Ath Cross lift 50 User manual

OPERATING INSTRUCTIONS

ATH Cross Lift 50

Manufacturer ATH-Heinl GmbH & CO.KG

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Contents

1.0 INTRODUCTION ................................................................................................................... - 3 -

1.1 General Information ........................................................................................................... - 3 -

1.2 Description ........................................................................................................................ - 4 -

1.3 Operation.......................................................................................................................... - 6 -

1.4 Technical Data .................................................................................................................. - 9 -

1.5 Scale Drawing ................................................................................................................. - 10 -

2.0 INSTALLATION ................................................................................................................... - 14 -

2.1 Transport & Storage Conditions ........................................................................................ - 14 -

2.2 Unpacking the machine .................................................................................................... - 14 -

2.3 Delivery Contents ............................................................................................................ - 15 -

2.4 Location .......................................................................................................................... - 17 -

2.5 Fixing ............................................................................................................................. - 18 -

2.6 Electrical Connection ........................................................................................................ - 18 -

2.7 Pneumatic Connection ...................................................................................................... - 19 -

2.8 Hydraulic Connection ....................................................................................................... - 19 -

2.9 Assembly ........................................................................................................................ - 19 -

2.10 Completion of Work ...................................................................................................... - 31 -

3.0 OPERATION ....................................................................................................................... - 32 -

3.1 Operating Instructions ..................................................................................................... - 32 -

3.2 Basic Information ............................................................................................................ - 33 -

4.0 MAINTENANCE ................................................................................................................... - 34 -

4.1 Consumables for installation, maintenance and servicing..................................................... - 34 -

4.2 Safety Regulations for Oil ................................................................................................. - 35 -

4.3 Notes ............................................................................................................................. - 36 -

4.4 Maintenance or Service Plan ............................................................................................. - 36 -

4.5 Troubleshooting / Error Display and Solutions .................................................................... - 37 -

4.6 Maintenance and Service Instructions ................................................................................ - 39 -

4.7 Disposal .......................................................................................................................... - 40 -

5.0 EG-/EU-KONFORMITÄTSERKLÄRUNG / EC-/EU-DECLARATION OF CONFORMITY...................... - 41 -

6.0 APPENDIX .......................................................................................................................... - 42 -

6.1 Pneumatic circuit diagram ................................................................................................ - 42 -

6.2 Electric circuit diagram ..................................................................................................... - 43 -

6.3 Hydraulic circuit diagram .................................................................................................. - 44 -

7.0 WARRANTY CARD ............................................................................................................... - 45 -

7.1 Scope of the Product Warranty ......................................................................................... - 46 -

8.0 INSPECTION LOG ............................................................................................................... - 47 -

8.1 Installation and Handover Log .......................................................................................... - 48 -

8.2 Inspection Plan ................................................................................................................ - 49 -

8.3 Visual inspection (authorised expert) ................................................................................. - 50 -

9.0 SPARE PART BOOK ............................................................................................................. - 54 -

10.0 NOTES ............................................................................................................................... - 87 -

Manufacturer ATH-Heinl GmbH & CO.KG

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1.0 INTRODUCTION

1.1 General Information

THESE INSTRUCTIONS ARE AN INTEGRAL PART OF THE MACHINE.

THEY MUST BE READ AND UNDERSTOOD BY THE USER.

NO LIABILITY IS ASSUMED FOR ANY DAMAGES CAUSED BY FAILURE TO

FOLLOW THESE INSTRUCTIONS OR THE VALID SECURITY PROVISIONS.

WARNING: Follow the instructions to prevent injury or damage.

TIP: Provides more information on functionality and tips for using the device efficiently.

Appropriate protective clothing must be worn for all work on the described system.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.2 Description

Manufacturer ATH-Heinl GmbH & CO.KG

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1. Access ramp secondary side main lift

2. Access ramp control side main lift

These are moved upwards using the internal scissor lift system (6) and hydraulic cylinder (7)

3. Wheel-free lift

This facilitates additional vehicle lifting on the rocker rail.

4. Base frame

This secures the lifting system.

5. Jacking beam (optional)

This facilitates additional vehicle lifting on the axle or chassis.

6. Scissor lift system

7. Hydraulic lift cylinder

8. Cover plates

Allow optional wheel alignment rotary plates to be used

9. Control box

Contains the complete electrical control system. All buttons are protected by a front ring in order to

prevent the button from being pressed accidentally. Furthermore, all movements are immediately

stopped when the buttons

are released (dead man’s control).

Including hydraulic unit

The hydraulic oil in the tank is fed to the cylinders via a gear pump driven by the

engine. A lowering valve returns the oil to the tank.

10. Safety catches on the main and wheel-free lift

This system prevents the raised platform from lowering by more than 100 mm in the event of any

defects.

Electromagnets unlock the system each time it is lowered.

11. Light barrier

Ensures secure synchronisation of the two scissors

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3 Operation

1. Lockable main switch with emergency stop function

to switch the lift on and off

and to prevent operation of the lift by unauthorised persons.

