MAHA MPJ Series Original Operating Instructions Download

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BA550001-en

Bleeding the hydraulic system

WARNING

Use personal protective equipment!

Pit jack is unloaded, freely accessible and cleaned!
The pit jack is fully retracted and load-free!
The pit jack must be disconnected from the compressed air supply.

Bleeding block

1 Check the oil level and top up with hydraulic oil if necessary. The target fill

level of the hydraulic oil is in the center of the oil sight glass when retracted.

Summary of Contents for MPJ Series

Page 1: ...0 750 1S HM MPJ 4 0 750 1S HA MPJ 16 5 750 1S HM MPJ 16 5 750 1S HA MPJ 16 5 750 1S FA MPJ 16 5 750 1S TA MPJ 16 5 750 1S HAE MPJ 20 750 1S HM MPJ 20 750 1S HA MPJ 20 750 1S FA MPJ 20 750 1S TA MPJ 1...

Page 2: ...formance The company s concept includes the development manufacture and sale of products for use in automotive workshops by vehicle manufacturers and testing organisations MAHA s claim is to also be a...

Page 3: ...imiting the end position of the cylinders 12 5 4 HAE main switch 12 6 Technical data 13 6 1 Relevant pit dimensions 13 6 2 Nomenclature 14 6 3 Pit jack 15 6 4 Chassis 15 6 4 1 Suspended chassis 16 6 4...

Page 4: ...0 7 3 MPJ HAE 47 10 8 Moving units onto pit jacks 47 10 9 Extend 48 11 Troubleshooting 49 11 1 Manual pneumatic hydraulic pit jacks 50 11 2 Electrohydraulic pit jacks 52 12 Regular and recurring inspe...

Page 5: ...d 79 14 2 2 Overview of components for seal kit 80 14 2 3 Work sequence for changing seal kit 2S 3S pit jacks 80 14 3 Replace hydraulic unit 89 14 3 1 Replace hydraulic unit MPJ 1S 89 14 3 2 Replace h...

Page 6: ...6 BA550001 en Blank page...

Page 7: ...he following is a list of generally applicable safety instructions that must be observed for all work on and with the system Safety instructions for special work are given at the beginning of the rele...

Page 8: ...1 4 Procedure in the event of a malfunction In the event of irregularities during operation lower the lift immediately to the home position or support it Turn off the main switch and secure against u...

Page 9: ...wear ageing and the like will affect the safety of the lift 2 Intended and improper use Observe the maximum axle load according to the load capacity specifica tion on the rating plate of the jack and...

Page 10: ...is not restricted The pit jacks can be combined with different chassis within the limits of a sensible workflow and what is technically feasible There are basically three types of chassis In addition...

Page 11: ...kly The telescopic pit jacks are based on the synchronization principle of all telescopic stages An overflow system is installed for automatic Bleeding of the single stage pit jacks The pump block con...

Page 12: ...ve closes automatically when the button is released All other types are equipped with a drain spindle that opens the drain valve by turning it counterclockwise When the drain spindle is released a spr...

Page 13: ...BA550001 en 13 6 Technical data 6 1 Relevant pit dimensions...

Page 14: ...c steps Telescopic steps S Number of telescopic steps Design of the chassis H Suspended version F Floor Floor running freely movable version T Track Floor running rail guided version Type of drive M M...

Page 15: ...215 410 285 230 215 410 300 510 410 362 572 Actuator 8 max 10 bar at 350 L min x x x x x x x x x x x x Drive 2 5 kW 3 x 400 V 50 Hz 16A x Operating pressure bar 159 254 308 240 195 Stroke mm 750 1200...

Page 16: ...ew For pit jacks up to and including 16 5 t Track width 70 mm adjustable Cylindrical or conical rollers For pit jacks up to and including 16 5 t Track width 70 mm adjustable Cylindrical or conical rol...

Page 17: ...to and including 16 5 t Adjustable track Cylindrical or conical rollers Internal or external rollers Internal chassis roller Cylindrical shape With guide collar Suitable for flat steel min 75 x 10 mm...

