Four-Column Vehicle Lift
Trucklift
for passenger cars and vans up to max. gross weight of 8 t/10 t
Standard Operating Procedure
and User’s Manual
Englisch/English
D1 3602BA1-GB03
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Trucklift
TABLE OF CONTENTS
1
Safety Instructions....................................................................................................1
1.1 Safety Information..........................................................................................................................1
1.2 Further Information ........................................................................................................................2
1.3 Safety Features..............................................................................................................................2
1.4 Safety Guidelines...........................................................................................................................3
2
Description ................................................................................................................5
2.1 Usage, Applications .......................................................................................................................5
2.2 General View .................................................................................................................................5
2.3 Specifications.................................................................................................................................6
2.4 Noise Emissions ............................................................................................................................6
3
4
Installation .................................................................................................................7
3.1 General Information .......................................................................................................................7
3.2 Installation Location .......................................................................................................................7
3.3 Foundations ...................................................................................................................................8
Operation ...................................................................................................................9
4.1 Controls..........................................................................................................................................9
4.2 Vehicle Tracks .............................................................................................................................10
4.3 Driving onto the Lift......................................................................................................................11
4.4 Lifting............................................................................................................................................12
4.5 Working on Raised Vehicles........................................................................................................12
4.6 Lowering ......................................................................................................................................13
4.7 Locking the Lift to Prevent Unauthorised Operation....................................................................13
5
6
Maintenance, Troubleshooting ..............................................................................15
5.1 Maintenance ................................................................................................................................15
5.2 Repair Notes................................................................................................................................16
5.3 Troubleshooting Checklist ...........................................................................................................17
5.4 Lowering the Lift in the Event of a Power Failure........................................................................19
Warranty, Service....................................................................................................21
6.1 Warranty ......................................................................................................................................21
6.2 Warranty Exclusion Clause..........................................................................................................21
6.3 Service .........................................................................................................................................22
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Trucklift
1
Safety Instructions
1.1
Safety Information
Safety Instructions are provided to warn about dangerous situations and to help avoid
injury to people.
The truck lift is only to be used for its intended purpose as described in the operating
instructions!
Only trained authorized personnel may operate the truck lift.
Explosion protection!
The truck lift is not to be used in rooms liable to contain explosive mixtures! Standard
lifts have no EX-protection!
The main power switch serves as Emergency-Off switch!
In case of emergency, turn switch to 0-position.
Persons are not permitted in the danger zone during lifting and lowering cycles.
Unauthorized persons may not in any way be positioned underneath the lifted vehicle!
The net load capacity stated on the identification plate of the lift may not be exceeded!
Persons may not climb on or be transported on the lift.
Before repair-/maintenance-/set up work turn off main switch and secure against
tampering.
Secure the lift from unauthorized usage by locking the main switch.
All work done on electrical parts of the equipment is to be carried out by trained, qualified
electricians or service technicians only.
Protect all parts of the machinery from humidity and moisture.
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Trucklift
Safety Instructions
1.2
Further Information
At installation pay attention to the following:
Standard lifting platforms may not be operated in washing halls, rooms with high humidity or
outdoors! The lifting platform must be protected from any form of water splashing! Never
clean the lifting platform with high pressure cleaners or steam cleaners!
In rooms with very low ceilings it is recommended to install a ceiling light barrier. This can be
ordered from the manufacturer.
For safe operation pay attention to the following:
Read the standard operating procedures and user`s manual thoroughly! MAHA will not
accept and is not liable for any claims for damage or service costs incurred due to non-
compliance with these operating instructions.
All official Accident Prevention Regulations must be thoroughly complied with!
Damages to low-lying vehicle parts are not covered by the warranty.
Keep the lifting platform and the surrounding work area clean.
Do not deposit any parts on the support arms or on the driving platform.
The vehicle should be driven slowly onto the lifting platform to avoid putting any
unnecessary strain on vehicle and lifting platform.
On lifting platforms equipped with an axle jack pay close attention that no objects are
below the axle jack.
Balancing work on the lift while the platform is being loaded is forbidden. The vehicle may
roll off the driving platform.
Pull the parking brake of the vehicle after entering the lifting platform.
All work done on impulse sensors and proximity switches should be carried out by trained
electricians.
1.3
Safety Features
The TRUCKLIFT is equipped with the following safety features:
Electronic lift synchronisation monitoring. This system monitors all the lifting carriages
and ensures that they are synchronised during lifting and lowering. If one carriage blocks all
the drive motors are switched off automatically.