2. Alarm gives an acoustic and visual signal when the CE stop is reached

3. Selector switch

Choose between two drive versions

4. Lifting button

raises the lift

5. Parking button

parks the lift on safety catches. Depending on the setting of the selector switch, either the main or

wheel-free lift is activated.

6. Lowering button

After pressing the button for approx. 1-2 seconds, the safety catches are unlocked and then lowered.

An acoustic signal is also generated when the CE stop is reached.

7. Adjustment switch and work switch

Position: WORK indicates that the lift is in normal operation

Position: ADJ indicates that the lift is in adjustment mode

8. Switch for light barrier

Muting the light barrier for adjustment and/or installation measures

Manufacturer ATH-Heinl GmbH & CO.KG

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A = Motor

B = Pressure control valve

C = Solenoid valves D = Emergency manual pump

E = Lowering solenoid valve F = Levelling valves

G = Manometer

Manufacturer ATH-Heinl GmbH & CO.KG

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OPERATION

Safety instructions

1. Ensure there is correct weight

distribution of the vehicle

2. Changes to the lift of any kind are

not permitted

3. Leave the danger zone when

lowering the lift

4. No objects or persons may be

transported on the lift, the support

arms or on the vehicle that is being

lifted.

5. If there is a danger of the vehicle

falling, you must immediately leave

the danger zone

6. Prevent the lifted vehicle from

swaying significantly

7. The lift may only be operated by

trained personnel.

8. Use suitable roll protection

9. Only authorised persons are allowed

to enter the danger zone.

10. Proper maintenance and inspections

are necessary for safe work

11. Read and understand the operating

instructions before operating the lift

12. Do not work on damaged lifts

13. Keep the shearing points free when

moving the lift

14. Do not clean the lift under running

water.

15. The danger zone must be kept clear

when lifting and lowering

Manufacturer ATH-Heinl GmbH & CO.KG

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1.4 Technical Data

Model ATH Cross Lift 50HA

Load capacity of main lift 5,000 kg

Load capacity of wheel

free lift

4,000 kg

Lift time (for 2,000 kg)

70 s

Lowering time (for 2,000 kg) 60 s

Electric system 3/400V/50Hz

Control voltage DC24V

Motor 3.5 kW

rpm

1375

Motor housing

B14

Upstream fuse 3 C 16 A

Connection cable Min. 5 x 2.5 m²

Protection type IP 54

Flow rate

4.8 cm³/g

Working pressure ²

300 bar (max. 300 bar)

Required compressed air connection 7 bar

Recommended hydraulic oil Summer (15 °C to 45 °C): HVLP-D 46 (e.g.: Eni PRECIS HVLP-D)

Winter (under 10 °C): HVLP-D 32 (e.g.: Eni PRECIS HVLP-D)

Oil quantity

Approx. 18 l

Floor anchor Bolt anchor: M16 x 180 (e.g.: Atrion ABL-W 16-060-180)

Compound anchor: M16 x 190 (e.g.: Atrion AVA-W 16-045-190)

Number of anchors 16 units

Permissible sound level

≤ 80 dB

Weight

2,840 kg

² The factory set working pressure is adjusted to the maximum power rating. The pressure relief

valve must not be manipulated. Changing the settings can lead to serious damage.

If the stated rated load cannot be lifted, please contact our service team.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.5 Scale Drawing

ATH Cross Lift 50 floor-level installation:

Manufacturer ATH-Heinl GmbH & CO.KG

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ATH Cross Lift 50 elevated installation:

Manufacturer ATH-Heinl GmbH & CO.KG

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ATH Cross Lift 50 Plus floor-level installation:

Manufacturer ATH-Heinl GmbH & CO.KG

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ATH Cross Lift 50 Plus elevated installation:

Manufacturer ATH-Heinl GmbH & CO.KG

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2.0 INSTALLATION

The machine must be installed by an authorised person according to the instructions.

The operating instructions (including the log) are an important part

of the machine / product.

!!!PLEASE STORE CAREFULLY!!!

The product must be checked after completion of the installation, handover, if necessary briefing and then

regularly in accordance with the applicable regulations and legal provisions in the country of operation by a

suitable and approved company or facility.

2.1 Transport & Storage Conditions

When transporting and positioning the machine, always use suitable lifting and material handling

equipment and consider the machine’s centre of gravity.

The machine should only be transported with the original packaging.

Data: 2.550 kg

Width

700 mm

Length

5.000 mm

Height 1.440 mm

Storage temperature -10 to +50 °C

2.2 Unpacking the machine

Remove the top cover of the packaging and make sure that no damage has occurred

during transport.

Remove the safety bolt to remove the machine from the pallet / rack.

Use a suitable lifting device (possibly with a stopping rope) to lower the machine from the

pallet / frame.

The packaging material used for the machine should be stored carefully.

Keep the packaging material out of the reach of children as it may be hazardous.

