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Rotary AR43-5MB, Operating And Maintenance Manual

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Rotary AR43-5MB Operating And Maintenance Manual Download Page 33

 

9. Maintenance and repair 

  27 

Rev.D 2013_03_en 

9.3  Maintenance work 

 

 

WARNING

 

Potential crushing and shearing 
hazard to limbs caused by uncon-
trolled lowering motion. 

 In particularly dirty environments, maintain the 

post lifts accordingly more frequently.  

 Only perform maintenance on unloaded lifts, 

i.e. without vehicle. 

 Before maintenance work lower the main lift 

completely or lower and latch into the lock 
(locking latches). 

 Turn the main switch to OFF ("OFF

“ setting) 

and lock with a padlock. 

 Cordon off the maintenance area to unauthor-

ized persons (red-white chain, warning notic-
es). 

 Disconnect the air supply (Compressor unit 

manometer to 0 bar). 

 Inform all persons in the area about the 

maintenance work. 

 

 

WARNING

 

Risk to people and the environment 
caused by toxic substances when 
emptying or filling the hydraulic oil 
tank or lubricator (Compressor 
unit). 

 Avoid contact with or inhalation of hydraulic oil 

or Vaseline oil. 

 Provide a suitable oil drain pan and oil absor-

bent.  

 Ensure that used oil does not contaminate the 

soil or wash away into the drainage system. 

 Comply with local regulations for handling wa-

ter pollutants.  

 Dispose of used oil in an environmentally 

friendly manner. 

 Hydraulic oil is highly inflammable, combus-

tible. 

 

 

DANGER

 

Risk of fatal injury if anchor bolts 
are loose. Post lift may slip, the 
load may collapse. 

 Stop operating the post lift. 

 Secure the post lift. If this cannot be done, 

provide an approved foundation then anchor 
and secure the post lift properly. 

 
 
 

Daily inspection 

1. 

Check whether the automatic wheel chocks, 
drive-on ramps, or the chocks and drive-on 

chocks are damaged or show signs of wear.  
Replace damaged or worn parts. 

2. 

Check the function of the locking latches on the 
main lift (visual inspection). To do so, lock the 
main lift in the locking latches then raise and 
tension the cable. 

3. 

Check horizontal alignment of runways. Run-
ways must be horizontally aligned and at the 
same height. If not, correct the alignment 
(

Chapter 13. Commissioning). 

4. 

Check the cables and cable sheaves for wear 
along their entire length (visual inspection). If 
necessary, raise the main lift. Promptly replace 
damaged or worn parts. 

 

 

24

 

 

Cables normally break if they show signs 
some of the damage illustrated here. These 
tend to be damaged, frayed, overstretched, or 
warped cables, sometimes of different diame-
ters. 

 

 

i 

Acceptable, undamaged 
cable 

Unacceptable cable with 
broken strands 

Unacceptable cable -
heavily frayed 

Unacceptable cable 

– 

severely contracted 

Summary of Contents for AR43-5MB

Page 1: ...4 Post Lift AR43 5MB SM40 SM40 47BMW SM40LT SM55 M51VAS SM60 O P E R A T I N G A N D M A I N T E N A N C E M A N U A L Rotary Lift 03 2013 CO6941 3 LP20100 OM20121 Rev D 03 2013 ...

Page 2: ......

Page 3: ... provisions of Machinery Directive 2006 42 EC Furthermore the machine complies with the provisions of the Electromagnetic Compatibility Directive 2004 108 EC and the Low Voltage Directive 2006 95 EC safety standards have been met pursuant to Annex I No 1 5 1 of the Machinery Directive 2006 42 EC Related harmonised standards EN 1493 2010 Vehicle lifts EN ISO 12100 1 2003 Safety of machinery basic c...

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Page 5: ...ractors 18 6 Authorized lowering 21 6 1 Manually lowering the lift when there is a height difference of 50 mm 21 6 2 Leveling the rolling jacks 22 6 3 Emergency manual function 22 7 Technical data 24 8 Cleaning 25 9 Maintenance and repair 26 9 1 Qualification of maintenance and repair staff 26 9 2 Maintenance and repair safety regulations 26 9 3 Maintenance work 27 9 4 Approved hydraulic oils 30 9...