Electronic bearing nut monitoring system on all four columns. If a bearing nut breaks the
system only permits the unit to be moved to its lower starting position.
Bearing nut wear indicator, lets you know in good time when the bearing nuts need to be
replaced.
Drive belt breakage safety system on all four columns. All motors are switched off
automatically if a drive belt is defective.
Motor overload protection system on all four columns.
Catch nuts, which support the load on the lift in the event of failure of the bearing nuts.
The main switch doubles as an emergency off switch. In an emergency, the unit can be
switched off by turning the switch to position 0.
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Trucklift
Adjustable guard rails around the lift and on the ramps. The guard rails on the four
columns must be adjusted in such a way, that there is a clearance of approx. 150 mm
between the extension and the connection plates of the column. The adjustable guard rail
can be locked by tightening the M 8 screw.
150
Adjustable guard rails on all four columns
1.4
Safety Guidelines
The following points were taken into consideration at construction:
The safety regulations correspond with the prEN 1493.
The lifting platform meets the safety demands of the following guidelines:
- 89/392/EWG in connection with 91/368/EWG and 93/44/EWG EG-Maschinery Guidelines.
- 73/23/EWG EG-Low Voltage Guidelines
- 89/336/EWG EG-guidelines regarding electro-magnetic tolerance.
The CE-Declaration of Conformity is attached to the Operating Instructions or Test Booklet.
Pay attention during operation:
The Accident Prevention Regulations of the country in which the lifting platform is being
operated apply.
The following guidelines apply within the European Union countries:
- 89/391/EWG Safety and Health Protection for the Employee.
- 89/654/EWG Safety and Health Protection in the Work Area.
- 89/655/EWG Safety and Health Protection when using Working Materials.
- 89/656/EWG Safety and Health Protetion when using personal Protective Clothing.
- 92/58/EWG Safety and/or Health Protection Identification at the Place of Work.
EU-Guidelines are available from
DITR German Information Center for Technical Rules in DIN e.V.
10772 Berlin
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Trucklift
Safety Instructions
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Trucklift
2
Description
2.1
Usage, Applications
The TRUCKLIFT 8 / TRUCKLIFT 10 is a device for lifting motor vehicles up to a maximum gross
weight of 8,000 kg / 10000 kg, with a maximum load of 6000 kg / 6600 kg permitted on any pair
of columns. The maximum lifting height of the unit is 2,1 m, making it easy to work on the
underside of the vehicle, even for taller staff members.
TRUCKLIFT is designed primarily for lifting vans. However, the vehicle tracks can easily be
adjusted for lifting normal cars as well.
The lift must be installed and prepared for operation by a properly trained technician.
Structural and technical alterations to the lift are prohibited.
Always observe the detailed operating and service instructions provided.
2.2
General View
Column 4 is the control column.
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Trucklift
Descriptions
2.3
Specifications
Trucklift 8
Trucklift 10
Max. rated load in t
Machine weight in kg
8
10
3500
2650
1975
200
Column height H in mm
S
Max. lifting height H in mm
o
Height above ground surfaceFehler!
Textmarke nicht definiert. H
u in
mm
Height to guard rail lower edge H in
B
5810
mm
Overall height H in mm
G
5850
3200
Inside column width B in mm
L
Max. horizontal clearance B in mm
M
2980
Overall width B in mm
G
3800
Inside track width B
E in mm
1100 - 1640
617
Vehicle track width B in mm
B
Column spacing L in mm
S
6200
Overall baseplate length L in mm
G
6510
Effective vehicle track length L in
F
mm
5940
Overall length L in mm
Lifting period in s
Lifting travel in mm
Lifting speed in mm/s
Anchoring dowels
Concrete grade
Motor output
7800
54
1775
ca. 35
composite dowels
min. BN 25
20 x UPAT
UKA 3 M 16
4 x 2,2 kW
Voltage supply
3 x 400 V + N + PE; 50 Hz
Specifications subject to change without notice!
2.4
Noise Emissions
The noise emissions of the lift in the area occupied by the operating personnel are lower than
70 dB (A)
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Trucklift
3
Installation
3.1
General Information
TRUCKLIFT is normally installed by the manufacturer's own trained technicians.
However, the lift can also be installed by the operator's own technical staff, provided that they
are properly trained, with the necessary skills. It is important that they should have
experience in the proper use of composite dowels and the proper installation of the electrical
connections in accordance with the VDE regulations.
