Rotary Lift ML40, Operation & Maintenance Manual

Page 1: ...Rheinland TUV O P E R A T I O N M A I N T E N A N C E M A N U A L O P E R A T I O N M A I N T E N A N C E M A N U A L October 2006 by Rotary Lift Rev B 03 2013 ML40 ML50 Scissor Lifts...

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Page 3: ...pat ibility safety objectives were complied with according to Annex I no 1 5 1 machine directive 2006 42 EG Applied harmonized standards EN 1493 1998 A1 2008 Vehicle lifts EN ISO 12100 1 2003 Safety o...

Page 4: ...ety 12 3 7 Safety instructions in regard to specific energy systems 13 3 7 1 Electrical system 13 3 7 2 Hydraulic system 13 3 7 3 Mechanical system 13 3 7 4 Surface temperature 14 3 8 Safety devices o...

Page 5: ...30 9 3 Cleaning the machine 30 9 4 Inspecting the sliding bearings 31 9 5 Servicing the hydraulic system 31 9 5 1 Checking the hydraulic oil level 32 9 5 2 Changing the hydraulic oil 32 9 5 3 Bleedin...

Page 6: ...to the extent that legal regulations permit Proprietary note 2008 BlitzRotary GmbH H finger Stra e 55 78199 Br ulingen Germany All rights reserved Photocopying reproducing translating or recording ont...

Page 7: ...ine is overloaded improperly handled or spare parts have been im properly installed and thereby cause damage 1 5 Transport damage All deliveries are to be insured by the customer We will not honor any...

Page 8: ...tion By pressing the Lift control on the control device the electric motor of the hy draulic unit is switched on The oil pump of the hydraulic unit pumps hydraulic oil into the hydraulic cylinders The...

Page 9: ...ble stroke 1 670 mm Platform length 4 800 mm Platform width 729 mm Platform surface plain sheet Weight 3 500 kg Electrical system Connection 3Ph400V PE 50Hz 16A Power 3 6 kW N NAT 4 0 kW LT LTAT Curre...

Page 10: ...ronment cannot be ruled out All work on the machine may only be performed by qualified and authorised per sons who have read the relevant sections in this operating manual and agree to observe them Fo...

Page 11: ...l data page 7 The machine may only be used as intended Severe injuries or equipment dam age can result from improper use This is not the responsibility of the manufac turer of the machine but of the o...

Page 12: ...cture of the warning notices The warning notices of this operating manual have an identical basic structure DANGER Type and source of danger Possible consequences of non observance Avoidance measures...

Page 13: ...The following icons are examples Icon Meaning Warning of a danger to persons Warning of electrical shock Warning of points where crushing can occur Warning of health hazards posed by toxic substances...

Page 14: ...disabled or have their functions restricted The maintenance and inspection intervals specified in this operating manual are observed Chap 9 Maintenance and inspections page 29 All safety and warning...

Page 15: ...lines so that they do not pose a stumbling hazard and so that damage due to falling objects pinching or abrasion is avoided Do not lay lines around moving components and ensure that the lines cannot c...

Page 16: ...Due to friction certain components particularly of the hydraulic system can have high surface temperatures Before inspections and maintenance work allow the machine to cool down Use personal protectiv...

Page 17: ...the lowering process in order to prevent crushing and other hazards The sensor for the Euro Stop must be set at the time of initial commissioning Chap 6 3 2 Euro Stop sensor page 23 3 8 4 Main switch...

Page 18: ...Basic safety instructions 16 3 9 Safety and warning notices The machine is labelled with various notices The notices should always be present and in legible condition Note Maximum load capacity...

Page 19: ...perienced persons authorised to do so and using this operating manual as a basis Instructed persons confirm in writing the scope of instruction received and their successful completion of it 3 11 Safe...

Page 20: ...ast correspond to the dead weight of the machine see load capacity plate type plate or Chap 2 3 Technical data page 7 Wear a protective helmet Do not step under suspended loads 4 2 Transport to the in...

Page 21: ...pe higher than IP 54 The ambient temperature must lie between 10 C and 40 C The installation site must provide a sufficiently load bearing and level foun dation The flooring at the installation site m...

