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Maber MB500/120-SP, Instruction And Maintenance Manual

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RACK AND PINION HOIST 

MABER  

ONE-PHASE

INSTRUCTION AND MAINTENANCE MANUAL 

THIS MANUAL IS AN INTEGRATED PART OF THE MACHINE 

IMPORTANTE WARNING: 

This instruction manual should be completely read carefully before putting the equipement to 

use; all the assembly instructions, the use and maintenance must be precisely 

precluded to unauthorized personnel. 

MABER 

costruzioni srl

36050 Bressanvido (VI)  Italy  via S. Benedetto, 14/P z.a. 

Telefono: +39-0444-660871  Fax: +39-0444-660872 

14/09/98 –libretto uso manutenzione MB500/120 - SP 

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Summary of Contents for MB500/120-SP

Page 1: ... manual should be completely read carefully before putting the equipement to use all the assembly instructions the use and maintenance must be precisely precluded to unauthorized personnel MABER costruzioni srl 36050 Bressanvido VI Italy via S Benedetto 14 P z a Telefono 39 0444 660871 Fax 39 0444 660872 14 09 98 libretto uso manutenzione MB500 120 SP C O P Y ...

Page 2: ...ansportation 14 11 Packaging 14 12 Loading unloading support 15 13 Installation 16 14 Assembling the vertical column 18 14a Emergency brake test 19 15 Standard wall mounting 22 15a Special wall mounting 23 16 Trial before use 24 Machine operation 17 Machine controls page 24 18 Checks and tips before use 25 19 Operator s guide 25 20 Start up 26 21 Setting the machine up for idling 26 22 Adjustments...

Page 3: ...max load 300 kg confirms that it complies to the safety regulations specified in the health and safety regulations and guidelines as defined in enclosure N 01 of Machine directive 98 37 E E C Section V including all supplementary guidelines The planning refers when it is possible at the following rules DPR 27 04 55 n 547 DPR 07 01 56 n 164 CNR UNI 10011 88 The technical documentation with enclosur...

Page 4: ...NZA ITALY CLIENT CITY TOWN MACHINE RACK AND PINION ELEVATOR MODEL MB 500 120 SP MAX LOAD 300 Kg MAX HEIGHT 120 m POWER SUPPLY VOLTAGE ONE PHASE 220 50 Hz YEAR OF MANUFACTURE SERIAL NUMBER DELIVERY DATE EXPIRY DATE OF THE GUARANTEE 12 MONTHS AREA AGENT AFTER SALE SERVICE The identification data are printed on a special plate attached directly to the machine in the position shown in the diagram belo...

Page 5: ...x load of 300 kg The lift is basically made up of the following parts x A base fitted with adjustable worm screws x A vertical column fitted with a rack composed of modular latticed elements that must be joined every 6 m to a wall or a support frame x An loading deck driven by an electric motor via a rack and pinion coupling x A series of securing bolts let the frame be held vertically every 6m x ...

Page 6: ... speed exceeds approx 20 of the normal preset values The device enables a ratchet gear that allows the deck to stop in a damped and gradual way at any point of the vertical column The machine in question has been produced to comply with the regulations mentioned in the declaration of compliance attached to this manual and subjected a trial as is stated in the declaration itself see page 3 C O P Y ...

Page 7: ...e see page 16 x After correctly installing the vertical columns and securing bolts on the wall as required by specifications x After checking the safety devices and accesses to the various storeys x After checking the emergency brake works properly x In winds up to maximum speed of 70 km hour x In ambient temperatures ranging between 15 and 45 C Persons may only be carried during the assembly and ...

Page 8: ...harsh temperatures or with ice that might stop the ratchet gear of the emergency brake DO NOT USE Operation at ambient temperatures over 45 Operation at ambient temperatures below 15 Machine operation without terminal switches Operation without periodic maintenance Operation when the column has not been firmly secured Operation after tampering or modification unauthorised by the manufacturer Use o...

Page 9: ...in part x Replacement of any parts or components must always be previously authorised by the manufacturer The guarantee does not cover the electric parts of the machine The law court of PADOVA ITALY is responsible for any litigation 6 HOW TO CONSULT THE MANUAL The operating and maintenance manual is an integral part of the machine Before commencing any installation jobs and machine operation the o...