Page 18: ...Suitable for flat steel from a width of 55 mm 6 4 3 Freely movable chassis Freely movable chassis run on the pit floor or outside the working pit and bear the code letter F vlg Nomenclature 2 of the 4...

Page 19: ...trucks and buses 16 5 t 750 mm 1S F A MPJ 16 5 750 1S FA T A MPJ 16 5 750 1S TA H M MPJ 16 5 750 1S HM H A MPJ 16 5 750 1S HA H A E MPJ 16 5 750 1S HAE 1200 mm 2S F A MPJ 16 5 1200 2S FA T A MPJ 16 5...

Page 20: ...as the pit jack incl test vehicle plus the safety distances specified in the following table Spatial boundaries Safety distances Front Vehicle 2 m Rear Vehicle 2 m Lateral Vehicle 2 m Top Vehicle lift...

Page 21: ...essories Only use lifting equipment and slings that are suitable in terms of type and per mitted load capacity Always ensure that the parts to be transported are suspended or loaded proper ly and in a...

Page 22: ...tion Report any transport damage to the carrier immediately As the pit jacks are shipped on Euro pallets they can be moved with all standard industrial trucks and crane forks The dimensions and center...

Page 23: ...eration 8 1 Safety instructions WARNING Installation may only be carried out by authorised and trained specialist staff Such specialist staff include authorised trained specialists employed by the man...

Page 24: ...head screws A When using the telescopic pit jack ensure that the cover of the operating unit is secured 3 Using suitable lifting gear lift out the pit jack in an upright position as it sits in the cha...

Page 25: ...Tighten the four hexagon head screws A to fix the pit jack with a tightening torque of 85 5 Nm Note that the collar of the chassis rollers or the entire chassis in particular must be able to move fre...

Page 26: ...ocket A F 19 2 lashing straps Delivery state 1 Attach a round sling tied to the front lifting rollers Then lift the pit jack off the pallet and place it on level ground Remove the round sling Attentio...

Page 27: ...far as it will go Then replace the previously removed M12 screws including washers and tighten them hand tight Align already mounted chassis components load symmetrically on the jack i e the center o...

Page 28: ...urned freely Now pull out the side part until the frets of the chassis rollers are in contact with the pit profile Repeat the process with the second side panel Make sure that both side parts are exte...

Page 29: ...BA550001 en 29 10 mm...

Page 30: ...ressed air line Remove the jack axles including rollers by loosening the four M12 screws on the jack support plate see illustration Raise the chassis using suitable lifting gear so that it cannot tip...

Page 31: ...sis For safety reasons the jack must be disconnected from the chassis during the installation process To do this remove all four hexagon head screws A When using the telescopic pit jack ensure that th...

Page 32: ...hat for disassembly Tighten the four hexagon head screws A to fix the pit jack with a tightening torque of 85 5 Nm 3 Reinsert the reinforcement tubes 4 Push pit jack through the entire working pit At...

Page 33: ...or gearbox jack are fully assembled in the chassis 2 Remove the packaging and attach the pit jack incl chassis to the head plate using two round slings see illustration 3 Lift the pit jack from the E...

Page 34: ...safety Pre position the lifting device and load handling attachment at the pick up points Always pick up the load securely without slipping and centrally to the center of gravity Position the adjusti...

Page 35: ...BA550001 en 35...

Page 36: ...ee section Bleeding 9 4 Foot pump The manually operated foot pump enables precise positioning of the load handling attachments under the vehicle or gearbox This option is available for telescopic pit...

Page 37: ...sure for this but this is at the expense of the displaced volume and therefore the lifting speed Switching from rapid to load stroke is done by changing the position of the hand lever The hydraulic pn...

Page 38: ...operated F Oil sight glass Option G Foot pump H Rapid control manually operated I Load lift control manually operated J Foot pedal K Hand held remote control with magnetic holder L Quick coupling Two...

Page 39: ...BA550001 en 39 I F H G J A E C D K B...