Manufacturer ATH-Heinl GmbH & CO.KG

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2.3 Delivery Contents

Basic package with:

 2 x pairs of scissors including integrated cylinders

Dimensions (L x W x H): 5100 x 7000 x 300 mm

Weight: 700 kg



1 x package with control box, hydraulic and pneumatic hoses:

Dimensions (L x W x H): 400 x 540 x 1,140 mm

Weight: 130 kg



1 x package with accessories, ramps and bridging track sections.

Dimensions (L x W x H): 400 x 540 x 1,140 mm

Weight: 130 kg

OPTIONAL

Scissor jacking beam 1 x 1000 x 600 x 400 mm Weight: 130 kg

Manufacturer ATH-Heinl GmbH & CO.KG

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If something is missing from your delivery, please contact our sales department.

Tips for transport and storage:

- Lift carefully. Support the weight properly using suitable equipment that is in good order and condition.

- Avoid unexpected raises and jerky movements. Beware of bumps, gutters, etc.

- Store the removed packaging at a collection point inaccessible to children and animals until it is

disposed.

- Storage temperature: 10 °C～+40 °C

Manufacturer ATH-Heinl GmbH & CO.KG

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2.4 Location

The machine should be kept away from flammable and explosive materials, as well as from sunlight and

intense light. The machine should be placed in a well-ventilated location.

The machine must be set up on sufficiently firm ground, if necessary, according to the minimum

requirements of the information given in the foundation plan.

In addition to the ground conditions, the guidelines and instructions of the accident prevention regulations

as well as the workplace regulations must be observed when selecting an installation site.

When assembling on floor coverings, check their load-bearing capacity. A construction expert should be

consulted for inspection when mounting on floor coverings.

The machine should only be mounted and used within closed rooms. It has no corresponding safety

features (e.g. IP protection, galvanised design, etc.).

Temperature 4-40 °C

Sea level

< 1500 m

Humidity 50% at 40 °C – 90% at 20 °C

Drawing

Manufacturer ATH-Heinl GmbH & CO.KG

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Safety area

min. 1 m

Permissible operating temperatures: 10 - 40 °C

Maximum permitted humidity: ≤80 % at 30 °C

Height above sea level:

≤ 2000 m

Power connection & earthing cable (see technical data) is to be installed as a connector system (socket and

plug) or a fixed connection.

Required supply

See technical data

The lift must not be installed in damp, wet or potentially explosive areas.

The lift may only be installed indoors and may not be installed outdoors.

2.5 Fixing

General and local regulations must be observed. Therefore,

these steps should only

carried out by a trained professional.

The machine must be set up and fixed on sufficiently firm ground, if necessary, according to the minimum

requirements of the information given in the foundation plan.

The machine must be fastened at the points provided with suitable or specified fastening material.

In addition to the ground conditions, the guidelines and instructions of the accident prevention regulations

as well as the workplace regulations must be observed when selecting an installation site.

When assembling on floor coverings, check their load-bearing capacity. A construction expert should be

consulted for inspection when mounting on floor coverings.

2.6 Electrical Connection

General and local regulations must be observed. Therefore, these steps may only be

carried out by a trained professional.

Pay attention to the necessary supply line (see technical data).

The connection should be made with a 230V Schuko plug or 5-phase 16 A CEE plug (partially included).

Voltage deviations should be 0.9 - 1.1 times the nominal voltage range and the frequency deviation should

be 0.99 - 1.01 times the frequency range.

Necessary protective measures must be taken to guarantee this.

At the end of the work, the direction that the motor rotates must be checked.

Manufacturer ATH-Heinl GmbH & CO.KG

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2.7 Pneumatic Connection

For all pneumatic systems, a compressed air maintenance unit (partially included) must

be installed between the supply line and the system.

The air pressure of the supply line must at least correspond to the technical data.

The compressed air maintenance unit must be set correctly and checked.

The compressed air maintenance unit must be serviced at regular intervals.

The maximum or minimum pressure ensures perfect functioning without any damage.

2.8 Hydraulic Connection

Before the system is put into operation or operated for the first time with oil, the

following must be observed with regard to the optimal, trouble-free and almost air-free

functioning

All hydraulic lines must be connected and tightened according to the hydraulic plan and, if applicable

according to the hose designation.

All hydraulic lines and cylinders must be vented according to the hydraulic plan and, if applicable, according

to the hose designation.

In order to ensure the faultless and safe functioning of the system and the hose assemblies used, the

hydraulic fluids used must comply with the specific instructions and recommendations of the manufacturer.

Used media that do not meet the specific requirements or which have unauthorised contamination damage

the entire hydraulic system and shorten the service life of the hydraulic systems used. Warning: (system

contamination can also occur when oil is refilled)

The minimum requirement and minimum oil quantity must be checked and ensured.

2.9 Assembly

These instructions are no

t to be viewed as assembly instructions; hints and tips are

provided only for trained expert installers. Suitable clothing and personal protection must

be worn for the following work.

Incorrect installation and settings lead to exclusion of liability and warranty.

Partly pre-assembled machines must be checked, introduced and approved by a competent person before

commissioning.

Machine assembly must be carried out by a qualified and competent person.

Manufacturer ATH-Heinl GmbH & CO.KG

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INSTALLATION

Foundation

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