Rotary SGL35, Operating And Maintenance Manual

Page 1: ...sss1 Introduction 2 Post Vehicle Lift SGL35 O O P P E E R R A A T T I I N N G G a a n n d d M M A A I I N N T T E E N N A A N N C C E E M M A A N N U U A A L L Rotary Lift 03 2013 117592 Rev C ...

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Page 3: ...he EC Directives 2004 108 EC relating to electromagnetic compatibility and 2006 95 EC relating to electrical equipment Protection objectives have been met in accordance with Annex I No 1 5 1 of the Machinery Directive 2006 42 EC Harmonised Standards used EN 1493 2010 Vehicle lifts EN ISO 12100 1 2003 Safety of Machinery Basic concepts EN ISO 12100 2 2003 Safety of Machinery Basic concepts EN 60204...

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Page 5: ...he system 13 6 Action in the event of a fault 14 6 1 Operator troubleshooting 14 6 2 Troubleshooting for competent persons15 6 3 Emergency lowering 17 6 4 Recommissioning the lift after incorrect alignment of the slider blocks 18 7 Maintenance 19 7 1 Maintenance staff qualification 19 7 2 Safety regulations 19 7 3 Maintenance schedule 19 7 4 Cleaning 20 7 5 Check the hydraulic oil level 20 7 6 App...

Page 6: ...ed form Installation record must be sent to the manufacturer to verify the installation of the lift The Inspection logbook contains forms for verifying the initial regular and unscheduled safety inspections Use the forms to record the inspections and add the completed forms to the inspection logbook Design modifications must be entered in the Machine master data sheet The machine operator is respo...

Page 7: ...rating manual does not contain information and instructions with actions in the event of accidents and health risks The in house operating instruction must be supplied by the operator of the lift 1 5 Warning and information symbols Warnings are identified by the following symbols depending on the hazard classification Be especially aware of safety and hazards when working in situations identified ...

Page 8: ...hicle 2 2 Incorrect use Incorrect use presents a residual risk to the life and health of the people working in the lift zone The manufacturer assumes no liability for damage resulting from use other than the intended purpose and misconduct The following is prohibited Climbing onto or riding on the load or pick up equipment Loitering under the load when raising or lowering Raising vehicles loaded w...

Page 9: ...st lift 1 Primary column 2 Secondary column 3 Drive through ramp 4 Control unit 5 Hydraulic unit 6 Column base plate 7 Arm 8 Adapter 9 Slide 10 Base plate support optional extra 11 Lever for latch mechanism 12 Latch mechanism cover 13 Hole for anchor bolts 14 Cover plate 1 ...

Page 10: ... 50 Hz Rise time sec 40 Required ceiling height mm 3170 2 3 4 Identification of lift The customer service department of your authorised dealer can react quicker to your maintenance queries if you specify the lift serial number and any possible accessories The information below is given on the information plates BlitzRotary GmbH Hüfinger Str 55 78199 Bräunlingen Deutschland Telephone 49 771 9233 0 ...

Page 11: ...placed on the long or the short arms P1 1 3 P2 2 3 of the maximum load Figure 3 Minimum distance between two adapters Not less than 1000 mm If the distance is less the load capacity of the lift will be reduced The weight distribution must match the guidelines specified in this chapter We therefore recommend distributing the weight as centrally as possible in relation to the axis of the posts 3 4 i...

Page 12: ...on each column as well as a bar with notches on each slider block This latch and bar assembly stops the lift from accidentally dropping in the event of a leak in the hydraulic system or breaks in the system components Figure 7 Arm restraints consist of a ring gear on the end of the arm which engages the pinion of the lift slide This assembly is activated as soon as the slide leaves its lowest poin...

Page 13: ...at when the button is released raising of the lift is halted immediately 4 Down button When this button is pressed and the latching system lever is activated at the same time s Figure 7 the slider block is lowered This works on the dead man s switch principle meaning that when the button is released lowering of the lift is halted immediately The system is also locked by the latching mechanism Befo...