Page 6: ...s grease and other chemical substances 55 16 4 Metals Electronic waste 55 ANNEX SM40 47 SM40 47BMW und SM40 51 Pneumatic circuit diagram wiring diagrams hydraulic circuit diagram spare parts lists SM55 M51 VAS AR43 5MB SM60 51 and SM60 55 Pneumatic circuit diagram wiring diagrams hydraulic circuit diagram spare parts lists SM40LT 47and SM40LT 51 Pneumatic circuit diagram wiring diagrams hydraulic ...

Page 7: ...tion specialists and qualified electricians If you should run into difficulties please contact a specialist our customer service or spare parts department or one of our representatives Illustrations may differ from the supplied version of the machine Functions or processes to be car ried out remain the same 1 2 Warning and information symbols Warnings are identified by the following symbols depend...

Page 8: ...riding on the post lift or the load Lifting when there are people in the vehicle Lifting lowering when people or animals are in the danger zone in particular below the lift Jerky lifting or lowering Do not cause the lift to vibrate Throwing objects onto or under the lift Lifting a vehicle at the incorrect pick up points when using a rolling jack Lifting a load on only one runway of the main lift o...

Page 9: ...ring Always stop the vehicles safely centered on the runways Secure the vehicle against rolling with wheel chocks For lifts with rolling jacks Always lift the vehicle with the rolling jack on the pick up points approved by the vehicle manufac turer Lift it for a short distance and check that the pick up points are secure Only then can the ve hicle be moved to the required height Take steps against...

Page 10: ...n pick up points as in Fig 3 Figure 1 SM40LT with rolling jack Load capacity Main lift 4000 kg Rolling jack 3000 kg Permitted weight distribution Main lift front max 2 3 F1 max 2670 kg back max 1 3 F2 max 1330 kg Rolling jack front max 3 5 F1 1800 kg back max 2 5 F2 1200 kg Figure 2 SM40 AR43 5MB SM55M51 VAS or SM60 Load capacity AR43 5MB 4000 kg SM40 SM40 47 BMW 4000 kg SM55M51 VAS 5500 kg SM60 6...

Page 11: ...ciently familiar with health safety and accident prevention regulations as well as with lift technology in order to be able to assess the oc cupational health safety compliance of lifts 2 6 Maintenance contractors installa tion staff Maintenance servicing and installation work may only be done by companies or specialists authorized by the manufacturer These people trained in the field of lifts are...

Page 12: ...ign modification to parts of the lift Use the form Unscheduled Safety Inspection The initial safety inspection as well as the safety inspections must be carried out by a competent person We recommend that you also perform maintenance in the course of the inspection Unscheduled safety inspections and special maintenance work are required in the event of design modifications to the lift fitting addi...

Page 13: ...unways the vehicle is driven onto the main lift and secured against rolling The vehicle is raised to the desired height with the main lift With optional rolling jack If a rolling jack is used the manufacturer approved pick up points on the vehicle are se lected and the matching supports are placed un derneath After adjusting the selector on the con trol unit and checking that the weight distributi...

Page 14: ...an emergency 3 4 Safety mechanisms See figures 6 15 WARNING Safety mechanisms protect both people and lift They must not be disabled Post lift danger zones are protected by safety mechanisms Function and condition of the safety mecha nisms must be checked daily If safety mechanisms are triggered the post lift stops immediately If safety mechanisms are defective the post lift must be taken out of u...

Page 15: ...king latch notches If a fault occurs in the hydraulic system or if the cable breaks or becomes slack the brake mechanism is activated The cam is pressed against the latch bar through a powerful spring action In addition a lock cam latches via an air piston into the latch bar All up or down movements stop immediately Any further low ering is prevented 4 Locking latch on both rolling jacks The locki...

Page 16: ...k Fitted differently ac cording to variant Before use check assignment to main lift and rolling jack During a power failure the valves close and stop any movement 8 Broken cable and slack cable switch Pos 8 1 Broken cable switch This switch is activated if the cable is broken All movement of the post lift stops immediately The control buttons will not function Consult a com petent person for repai...