Page 10: ...very 6 m to a support wall or a frame able to bear the transmitted loads indicated in paragraph 15 on page 22 The loading deck 5 consists of a welded sheet walkway on a support frame made of section bars The walkway is limited by a pair of fixed guards 6 along the longer sides and two access gates are provided on the shorter sides equipped with tilting bar 7 and lower walkway 8 that can be let dow...

Page 11: ...9 m In windy areas at least every 6 m The cable is gathered in a special container 17 placed on the base To make easier the loading and unloading of the deck two ramps 8 are lowered to form a support deck When the ramps are opened and closed the movement of the lift is stopped The lift movement is controlled via a suspended control panel 18 that is located to the ground or directly connected to th...

Page 12: ... the temporary assembly and disassembly bolt 2 m Deck width 1 5 m Deck length 1 3 m Weight of the complete unit deck at base 440 kg Guard height 1 m Height of the loading deck from ground at bottom terminal switch 0 25 m Three phase electric power supply 230 50 Hz Voltage for low tension controls 48 Volts Electric gear motor power 2 5 kW Input current while working 18 A Rack module 5 mm Lifting pi...

Page 13: ...ven on page 22 x Check that the accesses to the loading unloading decks are adequately cordoned off and that these barriers can be removed only after the lift has reached its height and are compulsorily refitted when the lift is not on the storey x The machinery assembly and disassembly workers must be supplied with a safety belt x Do not assemble the machinery if the wind speed exceeds 40 km hour...

Page 14: ...ckaged and fastened with a metal strap The electric parts and most delicate components can be protected with a plastic sheet until delivery Take off the plastic sheet if present and make sure that it is not within children s reach Remove the packaging only using the containers provided for refuse collection Remove the metal fasteners discard them only after winding and dispose of them properly Mak...

Page 15: ... required using the pegs supplied The same applies to the right hand cross piece 3 x fit the two units in the relevant tubes 4 welded at the bottom of the lift deck x lower the deck so that the uprights 1 touch the ground the base is thus lifted Follow this procedure to reach the height required x place the vehicle under the lift base x start raising The deck will now lower to allow the base to re...

Page 16: ...ssemble the machine use a pair of 24 mm hexagonal wrenches After the above check install the machine strictly following the guidelines below x Lay the base on the ground x Check that its distance from the wall is regular matching the type of bolting supplied minimum distance 50 cm x Use a spirit level to check the horizontal alignment of the base and the vertical alignment of the column Make the n...

Page 17: ...the machine has been connected x About 1 3 m above the ground attach the first cable guide arm 1 and fix it with a clamp x Place the box 2 of the electric power supply cable 3 to ensure that it is regularly unwound and rewound during up and down movements x Plug the machine into the electric power line by inserting the plug 4 x Couple the connector 5 of the control board 8 Test movement by enablin...

Page 18: ...t vertical column on the deck lower the guard 1 Fit and connect the 1st vertical column with the screws provided Close securely x Alight and fit 2 m above the ground the 1st securing bolt temporary safety bolt for assembly and disassembly x Press the emergency stop button to stop any movement CAUTION A photocell control unit built into the motor drive unit automatically stops the lift near the end...

Page 19: ...ull the rope This action will open the motor brake x At this point the machinery always descends faster until it activates the emergency brake which must be applied 2 5 m above the ground The run from when the emergency brakes is applied to when the machinery is definitively locked must be around 300 mm x Should the machinery not stop immediately release the rope to reactivate the motor brake that...

Page 20: ...e diagram on page 22 The wall or the support scaffold must be able to bear the transmitted loads Then attach the wall mounting at least every 6 m x If necessary attach stroke limit stop runners on the storey 3 so as to ensure it stops at a preset height x Make sure that the storey accesses are adequately cordoned off and fitted with warnings on special signs attached to the inside of the building ...

Page 21: ...achinery operating conditions CAUTION From now on nobody must be allowed access to the deck The lift is ready for regular service for goods in compliance with the operating specification described in the paragraph on Machine Application To disassemble the column and the lift follow the above description in reverse order always ensuring the utmost safety conditions for workers handling and for the ...

Page 22: ...and is this a very important element of the machine Therefore very firmly tighten all screws and clamps and frequently check they are tightened properly Warning Not to interfere with the bolts fasten the release lever a of the turning plate parallel to the deck wall 15a SPECIAL WALL MOUNTING C O P Y ...

