Ath Frame lift 30fz User manual

OPERATING INSTRUCTIONS

ATH Frame Lift 30FZ

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.......................................................................................................................... - 5 -

1.4 Technical Data .................................................................................................................. - 8 -

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

2.0 INSTALLATION ................................................................................................................... - 11 -

2.1 Transport & Storage Conditions ........................................................................................ - 11 -

2.2 Unpacking the machine .................................................................................................... - 11 -

2.3 Delivery Contents ............................................................................................................ - 12 -

2.4 Location .......................................................................................................................... - 13 -

2.5 Fixing ............................................................................................................................. - 14 -

2.6 Electrical Connection ........................................................................................................ - 14 -

2.7 Pneumatic Connection ...................................................................................................... - 14 -

2.8 Hydraulic Connection ....................................................................................................... - 15 -

2.9 Assembly ........................................................................................................................ - 15 -

2.10 Completion of Work ...................................................................................................... - 20 -

3.0 OPERATION ....................................................................................................................... - 21 -

3.1 Operating Instructions ..................................................................................................... - 21 -

3.2 Basic Information ............................................................................................................ - 22 -

4.0 MAINTENANCE ................................................................................................................... - 23 -

4.1 Consumables for installation, maintenance and servicing..................................................... - 23 -

4.2 Safety Regulations for Oil ................................................................................................. - 24 -

4.3 Notes ............................................................................................................................. - 25 -

4.4 Maintenance or Service Plan ............................................................................................. - 25 -

4.5 Troubleshooting / Error Display and Solutions .................................................................... - 26 -

4.6 Maintenance and Service Instructions ................................................................................ - 28 -

4.7 Disposal .......................................................................................................................... - 29 -

5.0 EG-/EU-KONFORMITÄTSERKLÄRUNG / EC-/EU-DECLARATION OF CONFORMITY...................... - 30 -

6.0 APPENDIX .......................................................................................................................... - 31 -

6.1 Pneumatic circuit diagram ................................................................................................ - 31 -

6.2 Electric circuit diagram ..................................................................................................... - 32 -

6.3 Hydraulic circuit diagram .................................................................................................. - 33 -

7.0 WARRANTY CARD ............................................................................................................... - 34 -

7.1 Scope of the Product Warranty ......................................................................................... - 35 -

8.0 INSPECTION LOG ............................................................................................................... - 36 -

8.1 Installation and Handover Log .......................................................................................... - 37 -

8.2 Inspection Plan ................................................................................................................ - 38 -

8.3 Visual inspection (authorised expert) ................................................................................. - 39 -

9.0 SPARE PART BOOK ............................................................................................................. - 43 -

10.0 NOTES ............................................................................................................................... - 55 -

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

Main components

1. Lifting platform (P1)

2. Lifting platform (P2)

The platforms are moved upwards with internal hydraulic cylinders and the scissor principle.

The hydraulic safety device prevents the lift lowering unintentionally.

3. Access ramp

Allows the lifting ramp to be extended

4. Base frame

Fixing the lift

5. Lower scissors

6. Upper scissors

7. Main cylinder

8. Slave cylinder

9. Hydraulic power unit with control box (dead-man system)

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

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

10. CE stop & limit switch

The CE stop stops the lift descending at a height of 500 mm.

The limit switch terminates the lifting process when the maximum lifting height is reached,

protecting the hydraulic system.

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 lifting platform on and off andto prevent operation by unauthorised persons.

2. Alarm

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

3. Lifting button

raises the lifting platform

4. The lowering button

lowers the lifting platform

5. Button for bridging the limit switch

Suitable for bleeding the hydraulic cylinder

6. Button for bridging the light barrier

allows synchronisation adjustment

Manufacturer ATH-Heinl GmbH & CO.KG

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Usage

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. The danger zone must be kept clear

when lifting and lowering

5. If there is a danger of the vehicle

falling, you must immediately leave

the danger zone

6. Avoid the lifted vehicle swaying

7. Moving the vehicle on the lift is not

permitted

8. Lift may only be operated by trained

personnel.

9. Use roll-off protection

10. Only authorised persons are allowed

to enter the danger zone.

11. Proper maintenance and inspections

are necessary for safe work

12. Read and understand the operating

instructions before operating the lift

13. Do not work on damaged lifts

Replace damaged danger signs.

The product is intended for lifting vehicles. The corresponding technical data for the lift must be observed.

Manufacturer ATH-Heinl GmbH & CO.KG

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1. Preparation

a. Carefully read all safety instructions before operating the lift.

b. Completely lower the lift.

c. Position the vehicle centrally between the scissors, paying attention to the load distribution.

d. Place the rubber plate CENTRALLY under the original lifting points of the vehicle.

2. Lifting

a. Switch on the lift with the main switch

b. Lift the vehicle to a height of 100-150mm and stop lifting by releasing the lift button.

c. Check that the vehicle is safely on the lift.

d. Continue lifting and watch the lifting process.

3. Lowering

a. Before lowering, check for any objects under the vehicle.

b. Press the lower button.

c. When the CE stop is reached, the lower button must be released and then pressed again.