Page 17: ...ays Stops the lowering or lifting process if the dif ference in height between the two runways is greater than 50 mm 10 Rolling jack warning stripes yellow black Warning stripes on the rolling jack scissors Hand and finger protection warning otherwise a crushing and shearing hazard may exist dur ing the lifting or lowering process 14 15 ...

Page 18: ...ressed Main lift Locks the cross beams in the latch bars of the four lift columns Keep button pressed until all cross beams lock securely into the latch bars Rolling jack Lowers both runways onto the toothed lock bars ratchets Keep button pressed until both runways lock securely into the latch bars 6 DOWN button in the danger zone below 120 mm For main lifts or rolling jacks Only functions after t...

Page 19: ...hap ter 2 Safety 4 1 Emergency stop 1 To perform an emergency stop set the main switch to OFF OFF setting The main lift or the rolling jack stops immediately 4 2 Switch the machine on 1 Switch on the power supply with the main switch ON setting 2 Check the operational status of the main lift and the rolling jack 3 Check the functionality of the control buttons 4 Check the functionality of the buzz...

Page 20: ...en the lift or rolling jack moves Always monitor the danger zones when lifting or lowering No one must stand in the traffic zone of the lift WARNING Danger of crushing and shearing of limbs foot toe finger etc Possi ble uncontrolled movement when lowering in the danger zone below the runways cross beams or when moving the rolling jack scissors No parts of the body below the runways cross beams or ...

Page 21: ...able is slack press the Up button Raise the lift so that all 4 cables are ten sioned Lowering the main lift or rolling jack 1 Remove all objects in the lift and rolling jack zone in particular under the lift and rolling jacks 2 Set the selector to the desired position 3 Using the Down button steadily lower the lift or the rolling jack until the automatic shut off 120 mm is activated To do so first...

Page 22: ...cable is broken the whole lift is locked Lowering locked Rolling jack Photosensor disconnected Height difference 50 mm Whole lift is locked An object is blocking the downward motion The lower ing process is aborted Load unevenly distributed Settling function still active main lift and rolling jack partly still in the lock position Lock bar ratchets Slack or broken cable on one of the lift columns ...

Page 23: ... into the lock position Pneumatic solenoid valve not supplied with compressed air Check compressor connection Lift button does not work Main lift or rolling jack Runways do not move up Hydraulic oil level too low 1 Refill hydraulics up to gauge mark Chapter 9 4 2 Check with dipstick Attention Using rapeseed based oil destroys the seal Use only biodegradable oils HEES oils based on synthetic esters...

Page 24: ...limit switch Depending on cause Supply the correct voltage to the motor Check all wiring connections and repair or insulate if neces sary Test function of the Up switch Replace if necessary Check function of overhead limit switch Replace if necessary Change hydraulic power unit for motor Up button does not work Runways do not move up main lift or rolling jack Lowering valve is open Pump is sucking...

Page 25: ...s on suction pipe Attach return line Replace hydraulic hoses Runways lift unevenly Height difference in runways Cables are out of adjustment Lift not leveled Floor is uneven Depending on cause Correct the cable tension Chapter 11 11 and 13 4 Reset and accurately level the lift Place spacers shims under neath Chapter 13 Commis sioning Anchor is loose Assembly fault for example drill holes are too b...

Page 26: ...ontrol valve for air supply Locking mechanism is jammed Air cylinder for locking mech anism is dirty Check locking mechanism repair if necessary Lowering process stops abruptly A buzzer sounds the control unit is out of order Cable is too slack Cable broken Depending on cause turn main switch to OFF and lock it Check all cables Replace faulty or warped cables Chapter 9 6 ...

Page 27: ...een activated when the height difference between the runways is above 50 mm the rolling jacks are locked completely The main lift can also no longer be lowered To correct this proceed as follows A buzzer sounds throughout the entire lifting lowering process 1 Secure the danger zone see above 2 Remove the safety cover on the side of the con trol unit 3 Set the selector on the main lift or rolling j...