Page 23: ...w 3 until it touches the pipe of the vertical column This stiffens the securing point Do not secure near the corner for cement or similar structures Use M10 wall plugs suitable both for the indicated loads and the type of wall material Should the lift be fitted on fixed scaffolds or a tubular scaffolds make sure that they can bear the transmitted loads Warning Not to interfere with the bolts faste...

Page 24: ...y reading the following paragraphs Should you have any doubts on lift operation or on any malfunctions that may occur immediately before operation consult the manufacturer s technical support service 17 MACHINE CONTROLS In regular operation the lift must be controlled only by the pendant control at the ground whichis connected to the power supply functions 1 Stop Red 2 Run Green 3 Up White 4 Down ...

Page 25: ...ectly locked x Environmental conditions are favourable max wind speed of 70 km h etc 19 OPERATOR S GUIDE The lift operator must always do the following x Be previously authorised for machine operation He or she answers totally for any action performed by the equipment and is fully legally responsible x Stand in a place where full visibility can be ensured over the whole vertical column and especia...

Page 26: ...trol board or switch off 0 the switch located on the main control panel x Enable ascent until the required storey has been reached x The exact stop at a storey is ensured by the preset moving stop switch runner See page 24 x When the required height has been reached the operator on the storey may open the barrier release the stop lock of the turning plate and turn the deck x Lift the protecting ba...

Page 27: ...e motor crankcase 2 x By screw the motor brake ring nut 4 with a wrench clockwise about 180 so as to increase pressure of the springs 5 on the brake disc 6 Conduct an unloaded operation test and a fully loaded operation test x Refit the motor crankcase and enable the main power knob of the control panel B Adjusting the emergency brake fall stopper See page 29 Non Routine Maintenance CAUTION After ...

Page 28: ...tightened on every vertical column and on every mounting x Gear motor unit clamping screws are tightened x Elements on the vertical column have not yielded x The motor drive guide and sliding rollers regularly run on the column x the gear motor unit works efficiently Also check its noise level to verify the presence of any irregular clearances in the gears x The gear reducer is correctly lubricate...

Page 29: ...caps especially the magnetic cap before refitting them x We suggest you wash with detergent before refilling with new lubricant Adjusting the Service Brake See section 22 page 27 Also make sure the distance between magnet and counter magnet is about 0 2 mm The distance is adjusted with the three screws Adjusting the Emergency Brake Fall Stopper x The machine must be lowered to ground level x Disab...

Page 30: ...hine when replacing damaged parts or defects contact only the Manufacturer or the official TECHNICAL SUPPORT CENTRE represented in your country by Specially trained technicians are able to carry out all required MAINTENANCE jobs 26 MAINTENANCE SCHEDULE Dat e Hours of operation Type of maintenance job Operator s signature Result C O P Y ...

Page 31: ...LPHA SN 6 ALPHA SP 100 ELF ORITIS 125 MS REDUCTELF SP 100 ELF SYNTHERMA P30 ESSO COMPRESSOR OIL LG150 SPARTAN EP 100 I P TELESIA OIL 150 MELLANA 100 MOBIL GLYGOYLE 22 MOBIL GLYGOYLE 30 MOBIL SHC 630 SHELL OMALA OIL 100 TOTAL CARTER EP 100 N Check the oil level in the gear reducer every month Check levels if you notice any oil leaks from the gear reducer Before restoring the level check for cause o...

Page 32: ...32 28 ELECTRICAL DIAGRAM MB 500 120 SP RACK AND PINION HOIST ONE PHASE C O P Y ...

Page 33: ...r see page 21 Get down slowly and start to repair Part Emergency brake Problem The deck is jammed Cause The ratchet gear spring is broken Remedy Replace the spring with an original part Procedure This operation must be carried out by an authorised and pre trained technician To this purpose move the deck to first storey immediately above From the storey where it stops unload the deck Place under th...

Page 34: ...intervenes when the hoist exceeds the speed of 20 while going down The intervention of the emergency device blocks the downhill of the hoist mechanically Call immediately the assistance service in case there are some breakdowns to the emergency device When the hoist is near the bottom limit switch do a check of the emergency brake Disconnect the power line bringing the main switch in position 0 bl...