Page 40: ...jack is equipped with a 5 m long cable for the power supply To operate the pit jack an appropriate earthed socket is required within reach of this cable A Master switch B Lift button C Lower button D...

Page 41: ...surfaces Protect all parts of the electrical system from moisture Be careful when running vehicle engines ATTENTION Risk of poisoning During work breaks and at the end of the working day the system mu...

Page 42: ...ning and attaching to the load please note that even when the lift button is released the cylinder can continue to run and extend due to the system Move the pit jack under the load when lowered Move t...

Page 43: ...le for the lifting equipment due to the shape and position of the lifting points may be lifted The load may only be lifted at the component s center of gravity axle gearbox motor etc The vehicle must...

Page 44: ...d extends a little further after the button is released Risk of crushing between piston rod load handling attachment and test vehicle In the standard version the pit jacks are supplied with foot contr...

Page 45: ...tead drive through quickly Press button B to lift The respective button is only active as long as it is held down dead man s switch When a move command is triggered the cylinder moves at a constant sp...

Page 46: ...se A spring acts as an automatic reset This closes the lowering valve and stops the lowering movement When lowering without load the lowering spindle can be turned counterclockwise as far as it will g...

Page 47: ...d down the button and check the lowering speed using the rotary poten tiometer rotary knob 10 8 Moving units onto pit jacks WARNING Removed units must be secured on the load handling attachment If the...

Page 48: ...vehicle the jacks must be in the lower home position to prevent damage to the jacks and vehicle Exit only at walking speed and only if there are no persons in the pit or in the driveway ATTENTION Be c...

Page 49: ...upply or the compressed air supply must be interrupted and secured against being switched on again Maintenance and repair work should only be carried out when the lift is load free Only use original r...

Page 50: ...ncreasingly slower under load and then stops completely Air motor runs dry no oil in the maintenance unit Top up oil Air pressure too low local cause Contact service Air motor first lifts the load a c...

Page 51: ...become faster Oil level on the pit jack too low due to transport damage or natural consumption Top up oil Piston rods rattle inaccurate steering Oil level on the pit jack too low due to transport dam...

Page 52: ...itch box Replace potentiometer customer service Air in the system Loosen the bleed screw under the head plate and press the open button for approx 1 min Hydraulic valve block defective rare Remove the...

Page 53: ...ulic valve block defective rare See above Mech Damage to the pit jack Check the piston rod and guide bush for visible damage Loosen the bleed screw and observe whether the piston rod lowers Try to tur...

Page 54: ...repair has been completed 12 1 2 DL Hoses Dangerous situations can arise due to hose connections coming loose or porous compressed air lines or malfunctions due to leaks in the air lines and connectio...

Page 55: ...pit jack can continue to be used 12 3 Every 6 months 12 3 1 Oil level check NOTICE For measuring and refilling the piston rod must be fully retracted and the pit jack disconnected from the air or powe...

Page 56: ...s can no longer perform their task reliably and must be replaced Rollers and needle bearings must be replaced together to prevent premature failure 12 3 3 Movement parts All moving parts on the pit ja...

Page 57: ...ted at intervals of no more than 12 months In particular safety equipment fastenings and load bearing components must be inspected This inspection must be carried out by a competent person in order to...

Page 58: ...ted from the compressed air supply or the power supply 13 2 Washing cleaning oiling Residues of underbody coating and other uncleanliness can destroy the seals Remove dirt from the piston rod regularl...

Page 59: ...ING Use personal protective equipment Absorb dripping quantities immediately with an oil binding agent or absor bent cloth Dispose of cloths soiled with hydraulic oil in an environmentally friendly ma...

Page 60: ...n Drain oil Provide an oil tight container Remove the screw plugs and sealing rings see illustration below and drain the hydraulic oil into an oil tight container Reseal the oil drain plugs with new s...

Page 61: ...level and the lower end of the dipstick marks the minimum oil level Bleeding via remote control 1 Control the pit jack using the fast stroke B remote control until the pit jack has moved approx 100 2...