Page 28: ... both runways are completely lowered onto the floor 4 Turn the main switch to the OFF position wait a short while then turn the main switch to the ON position 5 Carry out a function test The lift is now ready again for operation 6 Attach the side safety cover and screw back into place 6 3 Emergency manual function Even if the post lift fails totally the vehicle can be lowered for example by discon...

Page 29: ... left to lower the main lift to the next lock position 22 7 Repeat the process until the main lift has been lowered completely to the floor 8 Turn the brass screw to the right as far as it will go to close the pressure control valve otherwise the lifting function will not work 9 Screw on the plastic cap 10 Refit the emergency manual valve Make sure that the metal cap is screwed on completely other...

Page 30: ...66 mm 190 mm G H Runway length SM40 47 SM60 51 SM40 51 SM60 55 SM40LT 47 SM40LT 51 Rolling jack 4700 mm 5100 mm 4700 mm 5100 mm 1490 to 2000 mm 5100 mm 5500 mm I J Runway width Rolling jack 560 mm 560 mm 560 mm K Inner distance be tween runways 3 positions 800 mm 950 mm 1100 mm 800 mm 950 mm 1100 mm Motor power rating 3 kW 3 kW Electrical connection 400 v 50 Hz 3 N PE 400 v 50 Hz 3 N PE Compressor...

Page 31: ... not use compressors or high pressure clean ers for cleaning work Always consult a maintenance contractor if you identify a hazard Prior to maintenance make sure that fittings and fixtures are free of oil lubricants and cleaning materials Cables running steel cable must be regular ly lubricated with a suitable lubricant from ex ample from Duotac CRC or Mobil Mobilarma 798 This can significantly in...

Page 32: ...orbing leaking fluids or fluids from oil separators Avoid contact with or inhalation of toxic sub stances such as hydraulic fluid Wear protective clothing for example protective goggles protective gloves etc Before all maintenance and repair work secure the post lift zone with a red white chain and warning notices turn the main switch to OFF OFF Position disconnect the air supply manometer on the ...

Page 33: ...of used oil in an environmentally friendly manner Hydraulic oil is highly inflammable combus tible DANGER Risk of fatal injury if anchor bolts are loose Post lift may slip the load may collapse Stop operating the post lift Secure the post lift If this cannot be done provide an approved foundation then anchor and secure the post lift properly Daily inspection 1 Check whether the automatic wheel cho...

Page 34: ...aintenance and repair 28 Rev D 2013_03_en 5 Test the buzzer Chapter 3 4 Pos 1 A buzzer must also sound when lowering in the foot protection zone If the buzzer is faulty the post lift must not be operated i ...

Page 35: ...an form Clean if necessary 6 Check hydraulic component seals visual in spection 7 Turn main switch to ON ON setting 8 Check that control buttons and switches func tion properly 9 Carry out a function test with and without load 10 Complete a maintenance report Annex Six month maintenance 1 Raise lift and rolling jacks 2 Turn main switch to OFF OFF setting and lock with a padlock 3 Lubricate post li...

Page 36: ...le oils HEES based on synthetic esters Use PTFE seals or foam elastomers if the water content is high ATTENTION Seals may be destroyed if the in correct hydraulic oil is used Do not use rapeseed based oils The water content of the hydraulic oil must not exceed 2 Do not mix bio oils with mineral oils Mixing leads to foaming problems and corrosion damage Make sure that the oil is not contaminated by...

Page 37: ...at the tank is properly sealed 5 Remove oil residues on the floor or on the lift with an approved detergent Dispose of used cleaning cloths in the correct manner 6 Complete a maintenance report Annex An oil change is carried out depending on the extent to which the hydraulic oil has degraded To do so proceed as follows 1 Lower all runways main lift and rolling jack completely turn main switch off ...

Page 38: ...supply remove fitting 8 Change cylinder 9 Reassemble in reverse order Worn ratchets 1 Proceed as above under Change cylinders Pos 1 to 4 2 To safeguard against unforeseen lowering also place suitable supports under the post lift at the lift columns 3 Loosen the ratchet mounting screws 4 Activate the hydraulic system without pressure 5 Disconnect the air supply at the air cylinder fitting 6 Disasse...