Page 14: ... lifting with the arms check the pick up points on the vehicle for load capacity corrosion damage and modifications Only lift vehicles at the points approved by the manufacturer Do not carry out any work on a raised vehicle which may affect the stability of the pick up points 4 4 Up down Only operate the lift if it poses no danger to people During the raising and lowering process no one should loi...

Page 15: ... the vehicle Do NOT drive against or over the arms Do NOT overload the lift Refer to the load capacity plate on the lift Refer to the weight distribution details in the Area of use chapter Never exceed the figures in this chapter in order not to expose the operator to danger Make sure that the vehicle is centred according to the longitudinal axis of the lift and that the pick up points of the vehi...

Page 16: ...e working height has been reached 7 When the required height has been reached the lift can engage the safety latch 8 Set the main switch to 0 as soon as the necessary working height has been reached Down 1 Connect the control unit to the power supply and set the main switch to 1 pull the SAFETY lever and push the DOWN button to lower the lift to the required level 2 If you cannot pull the lever do...

Page 17: ...5 Operation 13 117592 03 2013 3 Drive the vehicle away from the lift 5 9 Switch off the system 1 Set the main switch to 0 ...

Page 18: ...d 6 Broken chain switch or the lifting chain has reacted to unusual tensioning of the lifting chain Remedy 1 Connect the control unit to the power supply 2 Check the power supply 3 Replace the fuses 4 Wait until the thermal protection has cooled and continue operation 5 Replace the transformer 6 Make sure that there are no obstacles blocking the travel of the slider blocks If necessary tighten the...

Page 19: ...or circuit breaker burnt out 2 Incorrect power supply to the motor 3 Cable connections faulty loose 4 Motor UP switch burnt out 5 Motor windings burnt out Remedy 1 Replace the fuse or reset the circuit breaker 2 Provide the correct power supply to the motor 3 Repair and isolate all connections 4 Replace the main switch control buttons 5 Replace the motor The motor runs but the lift does not rise C...

Page 20: ...the requirements The lift does not rise completely or the lifting process is erratic Cause 1 Air in hydraulic lines or cylinders 2 The oil level is low Remedy 1 Start the system and raise and lower the slider block several times Lower the lift to the bottom position and refill the drive unit as in step 2 2 Lower the lift to the bottom position Fill the tank with ISO VG32 hydraulic oil or Dexron II...

Page 21: ... Fig 7 to release the mechanical safety latches 4 Loosen and remove the lock nut of the hydraulic solenoid valve for lowering the lift Fig 14 5 Slowly and carefully loosen the knurled head screw of the hydraulic solenoid valve Fig 14 arrow to slowly lower the slider block The lowering action is stopped when the screw is tightened 6 After lowering tighten the screw again and replace the lock nut No...

Page 22: ... engaged Check the status and adjust the latch control cable Fig 25 The weight is very unevenly distributed see the chapter Emergency lowering during a power failure A synchronisation cable has become slack for no obvious reason press the Up button to tension the cable again Fig 25 A synchronisation cable or a lifting chain is damaged set the main switch to 0 and lock with the key switch Replace t...

Page 23: ...related parts the lift must be inspected by a certified expert Before carrying out maintenance work display a warning sign and secure the lift zone with a red white chain Tighten fasteners after maintenance with the specified torque Do not disassemble or modify lift parts only maintenance technicians from the authorised dealer may do so Follow the maintenance schedule document the maintenance work...

Page 24: ...nozzles to top it up Check the hydraulic oil in the tank about every 1000 operating hours 11 litres Make sure that there is no residue in the tank New oil must be filtered 7 6 Approved hydraulic oils Important advice Only use hydraulic oil according to DIN 51524 for hydraulic systems Please inform us if you want to use hydraulic oil from another manufacturer ATTENTION Seals could be destroyed if t...

Page 25: ...y correct the failures and ensure that the operation runs smoothly 1 Check full functionality of the lift without load 2 Check full functionality of the lift with load 8 Repairs Repair work may only be carried out on equipment that is switched off and locked by trained and authorised specialists Refer to the safety regulations in chapter 7 2 All repairs must be documented Form Unscheduled safety i...

