Ath Single lift 35m User manual

OPERATING INSTRUCTIONS

ATH Single Lift 35M

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 .................................................................................................................. - 8 -

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

2.0 INSTALLATION ................................................................................................................... - 12 -

2.1 Transport & Storage Conditions ........................................................................................ - 12 -

2.2 Unpacking the machine .................................................................................................... - 12 -

2.3 Delivery Contents ............................................................ Fehler! Textmarke nicht definiert.

2.4 Location .......................................................................................................................... - 14 -

2.5 Fixing ............................................................................................................................. - 15 -

2.6 Electrical Connection ........................................................................................................ - 15 -

2.7 Pneumatic Connection ...................................................................................................... - 15 -

2.8 Hydraulic Connection ....................................................................................................... - 16 -

2.9 Assembly ........................................................................................................................ - 16 -

2.10 Completion of Work ...................................................................................................... - 22 -

3.0 OPERATION ....................................................................................................................... - 24 -

3.1 Operating Instructions ..................................................................................................... - 24 -

3.2 Basic Information ............................................................................................................ - 25 -

4.0 MAINTENANCE ................................................................................................................... - 26 -

4.1 Consumables for installation, maintenance and servicing..................................................... - 26 -

4.2 Safety Regulations for Oil ................................................................................................. - 27 -

4.3 Notes ............................................................................................................................. - 28 -

4.4 Maintenance or Service Plan ............................................................................................. - 28 -

4.5 Troubleshooting / Error Display and Solutions .................................................................... - 29 -

4.6 Maintenance and Service Instructions ................................................................................ - 31 -

4.7 Disposal .......................................................................................................................... - 32 -

5.0 EG-/EU-KONFORMITÄTSERKLÄRUNG / EC-/EU-DECLARATION OF CONFORMITY...................... - 33 -

6.0 APPENDIX .......................................................................................................................... - 34 -

6.1 Pneumatic circuit diagram ................................................................................................ - 34 -

6.2 Electric circuit diagram ..................................................................................................... - 35 -

6.3 Hydraulic circuit diagram .................................................................................................. - 36 -

7.0 WARRANTY CARD ............................................................................................................... - 37 -

7.1 Scope of the Product Warranty ......................................................................................... - 38 -

8.0 INSPECTION LOG ............................................................................................................... - 39 -

8.1 Installation and Handover Log .......................................................................................... - 40 -

8.2 Inspection Plan ................................................................................................................ - 41 -

8.3 Visual inspection (authorised expert) ................................................................................. - 42 -

9.0 SPARE PART BOOK ............................................................................................................. - 46 -

10.0 NOTES ............................................................................................................................... - 62 -

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. Lifting column

The lifting carriage is guided by rollers as it moves up and down the lifting column.

The hydraulic lifting cylinder and the lifting chain are also located here.

2. Lifting carriage

The lifting carriage supports the arm (load bearing equipment). It is lifted and lowered by the

hydraulic cylinder by means of chains; it is guided in the column by rollers.

3. Arm

The adjustable support arm and support plate are attached here. The length of the arm

can be adjusted.

4. Drive kit

Serves to drive and position the lift. The procedure may only be carried out when empty without a

load.

5. Control box

The complete electrical control system is located here. All buttons are protected by a front ring in

order to prevent them being pressed accidentally. Furthermore, all movements are immediately

stopped when the buttons are released (dead man’s control).

6. Hydraulic unit

The hydraulic oil is fed from the tank to the lifting cylinder by a gear pump driven by an electric

motor. The lowering valve allows the oil to flow back into the tank.

7. Base frame

Serves to stabilise the lift and contains the front rollers which drive the lift.

8. Release magnet

Electromagnet for releasing the safety catch during the lowering process.

The safety catch prevents the lift from lowering autonomously in the case of an error.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.3 Operation

1. Lockable main switch

To switch the lift on and off and

to prevent operation by

unauthorised persons.

2. Operating light

Indicates whether the lift is in operation.

3. Lift button

To raise the lift.

4. Lower button

To lower the lift.

5. Park button

To park and continue to lower the lift

after it has reached the CE stop.

6. Emergency stop button

To switch the lift off in

dangerous situations.

7. Override button

Overrides the chain emergency off switch

where necessary.

8. Alarm

Warning signal when the CE stop is reached.

Manufacturer ATH-Heinl GmbH & CO.KG

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Safety instructions

HAZARD NOTE

1. The danger zone must be kept

clear when lifting and lowering

2. If there is a danger of the vehicle

falling, you must leave the danger

zone immediately

WARNING NOTE

3. Lift may only be operated by

trained personnel.

4. Ensure there are no obstacles

when lowering

5. Prevent the lifted vehicle from

swaying significantly

6. Always ensure that the lifted

vehicle is secured against

slipping.

7. Changes to the lift of any kind are

not permitted

8. Leave the danger zone when

lowering the lift

9. Work on electrical components

may only be performed by

authorised electricians.

10. Do not work on damaged lifts

11. Only authorised persons are

allowed to enter the danger zone.

GUIDING PRINCIPLES

12. Read and understand the

operating instructions before

operating the lift

13. Do not clean the lift under running

water.

14. Do not use any paint-dissolving or

aggressive detergents

Manufacturer ATH-Heinl GmbH & CO.KG

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1.4 Technical Data

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 indicated rated load cannot be lifted, please contact our

service team.