3.2
Installation Location
The lift can be installed in any suitable location. The only restriction is that the standard version
of the lift is not rated for use in rooms with explosive atmospheres
The installation location must be provided with the necessary power supply by the operator:
3~/N + PE 400/230 V, 50 Hz. The operator must also see to it that the power supply is protected
with a T35A circuit breaker in accordance with the VDE 0100 regulation.
The standard point for the power supply cable inlet to the lift is at the top in the control column.
However, the power supply cable can also be routed in through the hole provided in the
baseplate. In both variants, the cable must be protected with a suitable cable support sleeve.
The power supply cable must be connected to the terminals of the main switch in the control
console on the control column.
Before installation, suitable foundations conforming to the specifications of the manufacturer
MAHA must be provided. They must either be built specifically for installation of the unit, or the
operator must provide evidence that they conform to the specifications. The installation location
must be perfectly flat and level. If the foundations are installed in the open or in rooms where
winter weather conditions or frost can be expected, the foundations must be sunk down to frost
depth.
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Trucklift
Installation
3.3
Foundations
The concrete used for the foundations must be at least grade B25 and reinforced. Because of
the anchoring dowels used, the concrete base slab must also have a minimum thickness of
200 mm.
The operator must provide evidence of the base slab load bearing capacity.
The foundations plan is also available from MAHA.
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Trucklift
4
Operation
4.1
Controls
The TRUCKLIFT unit has four controls.
The main switch is used to turn the entire system on and
off, and also doubles as an emergency off switch.
V
o r Öffne
Ge rä te
Ha up sc ha lte
n
d
e
s
r
s
a
ussc ha lte n!
Sic he rhe itsb e stim m ung e
n
1
The main switch must always be easily
accessible.
Be d ie nung :
0
Its position should never be changed.
The light switch is identified by a light symbol. Turn this
switch to the right to switch the light on.
The raise button is identified by an arrow pointing up. The
lift stops moving immediately as soon as you release the
button. The lift also stops automatically when it reaches its
upper travel limit.
The lower button is identified by an arrow pointing down.
The lift stops moving immediately as soon as you release
the button. The lift also stops automatically when it reaches
its lower travel limit.
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Trucklift
Ôperation
4.2
Vehicle Tracks
The vehicle tracks can be moved laterally on the
crossbars to adjust the width to match the track width
of the vehicle to be lifted. Normally, you will only need
to adjust the left track.
Track to be adjusted
To adjust the track width, first remove the retaining
pins at the front and rear. Then move the track in the
desired direction by inserting a lever in the retaining
lug and levering against one of the holes in the
perforated section below. This must be done both at
the front and the rear, otherwise the track will not be
straight.
Adjusting the track
Front retaining pin
After adjusting the track position you must
secure it again with the retaining pins!
You do not have to adjust the other track, but you can
if you wish, for example in order to centre a vehicle
over a working pit. To do this, you must first unscrew
the retaining disks on the two retaining pins, and then
unscrew and remove the pins themselves. You can
then adjust the position of the track. Since this only
needs to be done once, no leverage aids are provided.
Fixed track"
After you have adjusted the track position you must
replace the retaining pins.
Retaining pin
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Operation
Trucklift
4.3
Driving onto the Lift
The control console is mounted on lifting column 1.
The main switch is on the side of the console. Turn
this switch to position 1 to turn on the power. The lift is
then ready for operation.
1
0
The main switch doubles as the
emergency off switch. In emergencies, simply turn
the switch to the 0 position to switch off the lift!
1.
Remove all tools, chocks, stands etc. from the
working area of the lift.
2.
Always make sure that the working area is
kept free of excessive dirt!
Lower the lift (see Lowering) until it stops
automatically in its starting position.
=
=
Drive the vehicle onto the lift tracks and stop so that it
is centred between the end columns.
The vehicle tracks of the lift must be
adjusted to match the track width of the
vehicle.
The actual gross weight of the vehicle should
never exceed the maximum rated load of 8 t.
Secure the vehicle so that it can't roll away
(motor off, hand brake on, gear engaged,
chocks under the wheels).
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Trucklift
Ôperation
4.4
Lifting
Sic he rhe itsb e stim m ung e
n
You can lift the vehicle once it is properly positioned
on the lift and secured against rolling away. To start
the lift, press the '###' button. The lift stops as soon
as you release the button.
Be d ie nung :
V
o r Öffne
Ge rä te
Ha up sc ha lte
n
d
e
s
r
s
Nobody should ever be in the working area of
the lift while a vehicle is being lifted!
a
ussc ha lte n!
Whenever the lift is moved you should always
keep an eye on the load and everything used to keep
the load in place!