Page 62: ...g for approx 100 200 mm 3 Now actuate the fast stroke C pump again and move the pit jack to the mechanical stop Pit jack is now fully extended 4 Actuate the load stroke B pump at the mechanical stop a...

Page 63: ...ee section Bleeding the hydraulic system MPJ 2S 3S Drain oil Absorb dripping quantities immediately with absorbent rags Bind larger quantities with oil binding agent Dispose of rags or saturated bindi...

Page 64: ...ediately afterwards screw in the bleeder valve and tighten it hand tight Ensure that the bleeder valve is closed a small amount of hydraulic oil may escape during this process 4 Connect the pit jack t...

Page 65: ...k 3S 12 liters must be discharged by actuating the load lift 11 As soon as the specified quantity has been removed the bleeder valve is closed first and then the operation of the load stroke is stoppe...

Page 66: ...cessible and cleaned The pit jack is fully retracted and load free The pit jack must be disconnected from the compressed air supply Bleeding block 1 Check the oil level and top up with hydraulic oil i...

Page 67: ...d to the end stop Wait approx 10 seconds until the pneumatic overpressure has been released acoustic test 9 The bleeder valve can now be unlocked and the hydraulic system can be bled and flushed using...

Page 68: ...function and reliability the use of alternative hydraulic oil must be checked by MAHA Drain oil The pit jack must be disconnected from the power supply Provide a 20 l collection container for used oil...

Page 69: ...the oil cap and fit the sheet metal cover Bleeding the hydraulic system 1 Move the pit jack to the end stop and carefully open the screw C by pressing the lift command 2 The screw C must be opened gr...

Page 70: ...eplaced and normalizes within a few operating hours 6 If the piston rod still does not move smoothly bleed the air as often as necessary until smooth movement is achieved CAUTION The bleeding process...

Page 71: ...lay between the lifting rollers and their guide in the chassis The clearance of the lifting rollers in the chassis must be set to min 1 mm and max 2 mm The shims may only be added on the opposite side...

Page 72: ...all parts and any settling behavior For these tests we recommend using a typical vehicle to be lifted with a tare weight of approx 75 of the nominal load The nominal load specified on the rating plate...

Page 73: ...n the drain spindle slightly until the piston rod can be turned by hand the piston rod may drop slightly 6 Disconnect the pneumatic control line from the valve valve is located behind the drain spindl...

Page 74: ...en 7 Place an oil tight container under the hose 8 Remove the wiper using a slotted screwdriver Scraper is destroyed in the process 9 Push the scraper upwards 10 The retaining ring can then be removed...

Page 75: ...ate the load stroke WARNING Danger due to incorrect operation 13 Extend the piston rod using the load stroke as shown in the following picture Hold the piston rod firmly Another person must be consult...

Page 76: ...ture of the sealing package with full equipment is shown here as an example A Scraper NDA 07009510 F Piston rod B O ring NDO 08603 G Guide bushing C O ring NDO 07003 H Spacer bushing D O ring NDO 0300...

Page 77: ...checked for damage 17 Only fit all seals using suitable tools without sharp edges 18 Push all components guide bushing spacer bushing piston onto the piston rod from below and secure with hexagon nut...

Page 78: ...the seals in the cylinder tube are tight the lowering spindle of the pit jack must be actuated so that the piston rod in the pit jack can be lowered Lower the piston rod to approx half the lifting hei...

Page 79: ...stage 2 Material number 1283278 Mounting wrench for guide bushing stage 1 Material number 1283279 Threaded mandrel for telescopic stage 2 Material number 1281312 Threaded mandrel for telescopic stage...

Page 80: ...170x182x10 Rod seal 170x190x16 Guide tape 170x175x25 O ring 230x3 Piston seal 220x200x14 Drain the hydraulic oil see sections Replacing the hydraulic oil to Replacing the hydraulic unit 14 2 3 Work se...

Page 81: ...place on a clean surface Pit jack the hydraulic oil out of the opening 6 The guide bush can be pulled off upwards 7 Loosen the piston using an impact wrench nut A F 46 and cylinder head bolts with A...