Page 35: ...amp handle 8 Mast section 38 Limit switch on loading ramp 9 Anti crush grid 39 Complete control panel 10 Springs 40 Gearbox 11 Photocell 41 Electric motor 240V 1ph 400V 3ph 12 Brake spring 42 13 Brake lining 43 14 Brake wheel 44 Cable support arm 15 Rachet gear safety brake 45 Complete pendant 5 m cable 16 Spring 46 Manins connector 17 Upper platform pivot 47 18 Lower platform pivot 48 Control con...

Page 36: ...36 C O P Y ...

Page 37: ...e gear reducer empty oil and dispose of it only via a special waste disposal service operating in your area Send the electric motor to a specific waste disposal service unless all parts of motor iron copper other materials can be separated to send them to differentiated waste collection If the unused the machine has to be preserved before it is definitively scrapped make sure that It is stored in ...

Page 38: ...12 Loading Unloading support 15 27 Lubricants 31 4 Machine application 7 17 Machine controls 24 2 Machine identification 4 10 Machine transportation 14 26 Maintenance schedule 30 24 Non routine maintenance 29 19 Operator s guide 25 11 Packaging 14 23 Periodic maintenance 28 9 Safety regulations 13 21 Setting the machine up for idling 26 15 Standard wall mounting 22 30 Spare parts spare parts list ...

Page 39: ...e block go for the safety landing gate with a width of 1300mm In order to assemble the gate in a correct way please follow these instructions Erect all the masts useful to reach the final height for the gate employment Tie all the masts Assemble the stop landing slide adjusting its cam as the working floor of the transport drum exceeds of about 100mm the top of the landing floor this operation is ...

Page 40: ...gate mechanism on the transport drum Come back to the landing floor Rotate the transport drum open the unloading ramp and unload the saferty landing gate at the landing floor Assemble the gate on the scaffolding or on the wall by using tubes and joints assembled before Use all possible safety systems use the safety belts to work in safe conditions on the scaffolding Study the following picture for...

Page 41: ...king gate box Use clamps and fix them on the tube of 48mm Follow the measures specified in the following pictures for the correct position of the blocking gate box Front view of the transport drum View from the drum of the landing floor of the safety landing gate C O P Y ...

Page 42: ...of the gate is fixed and the standard of the scaffolding with protections according to law in order to avoid any dangerous situation In case the hoist is near a wall and the landing is a door on the wall follow these instructions to assemble the safety landing gate Follow the operations used for its erection described before and follow the same warnings In order to fix the safety landing gate asse...

Page 43: ... the front closing The assembly is made by using the blocking plate fixed through suitable screws Use the lever putting the shaped cam inside the box Hold the unblocking lever with its handle Keep the unblocking lever connected with the chain to the transport drum is always compulsory It does not allow the drum to rotate when the unblocking lever is inserted and the gate is open C O P Y ...

Page 44: ...on of the drum unfasten the unblocking lever from the drum and put it on the blocking box unblocking the safety landing gate The operator can open the safety landing gate making it rotate on its left pivot bringing it in vertical position After the loading and unloading operations of the transport drum the operator must close the safety landing gate before making the drum rotate The drum can rotat...

Page 45: ...te When the safety landing gate is closed the drum can be rotated When the transport drum is not rotated and the unblocking lever is not inside the box the inner mechanism is in the same position of the above picture thanks to its spring In the section C C it is impossible opening the safety landing gate because it has been blocked by the slit of the inner plate C O P Y ...

Page 46: ...put the unblocking lever inside the blocking gate box for the rotation of the transport drum This operation makes spring the mechanism which releases the hook of the safety landing gate see section E E and makes the opening gate possible When the safety landing gate is open the mobile lever connected to the drum with a chain blocks the rotation of the transport drum Anyway if someone tries to rota...

Page 47: ...llowed opening the gate accidentally Against the voluntary opening of the gate if the drum is not present The gate cannot be opened accidentally when the drum is not present thanks to the mechanical blocking system The system allows the opening of the gate only if the drum is present since it unblocks the stop and allows the movement of the gate Against the hoist movement while the gate is open Wh...

Page 48: ...48 DISEGNI TECNICI TECHNICAL DRAWINGS DESSINS TECHNIQUES TECHNISCHE ZEICHNUNGEN C O P Y ...

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