Lifting people and climbing on the lift or on the
vehicle when the lift is raised are all strictly prohibited!
You can now lift the vehicle to the desired height.
4.5
Working on Raised Vehicles
Never place any items on the lift or the vehicle
tracks!
Lifting people and climbing on the lift or on the
vehicle when the lift is raised are all strictly
prohibited!
Secure the vehicle so that it can't roll away
(motor off, hand brake on, gear engaged,
chocks under the wheels).
You can turn on the light by turning the light switch to
the right.
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Operation
Trucklift
4.6
Lowering
Sic he rhe itsb e stim m ung e n
Before lowering, always make absolutely
sure that nobody is in the working area of the lift!
Be d ie nung :
Remove all tools, chocks, stands etc. from the
working area of the lift.
V
o r Öffne n d e s
Ge rä te s
Ha up sc ha lte r
a
ussc ha lte n!
Press the ' ' key until the platform is in its lowest
position. The lift stops automatically in its starting
position.
4.7
Locking the Lift to Prevent Unauthorised Operation
1
When the lift is not being used you should
always lock it to prevent unauthorised operation!
0
To lock the main switch, first turn it to the 0 position.
Then press in the protruding pin and lock the switch in
this position with a padlock. This prevents
unauthorised operation of the lift.
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Trucklift
Ôperation
14
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Trucklift
5
Maintenance, Troubleshooting
5.1
Maintenance
Regular maintenance is necessary to ensure reliable operation of the lift and a long service life.
a)
b)
The support arm extension and the
support disc threading should be well
greased. It is recommended to use
lithium soap grease.
The oil level of the oil pan should be
checked quarterly. It is located on the
carriage slides behind the spindle
cover sheet. (see the upper part of the
diagram to the right) The pan should
have at least 5 mm of oil in it. If the oil
is not up to this level refill it. The neck
of the oil can be directly applied
through the brush cover of the column.
Use only SAE 140 gear or the special oil
available from the manufacturer, order no.
360004.
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Trucklift
Maintenance, Troubleshooting
c)
Wear and tear on the support nut must
be checked annually. Remove the
plastic cap from the spindle cover
sheet and move the carriage slides so
that the control drill holes lines up with
the window.
If there is no visible gap this is an
indicatioin that the support nut is worn
down beyond the permissable limit.
The support nut must be replaced. The
gap is approximately 2 mm. ex factory.
When the wear limit is reached the
lift must be shut down until the
bearing nuts have been replaced.
Lock the main switch to ensure that
nobody can use the machine.
5.2
Repair Notes
Only trained, skilled electricians are allowed to check impulse sensor and proximity
switches.
Immediately contact your MAHA dealer or the MAHA service center when there are problems
with impulse sensors or proximity switches.
Unskilled work on electrical parts of the lifting platform can be life threatening.
The main switch should be switched off and secured before any repair work or
malfunction troubleshooting is done on the lift!
Malfunctions due to unskilled repair or adjustment work are not covered by the warranty.
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Maintenance, Troubleshooting
Trucklift
5.3
Troubleshooting Checklist
The following checklist will help your service technicians to locate faults in the event of
problems.
Problem
Possible cause
Remedy
When lifting, lift stops of its a) Excessive load on the lift.
a) Check whether the load
exceeds the rated maximum
lifting capacity. Check the
jackscrew lubrication and the
tension of the toothed drive
belt.
own accord at an arbitrary
height.
b) The distance between the
pulse encoder and the drive
The LED on the circuit
board lights up (see ill. on
next page).
pulley is too great.
b) Check impulse encoder
distance (have it corrected, if
necessary).
Lowering from this position
is possible.
Lifting should then be possible
again after lowering the lift by at
least 2 cm.
When lowering, the lift
stops of its own accord at
an arbitrary height.
a) The lift has run into an
obstacle, lifting out the
jackscrew.
a) Remove the obstacle.
b) Check the upper pulse
encoder.
The LED on the circuit
board lights up (see ill. on
next page).
b) The distance between
the pulse encoder and the
drive pulley is too
great.
Lowering should then be
possible again after raising the
lift by at least 5 cm.
Lifting from this position is
possible.
Lift stops in the upper
position. After pressing the
RESET button followed by
the "Lower" button, all
motors activate briefly and
then stop.(see ill. on next
page)
No signals from the upper pulse Check the upper pulse
encoders. encoders.
When the "Lift" button is
pressed the motors
activate again briefly and
then stop.
Pressing the buttons again
produces no further
reaction from the lift.