Page 82: ...0 mm Lifting the jack off the ground should be avoided 3 Then remove the screw plug in the lower guide bushing Only with MPJ 16 5 1200 3S 4 Pull the piston rod up a further 200 mm The guide bush can t...

Page 83: ...st remove the grub screw The piston can then be unscrewed If this does not come loose there are two M8 threads in the piston crown for attaching a disassembly aid 8 Fit a new set of seals to the clean...

Page 84: ...age and contamination 9 Generously coat the area inside the guide bush with hydraulic oil and push the guide bush onto the cylinder barrel from below Then tighten the piston hand tight and secure with...

Page 85: ...the installation wrench Loosen the guide bush by tapping lightly with a rubber mallet on the installation wrench 4 Pull out the piston rod including piston and guide bushing completely and carefully p...

Page 86: ...urn valve can be seen inside the piston see large arrow Check for damage and contamination and replace if necessary 8 Generously coat the area inside the guide bush with hydraulic oil and push the gui...

Page 87: ...he largest section insert all sections into the pit jack one after the other Make sure that the screw plugs on the largest and smallest guide bushes are not fitted The screw plugs on the pit jack for...

Page 88: ...aded mandrel 7 Insert the remaining sections into the pit jack as described above 8 Install the screw plugs on the largest and smallest guide bush Minimum installation torque of the screw plug 7 1 Nm...

Page 89: ...rained for further steps 1 Remove the four screws on the block hexagon head screw SW13 cylinder head screw A F 6 The hydraulic block can then be removed 2 Clean the surface under the hydraulic block a...

Page 90: ...ove the joint of the drain spindle SW17 and then remove the four screws on the block SW13 The hydraulic block can then be removed 4 Clean the surface under the hydraulic block and fit the new hydrauli...

Page 91: ...Nm M10 8 8 50 Nm M12 8 8 85 Nm 15 2 Load application of the chassis Pit jack type F L1 kN F L2 kN F R1 kN F R2 kN Load application MPJ 4 0 750 1S H 26 93 26 93 5 32 5 32 FG Roll MPJ 16 5 750 1S H 76...

Page 92: ...ut release pull outs approx 14 mm extended to a total width of B dimension 1083 mm Maximum asymmetrical force transmission via rollers into the foundation 15 3 Hydraulic oil filling quantities Pit jac...

Page 93: ...mensions adjustable chassis B min B max mm Outer dimension pushed together mm 580 to 720 660 640 to 780 720 700 to 840 780 760 to 900 840 820 to 960 900 880 to 1020 960 940 to 1080 1020 1000 to 1140 1...

Page 94: ...ture mm mm mm mm 1267244 FG roller conical FG ROLLER 6 30T conical 8 80 40 95 10 Standard 1267245 FG roll RD 95x50 cylindrical 74 40 95 10 VZ 1267253 FG roller FG ROLLER 6 30T conical 14 80 40 95 10 I...

Page 95: ...1267254 FG roller FG ROLLER 6 30T conical 8 80 35 95 15 Collar 15 mm 1267252 N02 31 13 conical 8 66 30 80 10 Roller for U80 profiles 1267249 FG roll conical 14 80 30 95 10 I profile with 14 inclinatio...

Page 96: ...96 BA550001 en 15 6 Electrical circuit diagram MPJ HAE 15 7 Fluid plans 15 8 Operating instructions Maintenance unit 15 9 CE declarations of conformity See following page s...

Page 97: ...N PE 50Hz MAHA Maschinenbau Haldenwang GmbH Co KG Hoyen 20 D 87490 Haldenwang Fuse protection K16A EEL1_MAHA_serie_Farbe Germany Serial Number SN Barcode Dieser Schaltplan wurde f r den maximalen Aus...

Page 98: ...E Page description MAHA_hsc1 Page Cover page 1 Table of contents 2 hschropp Information to the electical diagram 22 06 2012 3 hschropp Documentation 22 06 2012 4 hschropp higher level function overvie...