Page 26: ...ort hydraulic components without oil Protect controls and hydraulic units against adverse weather conditions and avoid sudden fluctuations in temperature 10 3 Unpacking Unpack the lift with the forwarder still present After removing the packaging carry out a visual inspection to ensure that the various components of the lift are OK arms columns control units etc If damage is found please note this...

Page 27: ... the installation location must guarantee that the anchor bolts sit perfectly and must be the correct thickness of at least 15 cm for the SGL35H lift or 20 cm for the SGL35N lift Fig 17 If the lifts are installed on an upper floor please seek the advice of an architect The clearance on both sides of the column must be at least 800 mm Fig 7 Standard type lifts must not be installed in zones at risk...

Page 28: ...the synchronisation cables and the latch cable before aligning the columns according to the diagram in Fig 22 b Assembling the columns Use a piece of wood from the packaging to support the slider block 10 cm above the base plate Use suitable lifting gear and handling equipment to set up the two columns in their upright position Make sure that the cylinders stand properly in the column c Floor anch...

Page 29: ...o refer to the adjacent table and work instruction in Fig 22 21 Drill diameter 20 mm Recommended concrete thickness 200 mm Drilling depth A 140 mm Anchoring depth C 105 mm Anchor bolt Quantity min 5 per column Type M20 x 200 60 Tightening torque 200 Nm Minimum distance to edge of foundation slab 100 mm If the required tightening torque cannot be reached either the hole is too large and the thickne...

Page 30: ...noid valve with its screw Connect the two cables marked 23 and 25 at the right hand connections of the electric motor The power supply configuration depends on the following parameters The power consumption of the hydraulic unit and the connection to the power supply must be such that voltage drops at full load are less than 4 percent 10 percent during the start up phase according to the nominal v...

Page 31: ...t expressly intended for grounding 11 5 Final assembly of the mechanical unit a Installing the synchronisation cables The synchronisation cables and the lock cable are fully installed with the columns in an upright position To do so the slider blocks must be set up at the same height in the centre of the vertical travel and engage the rack teeth Now go back to Figure Fehler Verweisquelle konnte ni...

Page 32: ...g Fehler Verweisquelle konnte nicht gefunden werden Feed the other end of the cable upwards through the sheave to the latch cable clamp of the secondary column The control cable is routed in the column Screw the mechanical safety lever onto the primary column latch Adjust the tension of the cable with the clamp so that both latches disengage from their rack at the same time when you pull the latch...

Page 33: ...lows 25 Attach the guide motor as per Fig 26after assembling the arms and the bolts Fig 25 The guide bolts can now be tightened as in Fig 27 26 To test the function of the arms after assembly raise the slider block at least 25 mm from the bottom position Pull up the bolt ring and bring the arms into the desired position To engage the guide drop the bolt ring so that the teeth can engage It may be ...

Page 34: ...r is turning properly If there is no build up of pressure and the slider block does not move then alter the direction of rotation of the motor by inverting the phases of the power cable Carry out another check Check all functions of the controls and ensure that they react in accordance to the symbols b Hydraulic circuit Proceed as follows to commission the hydraulic circuit Set the main switch to ...

Page 35: ...age the bolt remains in its top position Adjust the arm restraint accordingly Slider block in the bottom position Pull on the end of each arm to ensure that the stop bolt prevents the arm from moving further outwards Otherwise restore the arm to its original position and tighten the stop bolt f Levelling the height of the slider blocks Pick up a medium sized vehicle on the lift Raise the vehicle u...

Page 36: ...ronmental procedures for disposal Prevent environmental hazards Avoid contact with or inhalation of toxic substances such as hydraulic fluid Oils and lubricants are water pollutants under the terms of the Water Management Act WGH Always dispose of these in an environmentally friendly manner in accordance with the regulations which apply in your country Mineral based hydraulic oil is hazardous to w...

