the hydraulic pump unit............................................................................................... 20

4.5 Installation of the control unit components........................................................................................ 21

4.5.1 Introduction ....................................................................................................................................... 21

4.5.2 Insulation test and continuity of the protective conductor ................................................................. 21

4.5.3 Cable connections............................................................................................................................. 22

4.5.4 Control box and terminal box ............................................................................................................ 22

4.5.4.1 Connection of the control unit ........................................................................................................... 23

4.5.4.2 Connection of the terminal box ......................................................................................................... 24

4.5.4.3 Terminal block on the hydraulic pump unit........................................................................................ 24

4.5.5 Installation of the sensor ladder rack - Combi................................................................................... 25

4.5.6 Installation of the sensor ladder rack - Combi "Check-in" ................................................................. 28

4.6 Connection of the synchronization bars............................................................................................ 31

4.7 Connection of pneumatic emergency lowering ................................................................................. 31

4.8 Aligning the hydraulic cylinders......................................................................................................... 32

4.9 Installation of recessed version......................................................................................................... 32

4.10 Installationrecessedversion(withushoordevice) ....................................................................... 33

4.10.1 Installation and adjustment of the cover plates................................................................................. 34

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5 Installation of superstructure ........................................................................................................ 35

5.1 Installation of the repair platform for ML Combi ................................................................................ 35

5.2 Installation of the repair platform for ML Combi "Check-in"............................................................... 36

5.3 Installation of the wheel free superstructures.................................................................................... 37

5.3.1 Repair platform superstructure type "Pv" .......................................................................................... 37

5.3.2 Swivel arm superstructure type "S"................................................................................................... 37

6 Adjustment of the lift ...................................................................................................................... 39

6.1 Adjusting the main cylinder ............................................................................................................... 39

6.2 Adjusting the safety zone.................................................................................................................. 40

6.3 Adjusting the limit switch ................................................................................................................... 40

6.4 Testing of adjustments ...................................................................................................................... 40

7 Installation of the cassette cover .................................................................................................. 41

8 Training of personnel in the operation of the lift ......................................................................... 41

9 Malfunction monitoring .................................................................................................................. 41

9.1 Malfunction indication PLC control unit............................................................................................. 41

9.2 Malfunction analysis.......................................................................................................................... 43

10 Overview: Wiring diagrams............................................................................................................ 44

11 Overview: Hydraulic circuit diagrams........................................................................................... 44

12 Overview: Other circuit diagrams.................................................................................................. 44

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1 General

1.1 Information for the installation instruction

This installation instruction describes the installation of the lifting unit and the superstructure. Compliance with

the notes on safety and procedural instructions is a prerequisite for the safe and proper installation of the lift.

Furthermore they are to be kept for the applicable local accident prevention guidelines and the general safety

regulations regarding the lift’s range of applications.

The graphic illustrations in this manual can, if necessary, differ slightly from the actual execution of the lift.

The operating manual for the lift as well as the installation and operating manuals of the supporting compo-

nents apply besides these installation instructions. Please observe the notes contained therein - especially the

safety notes.

1.2 Explanation of symbols

Important safety and machine-technical notes in these installation instructions are marked with symbols. The

notes must be respected to in order to avoid accidents, personal injuries and damage to property.

WARNING!

This symbolizes dangers that can lead to adverse effects on health, injuries, permanent physical dama-

ge or to death.

Adhere at all costs to the notes specied regarding work safety, and be particularly careful in these

cases.

WARNING! Danger of electric current!

This symbol draws attention to dangerous situations involving electrical currents. There is a danger of

serious injury or death if the safety notes are not complied with. The work may only be carried out by

qualied electricians.

ATTENTION!

This symbolizes notes, which if not complied with, can lead to damages, malfunctions and/or break-

down of the machine.

NOTE!

This symbol highlights tips and information that are to be observed for efcient and disruption-free assembly of

the machine.

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1.3 Liability and warranty

All information and notes in these installation instructions are provided under due consideration of valid regula-

tions, the latest technical status of development as well as our years of expertise and experience.

The translation of these installation instructions has also been made to the best of our knowledge. We do not

accept any liability for errors in translation. The version of the installation instructions marked with “Original

version” shall be binding.

For optional design versions, the use of additional ordering options or the implementation of the latest technical

modicationstheactualscopeofdeliverymaydifferfromthedescriptionsandillustrationsinthismanual.Ifyou

have any questions please contact the manufacturer.