Page 22: ...rences at the designated corners X Compensate for the differences at the corners with base plates laid under neath X Erect the machine at the installation site X Check the machine with a water level a...

Page 23: ...the connection diagrams The fitting of the hydraulic hoses is completed 5 4 Electrical installation WARNING High electrical voltage Severe injury or death from electrical shock Only trained electricia...

Page 24: ...ng on the machine X Notify your supervisor of the detected damage X Only use the machine if all damage has been repaired X Remove any foreign objects from the danger zone Fig 3 1 page 14 X Remove mate...

Page 25: ...op are located on the outer sides of both lifting units They are to be adjusted so that the lift platform stops if the distance between the upper edge of the underframe and the lower edge of the upper...

Page 26: ...ges in the position of the load NOTICE Incorrect operation Severe damage to the machine Avoid repeated sudden jolts when lifting and lowering the platform Before beginning each work shift X Inspect th...

Page 27: ...itch Setting the switch to 1 switches on the power supply control lamp A lights up Setting the switch to 0 switches off the power supply control lamp A goes dark The main switch can be locked with a p...

Page 28: ...ting unit and the wheel free lift 8 Moving platform lock control Switching the control locks unlocks the moving platform 7 3 Lifting and lowering the vehicle Fig 7 2 Vehicle on the platform NOTICE Inc...

Page 29: ...he platform When the Euro Stop sen sor is reached the lowering motion stops X Press the Lower control again The platform continues lowering more slowly A warning tone sounds X Lower the platform compl...

Page 30: ...appropriate for the storage condi tions and length of time to be stored X When putting the machine back into operation perform commissioning and an additional inspection Chap 6 Starting up page 22 Ch...

Page 31: ...ised persons from accessing the work area of the machine X Attach or erect a notice sign prohibiting switching on the machine and inform ing that the machine is undergoing maintenance X Remove the loa...

Page 32: ...n Replace them if necessary X Clean the running surfaces of the castors The cleaning is completed What When Description Clean the machine as needed at least 1x yearly Chap 9 3 page30 Inspect the slidi...

Page 33: ...subject to legal regulations Bring used oil to an authorised collection point For more information contact the responsible administrative offices Take care not to spill any hydraulic oil Take measure...

Page 34: ...e Lift control on the control device Fig 7 1 page 25 until no more hydraulic oil runs out of the hoses X Reattach the hydraulic hoses to the hydraulic cylinders X Remove the bleeder screw from the tan...

Page 35: ...e bleeder screws 6 on both slave hydraulic cylinders The pressure thereby decreases and the oil air mixture escapes X Screw in the bleeder screws 6 until they are about halfway screwed in about 3 revo...

Page 36: ...ew the bleeder screws 6 on the hydraulic cylinders approximately 3 to 4 revolutions and allow the air to escape X Carefully operate the Lift control inching mode until both platforms have reached the...

Page 37: ...switch S8 in the control column The control light flashes X Press the Lift control until oil flows out of the hoses the master slave con nection hoses are filled X Mount the hydraulic hoses on the cyl...

Page 38: ...aulic system is completed 9 5 4 Checking the hydraulic hoses For hydraulic hoses a yearly inspection of operationally safe condition is pre scribed The inspection must be performed by a qualified and...

Page 39: ...thorised specialist after each servicing and every repair of a malfunction An additional inspection is likewise required if the machine is to be restarted after being temporarily put out of service In...

Page 40: ...legible Welded points undamaged All screw connections are tight Hydraulic system No leaks in the hydraulic system Oil level is sufficient Chap 9 5 1 page32 No damage of the hoses Hydraulic hoses not...

Page 41: ...sure Replace hydraulic unit Motor turning in wrong direction Check the rotational direction of the voltage supply only for rotary current Factory supplies a right rotating field Top sensor position wa...

Page 42: ...tive Replace the solenoid Lowering valve defective Replace lowering valve Solenoid valve plug defective Replace solenoid valve plug Controller fuse defective Replace controller fuse Line break safety...

Page 43: ...Appendix 41 11 Appendix...