Page 37: ... SGL35 33 117592 03 2013 ANNEX Notes on conducting a visual inspection and a function test Diagrams spare parts lists Electrical circuit diagram see control box Hydraulic diagram Spare parts lists Hydraulic power unit ...

Page 38: ...nual controls Raising lowering Supports Condition Function Accessibility Clear assignment Permanent indication of direction Protection against accidental actuation 6 Emergency off switch Emergency lowering valve Condition Function Accessibility 7 Signalling devices Condition Function Visibility Reliability 8 Parts used for stable installation Supports Base plate Floor anchoring Condition Function ...

Page 39: ...ts Protection against cable jumping out of sheaves Condition Function 13 Steel sprocket chains chain links Accessibility Wear Flaws Secure bolts e g through rivet head ring Chain sprocket Condition Function Clamps Protection at chain attack point Condition Function 14 Hydraulics Leaks Seal test Bleeding Oil tank Condition of oil Check level Wiring Wire connections Strength Damage Deformation Corro...

Page 40: ...ment Wires Damage strength strain relief on outer wires Grounding conductor Damage strength 16 Safety latches Effectiveness strength condition damage 17 Special safety mechanisms Emergency stop Broken chain switch Control locks Emergency stop bars restart protection Safety catch mechanism Effectiveness strength condition deformation accessibility of switches Dirt condition of springs ...

Page 41: ... chain switch primary column F3 Thermal protection integrated in motor S7 Slack cable switch primary column S1 Main switch S8 Mechanical SAFETY lever switch S2 UP button T1 Transformer 230 V 400 V 24 V S3 DOWN button KM1 Power relay 24 VAC S4 Broken chain switch secondary column HV1 Hydraulic lowering solenoid valve 24 VAC M1 3 Phasen Motor 230 V 400 V main circuit Control circuit ...

Page 42: ...Diagrams spare parts lists 38 117592 03 2013 Hydraulic diagram CYINNDER VELOCITY FUSE LOWERING VALVE Hand pump option 1395 rev min 2 2kW 5 0 cc rev 205 BAR 7 I min ...

Page 43: ...linder 2 51 BL644 107P Chain 2 52 30400 5023 Chain bolt 4 53 B52 2 20 Locking pin Ø2x20 8 54 B23 6 16 Cylinder screw M6x16 4 Item Drawing no Name Qty 55 SGL35 6003 Cable duct 2 56 SGL35 6002 Synchronisation cable 1 57 N619 Cable mounting 4 58 G3T 5001 Arm bolt 4 59 40155 Hex bolt 3 8 16x5 8 8 60 40843 Lock washer3 8 8 61 N2122 Sprocket 4 62 SPL35 4300 Welded outer section 4 63 SPL35 4200 Welded mi...

Page 44: ...Diagrams spare parts lists 40 117592 03 2013 Figure 1 ...

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Page 46: ...Diagrams spare parts lists 42 117592 03 2013 Figure 3 Figure 4 ...

Page 47: ...Figure 5 Figure 7 Figure 6 ...

Page 48: ...Diagrams spare parts lists 44 117592 03 2013 Figure 8 ...

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Page 50: ...Diagrams spare parts lists 46 117592 03 2013 Hydraulic power unit Box with core hitches V3 892 71 OST CHECK VALVE V3 889 26 A03 RELIEF VALVE PIPE RILSAN ...

Page 51: ...85 10 1 K225566000 Suction filter 3 8 female 15l min 90 micron 11 1 K234722000 Return pipe M12x1 l 400 12 1 C014120000 Adaptor 3 8 for pipes Ø6 4 13 1 C1622S1380 948 Electric motor three phase 2 2kW 230 400V 50Hz 14 1 V38951900G STF14P Compensated flow control valve 7l min 15 1 C166401OH2 S2 CE C Coil 24Vac 50Hz 18W with connector 16 1 CR12009000 Plug DIN 908 1 4 BSPP copper ring 17 1 F331514000 G...

Page 52: ...Diagrams spare parts lists 48 117592 03 2013 ...

Page 53: ...on 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 ...