We reserve the right for technical changes to the product within the framework of improving the usability and

further development.

1.4 Copyright protection

Theseinstallationinstructionsistobetreatedascondential.Itissolelyintendedforthepersonsengagedin

the installation of the machine. Relinquishment of the installation instructions to third parties without the written

permission of the manufacturer is forbidden. If necessary please contact the manufacturer.

NOTE!

The contextual details, texts, drawings, pictures and special illustrations contained within are protected by copy-

right and subject to further commercial property rights. All misuses are punishable.

Reproduction in any kind or form – also in part – as well as the utilization and/or the communication of contents

are forbidden without the written permission of the manufacturer. Any violations require compensation. Further

claims remain reserved.

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2. Safety

This section gives an overview of all important security aspects for the optimal protection of personnel as well

as for the safety and malfunction-free operation of the machine.

Additionally, the individual chapters contain concrete safety notes, marked with safety symbols, for the preven-

tion of immediate dangers. Furthermore, any pictograms, signs and labels on the machine are to be observed

and kept in good, legible condition at all times.

2.1 General

At the time of its deployment and manufacture, the machine is built according to recognized codes of practice

and is deemed operationally safe. However, dangers may arise from this machine if it is not used professionally

by trained personnel, or if it is used improperly or not according to the designated purpose. Each person autho-

rized to work with the machine must have read and understood the assembly manual before beginning work.

Changes of any kind, as well as attachments or alterations to the machine are prohibited

All security, warning and handling notes on the machine are to be constantly kept in good, legible condition.

Damaged signs or labels must be immediately renewed.

Supplied setting values or adjustment ranges are to be complied with unconditionally.

2.2 Work safety

By following the security notes during work on the machine damages to equipment and personnel can be

avoided. Non-compliance with these notes leads to a considerable risk of injury to personnel and creates the

danger of damaging or destroying the machine.

With disregard of the safety regulations all liabilities and damage claims for compensation against the manufac-

turer or its commissaries are excluded.

2.3 Personal safety equipment

In principle, the following is to be worn when working on or with the machine:

Protective work clothing

Tightttingworkclothing(minimaltearstrength,nowidesleeves,no

rings or other jewellery, etc.)

Safety Shoes

Safety Shoes for protection against any heavy, falling parts and slipping

on non-skidproof ground.

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2.4 Behavior in case of danger or accidents

2.4.1 Preventative Measures

•Alwaysbepreparedforaccidentsorre!

•Keeprstaidequipment(rstaidkit,blankets,etc.)andreghtingequipmentclosetohand.

•Makepersonnelfamiliarwiththelocationanduseofsafety,accidentreporting,rstaidandrescueequip-

mentandhavethistrainingconrmed.

•Clear access routes for rescue vehicles.

2.4.2 If the worst comes to the worst: Do the right things!

•Operate the EMERGENCY STOP to shut down the machine.

•Inform the responsible person at the place of use.

•Alarmaphysicianandtherebrigade.

•Rescuepersonsfromthedangerzone,startrstaidmeasures.

•Keep access routes for rescue vehicles clear.

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3 Technical data

Generally the lifts Masterlift Combi and Masterlift Combi "Check-in" differ in respect of their general function.

3.1 General function of Masterlift Combi

The Masterlift Combi lift is a multi-functional lift both for diagnostics and repair work. The structure basically

represents to "nested" Masterlift lifting units. The outer lifting unit with the 1705 mm piston spacing supports the

platforms, the inner lifting unit carries the freely selectable wheel free device. The following superstructures can

be mounted as wheel free device:

Pv and Pvv

Saa 135

Saav 135 "Van"

Based on its principle of function, the max. stroke is 1900 mm. The stroke can thereby be freely divided bet-

weentheplatformandthewheelfreedevice.Iftheunitismountedushwiththeoortogetherwithushoor

device, the wheel free device can be used as "regular" work area.

Fig. 1: Schematic drawing Masterlift Combi

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3.2 General function of Masterlift Combi "Check-in"

The Masterlift Combi "Check in" lift is explicitly designed for the reception area.

Thelifthastwoliftingunits:therstoneforthemainplatformliftandthesecondoneforthewheelfreedevices.

The piston distance for both units is 1335mm.

Due to the principle of this lift, the maximum stroke is 1835 mm. The stroke can be spread on the superstructu-

res, platforms or wheel free device.

Fig. 2: Schematic drawing Masterlift Combi "Check-in"

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