Page 99: ...r temperature of 45 C 113 F NOTE All operational funds attached before the main switch must be wired with the warning color orange Legend of the color of conductor BK Schwarz Black Noir Nero BN Braun...

Page 100: ...Seite von 3 HEESK FEIN_RevA ZS DOKU 1 0 7 6 8 9 3 8 5 4 4 2 5 Lifter HEE 16 750 Bearb APR Datum Gepr 21 06 2017 Documentation 232 01 004573C F1 F2 K1 T1 U1 V1 X0...

Page 101: ...Seite von 4 HEESK FEIN_RevA ZS DOKU 1 0 7 6 8 9 3 8 S0 6 4 5 2 5 Lifter HEE 16 750 Bearb APR Datum Gepr 21 06 2017 higher level function overview 232 01 004573C overview Lifter A Lifter Control box S0...

Page 102: ...supply K16 A 3 0 kW 7 8 A Hydraulic pump Lifter Delta connection 230V Y connection 400V Jumpers inside Motor terminal board grounding hydraulic unit lid PE X1 L1 T1 L1 T2 L2 T3 L3 Q1 25 A 1 5 mm BU 1...

Page 103: ...ast slow GND F1 T2A F2 T1 25A 13 14 S1 Lifter Up A1 A2 K1 230VAC 4 2kW Hydraulic pump 2 1 6 4 4 3 6 4 6 5 6 5 21 22 7 6 BF 0910 A L1 24V N 0V T1 230VAC 0 22A 24VDC 2 1A V1 33 34 7 6 A2 1 2 13 14 S2 Li...

Page 104: ...0 F908 main switch 25A 4 pole ZS S0 6 0 SONTHEIMER Elektroschaltger te GmbH 50 1002 St ck SONTHEIMER Elektroschaltger te GmbH 1 51 0500 S1 ZS S0 7 1 Moeller GmbH 51 0500 M22 D X 1 51 0592 S1 ZS S0 7 1...

Page 105: ...id valve lowering 0 8 Lowering valve manual 0 9 Flow control valve 0 10 Plunger cylinder Jack cylinder 0 11 Bleeder leak oil valve manual F E D C B A D E B C F A 6 4 8 7 3 2 1 8 7 1 2 3 4 5 6 5 021637...

Page 106: ...0 5 Pump Load lifting manual or pneumatical 0 6 Non return valve with spring 2 0 7 Pump Quick lifting manual 0 8 Non return valve with spring 3 0 9 Non return valve with spring 4 0 10 Pressure relief...

Page 107: ...lve 0 10 non return valve 4 0 11 2 2 directional valve lowering manual 0 12 Non return valve ball lock 0 13 Hydraulic cylinder 0 14 Oil sight glass 0 15 Pneumatic block 0 16 Manual control 0 17 Quick...

Page 108: ...ed in the Festo main catalogue under Compressed airlubricator or Lubricator 3 Screw in the lubricator bowl again 4 Slowly pressurize the system 5 Turn the regulating screw in the oil level indicator u...

Page 109: ...tion of pneumatic control systems 3 Further information Accessories www festo com catalogue Spare parts www festo com spareparts 4 Service Contact your regional Festo contact person if you have techni...

Page 110: ...tridge LFM LFX unscrew the filter cartridge 4 Install new filter cartridge LFR S LF place filter cartridge on the filter plate Screw filter plate in until it stops LFM LFX hold filter cartridge at the...

Page 111: ...he product named hereaf ter meets the safety and health regulations both in design and construction required by the directives stated below This declaration becomes void if any change is made to the p...

Page 112: ...regulations both in design and construction required by the directives stated below This declaration becomes void if any change is made to the product that was not approved by named company beforehand...

Page 113: ...ts sole re sponsibility to ensure that the product named hereaf ter meets the safety and health regulations both in design and construction required by the directives stated below This declaration bec...

Page 114: ...20 PL670000_002 de...

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MAHA MPJ Series, Original Operating Instructions

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