Model ATH Single Lift 35M

Load capacity 3,500 kg

Lifting time (2,000 kg) 40 s

Lowering time (2,000 kg) 45 s

Electrical system 1/230V/50 Hz or 3/400V/50 Hz

Lifting height 100-1850 mm

Control voltage DC24V

Motor 2.2 KW or 2.6 KW

Upstream fuse 1 C 16 A / 3 C 16 A

Connection cable Min. 3 x 1.5 mm² or 5 x 2.5 mm²

Protection type IP 43

Working pressure ² Approx. 120 bar

Recommended hydraulic oil

Summer: HVLP

D 46 (e.g.: ENI Precis HVLP

D 46)

Winter: HVLP-D 32

Oil quantity Approx. 6 l

Permissible sound level ≤ 76 dB

Weight 1,300 kg

Manufacturer ATH-Heinl GmbH & CO.KG

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Load distribution

Total weight of the

vehicle

Max 2/5 x Q

Max 3/5 x Q

Load

distribution

2/3

Min. 1,000 mm ²

² The load capacity of the lift is reduced at lesser distances. Please consult the manufacturer in such

cases, as well as in all other cases not foreseen in these instructions.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.5 Scale Drawing

Manufacturer ATH-Heinl GmbH & CO.KG

- 11 -

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:

Width

1.150 mm

Length

2.480 mm

Height 700 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

1. Transport box with:

- column

- arm

- support arm and plate

- base frame

- drive kit

- hydraulic unit

- electric control

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 a good condition and in

good working order.

- 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 has been

disposed of.

- Storage temperature: -25°C ～ +55°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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2.5 Fixing

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

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.

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.

Manufacturer ATH-Heinl GmbH & CO.KG

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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 not 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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Base frame / column feet assembly

Place the column in a vertical position. Ensure the column is

standing securely and cannot be knocked over.

Place the two column feet at the side of the column. Check

whether both rollers are already installed in the feet.

Connect the two arms using the supplied M20X50 screws and

take care to follow the correct order of washers and spring

washers as shown in the adjacent diagram.

Hydraulic unit assembly

Attach the hydraulic unit to the bracket on the rear of the column as

shown in the adjacent diagram. Use the supplied M10X50 screws

and corresponding washers for this purpose.

Manufacturer ATH-Heinl GmbH & CO.KG

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Hydraulic line connection

Take care that the hoses and connection pieces are clean and free of contamination. Clean the parts if

required.

Check all parts for damage and ensure that all screw connections and connecting pieces are in good order.

Connect the hoses to the hydraulic unit and the cylinder in accordance with the drawing below. Tighten all

connections to prevent any oil leaks.

Manufacturer ATH-Heinl GmbH & CO.KG

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Base plate assembly

Install the middle rear cover with the

4 drill holes to fit the electric control to the column. Use the supplied

M6X10 screws

as shown in the adjacent diagram.

Electric control assembly

Fit the electric control to the column using the supplied screws as

shown in the adjacent diagram.

Check the nameplate to ensure that the motor is suitable for the

voltage available at the customer’s premises.

Establish the electrical connections as shown in the circuit diagram

(point 6.2). Use the cables and lines supplied for this purpose.

Work must be carried out in accordance with local regulations. Make

sure that the phases are properly connected (direction of rotation)

and

the lift is properly grounded.

Filling the oil and venting

Use only the hydraulic oil specified in the operating instructions.

Open the oil filler cap and fill approx. 6 litres of hydraulic oil into the tank.

Pressing the LIFT button moves the lift upwards until the max. height

has been reached. Release the button when the maximum height has been reached, as otherwise

the electric motor or the gear pump may be damaged. Pressing the LOWER button moves

the lift right to the bottom. Keep holding the LOWER button for around 3 seconds after the

lift has reached its lowest point to allow any trapped air to escape.

Repeat this LIFT and LOWER procedure three times.

Warning: Attempting to test without oil or when the motor is rotating in the wrong direction can destroy

the

hydraulic pump.

Manufacturer ATH-Heinl GmbH & CO.KG

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Assembling the arm together with the support

plates

Fit the arm on the lifting carriage of the

lift. Use the two M16X70 screws (1), four M16X60 screws

(2) and the

corresponding washers supplied for this purpose as shown

in the adjacent

diagram.

Install all the support arm components on the arm as shown in the adjacent diagram. Ensure that all

components are assembled and the safety equipment works reliably.

No.

Description

No.

Description

No.

Description

Rear support arm

M8X12 screw

M6X8 screw

2 Left rear support arm

extension 13 Mounting plate 24 Front right extension

Left rear support arm

holding fixture 14

Right rear

support arm

extension 25 D.25 circlip

4 Arm base plate 15 Support plate 26 M6X12 screw

5 Right rear support arm

holding fixture 16 Support plate holding

fixture 27 M10X20 screw

D.12 washer

Bolt

D.10 washer

7 M12X30 screw 18 Notched plate 29 Plastic sliding part

8 4X16 bolt 19 Support arm release 30 Variable arm extension

9 M8X60 screw 20 Flat-head bushing 31 Front left extension

Support arm release

Guard bracket

Spring

D.6 washer

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