Page 39: ... cables must be replaced promptly If cables cable sheaves are damaged inform maintenance contractors and customer ser vice immediately Always replace all cables together as a set If the cable is too slack Chapter 13 Commis sioning Replace cables as per the manufacturers train ing 30 ...

Page 40: ......

Page 41: ...ways transport hydraulic components empty of oil ATTENTION Lift components may be damaged if offloaded incorrectly Do not damage plates on the underside of the lift when lifting Several parts are inserted into the compo nents for example into the runways Offload these carefully to prevent damage When offloading proceed from top to bottom 10 1 Transport The lift is supplied in a packing unit base u...

Page 42: ...ed Raise the runways and cross beams slightly for example set down onto stable wood beams This will also enable you to better route the pneumatic lines and elec trical cables later 12 Remove all other components from the pallet and set down carefully 13 Inspect the supplied parts according to the packing list provided 14 Dispose of packaging in an environmentally friendly manner in compliance with...

Page 43: ...heck the foundation If necessary reinforce the foundations at the point where the lift col umns will be positioned 2 Make preparations for installation Prepare elec trical and pneumatic connections Check the foundation for unevenness and level it out Use spacers and shims 3 Set down both runways and prepare them for assembly 4 Set down both cross beams and prepare them for assembly Disassemble the...

Page 44: ...cturer s specifications 32 Runways must be fitted straight and level Height tolerance 5 mm max difference between di agonals 6 mm Tighter tolerances are defined for the optional wheel alignment kit according to manufactur er s specifications Factor in sufficient space for the approach and drive off Take drive on ramps into account Take note of the maximum bearing pressure under the lift column Tak...

Page 45: ...ds of the runways These must be rolled in under the runways and secured 33 3 Insert the cables into the cable sheaves of the runways Make sure they are correctly positioned in the cable sheaves 4 Lubricate the cable sheave grooves on both front ends of the fixed runways for grease see Chapter 9 4 34 5 Insert the fitting metal guard for flexible hoses from inside and outside into the fixed runway a...

Page 46: ...wo distance sleeves 3 and take out the cable sheave 5 5 Route the cable assembly with the electrical pneumatic and hydraulic lines through the fit ting Fig 34 6 If the optional lighting is used route the lighting power cable into the cable conduit of the run ways and cross beams and through the fitting Fig 34 ...

Page 47: ...ss beam and are not crossed 2 Fit the cross beam cable sheaves Fig 30 and 33 To do so insert the cable sheave and the two distance sleeves into the cross beam for each cross beam Slide the greased axle into the side and secure the guide 11 8 Fasten the runways to the cross beams 39 1 Align the fixed and adjustable runways with the cross beam mounting holes S at the front and back In doing so make ...

Page 48: ...ll gap 2 Insert latch bar and slide almost to the floor leave a small gap for the lift column base plate 11 10 Assemble the lift column Proceed as follows on all 4 lift columns Make sure the lift column with the control unit is correctly positioned 1 Set down the lift column onto the assembly po sition with a forklift truck 2 Slide the lift column from the back onto the latch bar and align approxi...

Page 49: ...11 Assembly 43 Rev D 2013_03_en cross beams leaving a 1 mm gap and align pre cisely using a spirit level ...

Page 50: ...hrough bolt anchor HST HST R and HST HCR M16 Fischer Anchor bolt FAZ II M16 Fischer High bond anchor FHB II chem M16x95 Würth FAZ M20 M16 Anchor bolt clamping zone The clamping zone for these anchor bolts is the sum of the non bearing flooring plus the thickness of the column base plateof 12 mm 7 Fit the 4 lift columns onto the shims with ap proved nuts and bolt locking devices Select the tighteni...

Page 51: ...Attach the flexible hose 47 8 Route the cable assembly with the electrical pneumatic and hydraulic cables through the flexible hose into the control box 9 Make sure that the flexible hose sits securely in the metal fitting of the fixed runway 10 Then tighten the 2nd metal fitting on the control box 11 13 Assemble the hydraulics module Only qualified staff with specialist knowledge and experience o...