The red LED on the circuit
board lights up after about
5 seconds.(see ill. on next
page)
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Trucklift
Maintenance, Troubleshooting
Problem
Possible cause
Remedy
The lift stops at a height of a) The distance between the
a) Check the wear of the bearing
approx. 260 mm
catch nuts and the jackscrew
nuts.
(measured from the floor to
the lower edge of the
carriage).
bearing nuts is too small.
b) Check the distance between
the proximity switches and the
switching cams on the frame
and on the catch nuts .5 mm).
b) A proximity switch is defective
or its setting is incorrect.
The lift can only be
lowered from this position.
Further raising is not
possible.
The LED on the circuit
board blinks.(see ill. on
next page)
The lift stops at a height of No signal pulse from the
Check the proximity switches.
(Call MAHA-Service Dept.).
approx. 400 mm
switching cam on the frame or
the catch nut.
(measured from the floor to
the lower edge of the
carriage).
Check the distance between the
proximity switches and the
switching cams on the frame
and on the catch nuts.
The lift can only be
lowered from this position.
Further raising is not
possible.
The LED on the circuit
board blinks.(see ill. on
next page)
The lift can only be moved A bearing nut is broken and the Have the bearing nut repaired.
to its lower starting
position.
load is being borne by the catch
nut.
Shut down the lift and
lock the main switch!
Lifting is no longer
possible.
At the beginning of lifting
the lift stops and the power simultaneously. This causes a
All motors are starting up
Change the setting of DIP switch
4 on the control PCB to
supply circuit breaker trips. voltage peak that trips the circuit "OFF".(see ill. on next page).
breaker
Neither lifting nor lowering
are possible.
This starts the motors in a
DIP switch 4 is set to "ON".(see staggered sequence.
ill. on next page)
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Maintenance, Troubleshooting
Trucklift
DIP
RESET
LED
1 2 3 4
D I P O N
Reset
LED
. r V e
A p p l .
o
6 3
4 7 0 n
J
S2.2
S3.2
PE
F1776-422-
3471 9220/
ERO
ERO
F1776-422-
3471 9220/
Control cabinet, opened
Control PCB
5.4
Lowering the Lift in the Event of a Power Failure
Remove the motor cover hoods. Each spindle can be turned separately at the large drive
pulleys with a ratchet (nut size 36) to lower the carriages. When doing this, two persons should
lower the front column pair at the same time and then the back column pair.
As soon as the power returns, synchronise the carriages again by pressing "###" and holding it
down until all movement stops.
The height difference between the lateral column pair should never be more than 20 mm.
The height difference between the column pair in driving direction may not exceed 100
mm!
Important: In the event of a power failure the lifting carriages should only be lowered!
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Trucklift
Maintenance, Troubleshooting
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Trucklift
6
Warranty, Service
6.1
Warranty
Subject to the provisions of their General Terms and Conditions of Business, Maschinenbau
Haldenwang (MAHA) undertakes to repair or replace any defective components free of charge
during the warranty period if the product is sent to MAHA – either directly or through an
authorised MAHA dealer – or if the product is repaired or installed by authorised personnel.
This warranty is only provided for products installed by authorised personnel.
Damage resulting from improper alterations or grossly negligent damage to the product is
excluded from the warranty.
No warranty coverage for MAHA products can be provided without a fully completed Warranty
Registration Card and a Warranty Application, together with a completed and signed original
sale receipt showing the date of purchase and the serial number of the product. Proper regular
servicing is also a requirement for warranty coverage.
6.2
Warranty Exclusion Clause
All warranty coverage is subject to the condition that our products must be used properly for
their intended purpose, in accordance with the Installation and Maintenance Instructions and
Operating Instructions, including any subsequent operating and service information provided.
Normal functional wear and tear on vehicle components are excluded from the warranty. The
warranty does also not cover any damage to vehicles and/or our equipment or other products
caused by alterations to motor vehicles or other deviations of the motor vehicles from the series
model specifications.
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Trucklift
Warranty, Service
6.3
Service
MAHA has customer service offices in many countries all over the world. You can contact these
offices at any time to obtain answers to any questions you may have regarding MAHA products.
If your product needs repair you can always contact your dealer, or you can contact MAHA
directly. A charge will be made for repairs after the end of the warranty period.
You can reach our central customer service office at the address below:
MAHA Maschinenbau Haldenwang GmbH & Co. KG.
D-87490 Haldenwang/Allgäu
Telephone : 08374 / 585-0
Telefax : 08374 / 585-491
E-Mail : [email protected]
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