Page 44: ...Appendix 42 Mechanical components...

Page 45: ...130 2 Bearing pin 10 16 405 140 2 Bushing 10 02 294 150 2 Bushing 10 02 284 160 4 Sliding block 10 28 049 170 1 E chain R435 1 2 3 180 4 Castor R435 1 4 3 1 190 1 Axle R435 1 4 3 2 200 1 Axle R435 1...

Page 46: ...Appendix 44 Mechanical components...

Page 47: ...r 12 40 076 ISO 7093 8 100HV 15 4 Locknut 12 55 042 DIN 985 M8 8 16 2 Washer 12 40 076 ISO 7093 8 100HV 17 2 Locknut 12 55 042 DIN 985 M8 8 18 4 Hexagon bolt 12 50 041 ISO 4017 M8x16 8 8 19 4 Washer 1...

Page 48: ...1 14 4 Washer 12 40 076 ISO 7093 8 100HV 15 4 Locknut 12 55 042 DIN 985 M8 8 16 2 Washer 12 40 076 ISO 7093 8 100HV 17 2 Locknut 12 55 042 DIN 985 M8 8 18 4 Hexagon bolt 12 50 041 ISO 4017 M8x16 8 8 1...

Page 49: ...er 12 40 076 ISO 7093 8 100HV 15 4 Locknut 12 55 042 DIN 985 M8 8 16 2 Washer 12 40 076 ISO 7093 8 100HV 17 2 Locknut 12 55 042 DIN 985 M8 8 18 4 Hexagon bolt 12 50 041 ISO 4017 M8x16 8 8 19 4 Washer...

Page 50: ...21 14 4 Washer 12 40 076 ISO 7093 8 100HV 15 4 Locknut 12 55 042 DIN 985 M8 8 16 2 Washer 12 40 076 ISO 7093 8 100HV 17 2 Locknut 12 55 042 DIN 985 M8 8 18 4 Hexagon bolt 12 50 041 ISO 4017 M8x16 8 8...

Page 51: ...12 40 076 ISO 7093 8 100HV 15 4 Locknut 12 55 042 DIN 985 M8 8 16 2 Washer 12 40 076 ISO 7093 8 100HV 17 2 Locknut 12 55 042 DIN 985 M8 8 18 4 Hexagon bolt 12 50 041 ISO 4017 M8x16 8 8 19 4 Washer 12...

Page 52: ...14 4 Washer 12 40 076 ISO 7093 8 100HV 15 4 Locknut 12 55 042 DIN 985 M8 8 16 2 Washer 12 40 076 ISO 7093 8 100HV 17 2 Locknut 12 55 042 DIN 985 M8 8 18 4 Hexagon bolt 12 50 041 ISO 4017 M8x16 8 8 19...

Page 53: ...r 12 40 076 ISO 7093 8 100HV 15 4 Locknut 12 55 042 DIN 985 M8 8 16 2 Washer 12 40 076 ISO 7093 8 100HV 17 2 Locknut 12 55 042 DIN 985 M8 8 18 4 Hexagon bolt 12 50 041 ISO 4017 M8x16 8 8 19 4 Washer 1...

Page 54: ...1 14 4 Washer 12 40 076 ISO 7093 8 100HV 15 4 Locknut 12 55 042 DIN 985 M8 8 16 2 Washer 12 40 076 ISO 7093 8 100HV 17 2 Locknut 12 55 042 DIN 985 M8 8 18 4 Hexagon bolt 12 50 041 ISO 4017 M8x16 8 8 1...

Page 55: ...Hydraulikplan 15 33 831 Datum Name Gepr Norm Zust nderung Datum Name Ma stab Urspr Ers f Ers d Blatt 1 5 07 02 2008 Konradt R400 HY2_2 R400 HY2_2 Bearb CAD 1 Korrektur 14 04 2008 R W ML40 ML50 N NAT...

Page 56: ...Hydraulikplan 15 33 832 Datum Name Gepr Norm Zust nderung Datum Name Ma stab Urspr Ers f Ers d Blatt 1 5 07 02 2008 Konradt R400 HY2 R400 HY2 Bearb CAD 1 Korrektur 14 04 2008 R W ML40 ML50 LT LTAT...