Page 52: ...k SM40LT with 2 emergency manual valves metallic fittings for main lift black fittings for rolling jacks SM40 AR43 5MB SM55 M51VAS and SM60 with 1 emergency manual valve 4 Open the tank cap and fill the tank with 11 liters of hydraulic oil For approved hydraulic oil types see Chapter 9 4 49 50 ...

Page 53: ...ched to O when working on the electrics of this machine The mains power supply must be disconnected at the fuse box disconnect the mains fuse and isolated to prevent accidental reconnection A clearly visible warning sign must be attached accordingly 12 2 Connect the lift power supply 51 1 Disconnect the mains fuse and attach a sign warning against reconnection 2 Connect the cable assembly terminal...

Page 54: ...ernatively 3 x 230 V connection Change the wiring on the transformer arrow Fig 54 to 230 V Remove the six M5 nuts in the motor connection box bridge U1 W2 V1 U2 W1 V2 according to the diagram and tighten the nuts again 8 Make sure that the equipment is properly earthed Do not connect the earth conductor to gas water or telecommunications installations 9 Attach the motor connection box cover 10 Che...

Page 55: ...fety shut off for the rolling jack in the same way Test the Anti Misalignment on the rolling jacks 5 Raise the rolling jacks with the Up button 6 Mask the photosensors between the runways 7 Push the Down button whilst turning the selec tor to main lift and rolling jack respectively The Down function must be deactivated Neither the main lift nor the rolling jacks may be low ered 8 Remove the adhesi...

Page 56: ...sting nuts 1 In each case place shims underneath When aligning the lift columns push against the cross beam so that there is a gap of 0 5 mm be tween the two guides and cross beam Then place shims underneath 6 Tighten all 4 anchor bolts with the correspond ing torque Chapter 11 8 Tightening torque table Fine adjustments to the latch bars and cables 1 Ensure that no vehicle is on the lift or the ro...

Page 57: ...of the cables 5 on the 4 lift columns slightly 14 Turn the main switch to ON and lower the main lift to the floor The rolling jacks are already height adjusted ex works and do not need to be leveled Adjust the cables 1 Drive a vehicle with a total weight of 2000 kg centered onto the main lift Make sure that the vehicle is also centered laterally on both run ways 2 Push the Up button until all cabl...

Page 58: ...plate on the approach side drive on ramp side 2 Insert the slip plate so that both bolts protrude from the underside of the runway 60 3 Secure the slip plate use the corresponding thread locker and nuts 4 Insert the two locking pins B 5 Remove the base plate on the drive off side automatic ramp chock end 61 6 Insert the filler plate in such a way that all bolts protrude from the underside of the r...

Page 59: ...the lift so that the front wheels stand on the turning radius gauge and the rear wheels on the slip plate The vehicle must come to a halt virtually cen tered on the lift in the direction of motion 6 Loosen the lock pins on the turning radius gauge and slip plates Make sure that the vehi cle can now slip easily on the plates and that no tension exists so that the adjustment work can be carried out ...

Page 60: ...To do so loosen the jam nuts on the threaded rods and raise or lower the latch bar with the adjusting nut Make sure that all 4 wheel footprints have the same height reading 15 Then tighten the jam nuts of the threaded rods again 16 Archive the measurement report with the updat ed measurements For your safety lock the post lift in the 4 latch bars during wheel alignment locking latch Only then may ...

Page 61: ...oss beams and runways Chapter 10 and 11 16 Disposal 16 1 Environmental procedures for dis posal Prevent environmental hazards Avoid contact with or inhalation of toxic sub stances such as hydraulic fluid Oils and lubricants are water pollutants under the terms of the Water Management Act WGH Al ways dispose of these in an environmentally friendly manner in compliance with the regula tions which ap...

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Page 64: ...el 49 771 9233 0 USA 1 812 273 1622 Headquarter Hüfinger Straße 55 Fax 49 771 9233 99 Canada 1 905 812 9920 D 78199 Bräunlingen info blitzrotary com United Kingdom 44 178 747 7711 www blitzrotary com Australasia 60 3 7660 0285 ...

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