Page 57: ...atikplan 15 33 833 Datum Name Gepr Norm Zust nderung Datum Name Ma stab Urspr Ers f Ers d Blatt 1 1 05 03 2008 Konradt R400 PN1 R400 PN1 Bearb CAD 1 Korrektur 15 04 2008 R W 17 04 2008 ML40 ML50 M50 N...

Page 58: ...tikplan 15 33 834 Datum Name Gepr Norm Zust nderung Datum Name Ma stab Urspr Ers f Ers d Blatt 1 1 05 03 2008 Konradt R400 PN3 R400 PN3 Bearb CAD 1 Korrektur 15 04 2008 R W 17 04 2008 ML40 ML50 M50 LT...

Page 59: ...otary Blatt Bl 1 1 ML40 50 Serie ML_40_50 Deckblatt 1 AB Nr Ger te Nr terminal supply voltage supply frequency Nominal power Nominal current Control voltage Signal voltage fuse Line cross section degr...

Page 60: ...7 PE PE br gr S01 8 4 D2 S01 7 4 C2 PE terminal board X2 terminal board X3 10 E2 N 1 3 5 2 4 6 2 1 3 4 5 6 97 98 95 96 10 C2 N Bimetal 1 4G1 5qmm N ML40 U V 7 2A 3 6kW Hydraulic pump ML40 W PE 2 3 PE...

Page 61: ...rie ML_40_50 S 2 Ger te Nr AB Nr L1 1 A8 L2 1 A8 L3 1 A8 PE 1 A8 K1 Kl 3 1 B8 K1 Kl 1 1 B8 24V DC L1 L2 0V 24V PE N supply unit 5A 400V AC 5A L 3 A1 L 3 A1 L1 L2 L3 PE 3 A1 Ersatz f r Ersatz durch nde...

Page 62: ...Q1 Q2 L L M M 8xDI 4xDO 24VDC I5 7 D5 7 D6 7 D7 7 D8 I6 I7 I8 10 B5 10 B7 Q3 Q4 N I1 8 D3 8 D4 8 D5 8 D7 11 B2 11 B4 I2 I3 I4 Q1 Q2 L L M M 4xDI 4xDO 24VDC 11 B5 11 B7 Q3 Q4 N RUN STOP I1 9 D3 9 D4 9...

Page 63: ...1 B2 4 2 N hoist 13 14 N Lower 21 22 N Lower to rests 21 22 5 6 13 14 7 13 14 LT 8 13 14 N 9 13 14 ATP 10 When starting up flashing light 11 In operation continuous light N X1 X2 3 PE N X1 X2 Sound tr...

Page 64: ...40_50 S 5 Ger te Nr AB Nr L 4 A8 L 3 A8 PE 4 A8 1 br 3 0 34qmm N S 1 3 4 2 sw 4 3 bl 1 br 3 0 34qmm N S 1 3 4 2 sw 4 3 bl 1 br 4 0 34qmm N 1 3 2 4 sw 4 3 bl 1 br 4 0 34qmm N 1 3 2 4 sw 4 3 bl L 6 A1 L...

Page 65: ...S br 4 0 34qmm ws 12 12 br 4 0 34qmm ws 4 grau 4 bl bl N SUB D plug N SUB D plug 1 rot 10 0 25qmm 1 br 3 0 34qmm LT Eurostop wheel free lift 1 3 2 4 sw 2 blau 2 2 blau 2 br 3 0 34qmm LT Eurostop whee...

Page 66: ...LOGO 24 DC I1 N Lower 3 B2 DI LOGO 24 DC I2 N Lower to rests 3 B2 DI LOGO 24 DC I3 N Switch for main lift unit wheel free lift 3 B2 DI LOGO 24 DC I4 N Preset position 1 3 B2 DI LOGO 24 DC I5 Stromlauf...

Page 67: ...5 E8 A2 I1 5 E8 N Eurostop on left platform 3 B4 DI DM 8 24DC I1 N Eurostop on right platform 3 B4 DI DM 8 24DC I2 N Synchronisation monitor 3 B4 DI DM 8 24DC I3 13 14 N Bypass for synchronisation mon...

Page 68: ...F8 LT Eurostop wheel free lift 3 B5 DI DM 8 24DC I1 1 4 0 75qmm 13 14 N Filling master slave cylinder of wheel free lift 2 LT Filling master slave cylinder of wheel free lift 3 B5 DI DM 8 24DC I2 LT L...

Page 69: ...tor contactor hydraulic pump 1 B6 1 B6 1 B6 1 3 5 2 4 6 N Lower left track of main lift unit 3 B2 DO LOGO 24 DC DO Q2 1 Q2 2 1 3G0 75qmm N 2 1 PE 2 PE N Lower right track of main lift unit 3 B2 DO LOG...

Page 70: ...Q1 2 A2 Q1 4 B8 A1 24V 4 E8 A2 Q2 4 A8 N When starting up flashing light 3 B4 DO DM 8 24DC DO Q2 1 Q2 2 N Pneumatic valve lock 3 B4 DO DM 8 24DC DO Q3 1 Q3 2 1 3G0 75qmm ATP 2 1 PE 2 PE N Solenoid val...

Page 71: ...5qmm LT 2 1 PE 2 PE LT SV additional lift unit switch for wheel free lift 3 B5 DO DM 8 24DC DO Q2 1 Q2 2 1 3G0 75qmm LT 2 1 PE 2 PE LT SV master slave line filling additional lift unit 3 B5 DO DM 8 24...

Page 72: ...Schere Hubende SW1 PS schlie er schlie er PS ffner P 1 2 3 4 5 6 7 8 Stromlaufplan Sensor bersicht ML40 1 2 3 4 5 6 7 8 A B C D E F A B C D E F Blitz Rotary Blatt Bl 13 15 ML40 50 Serie ML_40_50 13 Ge...

Page 73: ...ni 2 schwarz 5 5 5 6 6 6 7 7 7 8 8 8 9 9 9 24 Volt Eurostopp blau Gleichlauf Ini 1 blau Gleichlauf Ini 2 blau 10 11 12 Gleichlauf Inititor 1 schwarz Gleichlauf Initiator 2 braun Gleichlauf Initiator 2...

Page 74: ...L N PE BLS plug Lighting PE 2 1 3G0 75qmm PE 2 1 3G0 75qmm 1 4 0 75qmm 13 14 23 24 BLS desk 3 2 br 3G1 5qmm 1 BLS 2 4 11 bl 2 PE 3 4 5 6 7 8 9 BLS Fluorescent lamp 36 watts L N PE BLS Fluorescent lamp...

Page 75: ...er tekommentar Kabel extern Kabel intern Kommentar Darstellung Anz freier Adern Anz freier Adern Anlage Einbauort Ger t Anschlu Ger tekommentar Typ AB Nr Ger te Nr 0 Leiste St 3 Klemmenanzahl 3 X4 2 1...

Page 76: ...er tekommentar Kabel extern Kabel intern Kommentar Darstellung Anz freier Adern Anz freier Adern Anlage Einbauort Ger t Anschlu Ger tekommentar Typ AB Nr Ger te Nr 0 Leiste St 4 Klemmenanzahl 3 X4 3 1...

Page 77: ...freier Adern Anz freier Adern Anlage Einbauort Ger t Anschlu Ger tekommentar Typ AB Nr Ger te Nr 0 0 Leiste X4 Klemmenanzahl 14 1 S10 13 desk St 3 1 2 S10 14 St 4 1 3 4 5 6 7 8 9 10 S10 23 desk St 3...

Page 78: ...er tekommentar Kabel extern Kabel intern Kommentar Darstellung Anz freier Adern Anz freier Adern Anlage Einbauort Ger t Anschlu Ger tekommentar Typ AB Nr Ger te Nr 1 Leiste ES 1 Klemmenanzahl 3 120mm...

Page 79: ...Ger tekommentar Kabel extern Kabel intern Kommentar Darstellung Anz freier Adern Anz freier Adern Anlage Einbauort Ger t Anschlu Ger tekommentar Typ AB Nr Ger te Nr 1 Leiste ES 2 Klemmenanzahl 3 120mm...

Page 80: ...extern Kabel intern Kommentar Darstellung Anz freier Adern Anz freier Adern Anlage Einbauort Ger t Anschlu Ger tekommentar Typ AB Nr Ger te Nr 0 Leiste Pos 1 Klemmenanzahl 3 Lift stroke end N SW1 1 N...

Page 81: ...tekommentar Kabel extern Kabel intern Kommentar Darstellung Anz freier Adern Anz freier Adern Anlage Einbauort Ger t Anschlu Ger tekommentar Typ AB Nr Ger te Nr 0 Leiste Pos 2 Klemmenanzahl 3 Positio...

Page 82: ...extern Kabel intern Kommentar Darstellung Anz freier Adern Anz freier Adern Anlage Einbauort Ger t Anschlu Ger tekommentar Typ AB Nr Ger te Nr 0 6 Leiste St 1 Klemmenanzahl 4 X2 1 1 ES 2 1 St 2 1 X2 2...

Page 83: ...rn Kommentar Darstellung Anz freier Adern Anz freier Adern Anlage Einbauort Ger t Anschlu Ger tekommentar Typ AB Nr Ger te Nr 0 5 Leiste St 2 Klemmenanzahl 5 X3 1 1 St 1 1 St 1 2 2 X3 2 Logo add on mo...

Page 84: ...wheel free lift LT SW8 1 St 1 1 Synchronisation monitor 1 N SW9 1 1 24Volt Eurostop wheel free lift LT SW8 2 St 1 2 2 3 Synchronisation monitor 2 N SW9 1 2 4 St 1 4 4 5 6 7 8 Eurostop wheel free lift...

Page 85: ...iste X3 Klemmenanzahl 17 Lift stroke end of wheel free lift LT SW5 1 St 2 1 1 Eurostop wheel free lift LT SW8 1 2 St 2 2 2 Eurostop wheel free lift LT SW8 1 3 St 2 3 3 4 Lift stroke end of wheel free...

Page 86: ...watts 15 D7 10 30 816 Befestigungssatz f r Leuchstoffleuchte TECHMALUX 599 001 017 E BLS E3 BLS E3 10 BLS E4 Fluorescent lamp 36 watts 15 E7 10 30 815 230V 50Hz 36W Leuchstoffleuchte TECHMALUX 591 103...

Page 87: ...SW8 1 LT SW8 1 29 LT Y3 11 D8 10 30 048 Magnetspule 24VDC R GR 08 24 Y LT Y3 LT Y3 30 LT Y3 11 D8 10 30 392 MV Leitung MSUD 24V AC DC 5m MURRELEKTRONIK 7000 18021 2160500 W LT Y3 LT Y3 31 LT Y5 12 D4...

Page 88: ...N S3 N S3 51 N S4 Lower to rests 4 D3 10 30 573 Taster Senken TAIWAN S N S4 N S4 52 N S6 4 C5 10 30 586 Taster schwarz Fronteinbau TAIWAN S N S6 N S6 53 N S8 Filling master slave cylinder of wheel fr...

Page 89: ...N SW4 70 N SW4 5 C7 10 30 747 Rundsteckverbinder M12 4pol Stift gerade MURRELEKTRONIK 7000 1271 000 0000 X 27605 N SW4 N SW4 71 N SW9 Synchronisation monitor 1 6 B2 10 30 584 Art Nr 50081347 Reflexio...

Page 90: ...6 10 30 392 MV Leitung MSUD 24V AC DC 5m MURRELEKTRONIK 7000 18021 2160500 W N Y2 N Y2 84 N YPH1 10 D7 10 30 048 Magnetspule 24VDC R GR 08 24 Y N YPH1 N YPH1 85 N YPH1 10 D7 10 30 818 MV Stecker Pneum...

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Page 92: ...gional Sales Office Rotary Lift UK LTD Halstead Essex Phone 44 178 747 7711 Fax 44 178 747 7720 sales rotarylift idps co uk Austral Asia Regional Sales Office Rotary Lift Austral Asia Petaling Jaya Ma...