4. Finishing

a. Completely lower the platform.

b. Remove the rubber plate.

c. Drive the vehicle off the lifting platform.

Manufacturer ATH-Heinl GmbH & CO.KG

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1.4 Technical Data

Model ATH Frame Lift 30FZ

Load capacity 3,000 kg

Lift time 50 s

Lower time 50 s

Electric system 3/400V/50Hz

Control voltage DC24V

Motor 2.6 kW

Rotation speed 1,375 rpm

Upstream fuse 3 C 16 A

Connection cable Min. 5 x 1.5 mm²

Protection type IP 54

Working pressure ² 125 -145 bar

Recommended

hydraulic oil

Summer: H-LPD 32 (e.g.: OEST H-LPD 32 DD L)

Winter: H-LPD 22

Oil quantity

Floor anchor

Scissors 8 units

Floor anchor

Control box 4 units

Floor anchor

Bridging track

sections

16 units

Permissible sound

level ≤ 75 dB (A)/lm

Weight 830 kg

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

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

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

Manufacturer ATH-Heinl GmbH & CO.KG

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Load distribution

Q Total weight of the vehicle

P1 Max 2/5 x Q

P2 Max 3/5 x Q

Load distribution 2/3

² At greater distances, the load capacity of the lift is reduced. In such cases and in other cases not

provided for in this manual, please contact the manufacturer.

Min Max

A 1,900 mm 4,000 mm

B 100 mm

C 1,900 mm

D 900 mm

Manufacturer ATH-Heinl GmbH & CO.KG

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1.5 Scale Drawing

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

----

Length

----

Height ----

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 Package with scissors, ramps and bumpers:

Dimensions (L x W x H): 1,660 x 820 x 500 mm

Weight: 700 Kg

1 Package with control box, hydraulic and pneumatic hoses:

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

Weight: 130 Kg

If something is missing, please contact our sales department.

Tips for transport and storage:

- Carefully lift the load, using proper equipment in good 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: -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

B1 1,000 mm B2 1,000 mm

L1 Approx. 2,800 mm L2 Approx. 2,800 mm

H Approx. 4,000 mm

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 (at 400V) 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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INSTALLATION

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

Assembly

1. Setting up and aligning

a. The assembly position can be marked using chalk.

b. When assembling the scissors, pay attention to the approach direction.

c. Position the control box as indicated in the specifications.

2. Fixing with safety anchor:

Manufacturer ATH-Heinl GmbH & CO.KG

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3. Establish hydraulic connection

a. First, open the front cover of the control box

b. Install the hydraulic hoses as shown below.

Tighten all hydraulic connections.

Ensure that no moving parts can damage the hydraulic hoses.

Manufacturer ATH-Heinl GmbH & CO.KG

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4. Hydraulic oil

a. Fill hydraulic oil up to marking

5. 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).

Manufacturer ATH-Heinl GmbH & CO.KG

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6. Check before first lifting

a. Check all bolts, nuts, etc. are tight

b. Check all connections and cylinders for leaks and tighten if necessary

c. Check that all buttons works

d. Observe the motor rotation direction

e. Bleed the hydraulic circuit as described in the Maintenance chapter.

For the first lifting operation lubricate the slides of the scissor arms (See lubrication schedule

for grease type)

7. Correctly set limit switch

a. To set the maximum lift, position the lift at a height of 1,900mm

b. Loosen the nuts (3) at the limit switch and set it

c. Tighten the nuts (3) again

d. To set the CE stop, position the lift at a height of 400mm

e. Loosen the nuts (3) at the limit switch and set it

f. Tighten the nuts (3) again

8. Lifting under load

a. Lift a load to a height of approx. 1,000 mm, check the synchronisation and adjust if necessary

b. While continuing to lift, pay attention to the synchronisation

c. Lower the load and mount the missing covers or ramps

9. After setting up, fill in the attached inspection log.

This information is needed in case of service.

Manufacturer ATH-Heinl GmbH & CO.KG

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Bleeding the hydraulic system

1. After first filling with hydraulic oil, the lift button

must be pressed for about 30 seconds to pump

the oil into the hydraulic system.

2. Lift the lift up to the maximum lift height. (This

may NOT exceed 1,900mm)

3. Open the upper cover of the control box and

press the button to bypass the limit switch (5)

and the button to bridge the light barrier (6)

for a few seconds until both scissor platforms

are at the same height.

4. Completely lower the lift by pressing the

lowering button.

5. Repeat lifting and lowering operations at least

twice more

Emergency lowering

the event of a power failure

1. Switch off the lift with the main switch and

secure it against being switched on again

2. Open the front cover of the control box

3. Loosen the safety valve screw (A) by turning it

counter-clockwise

4. The lowering movement of the lift is triggered

by loosening the lowering valve screw (B).

!!! WARNING!!: The lowering speed can be

adjusted with this screw!

5. After fully lowering the lift, all screws must be

tightened again.

2.10 Completion of Work

Before commissioning, check all fastening screws, electrical, pneumatic and hydraulic

lines and, if necessary, tighten these. Warning: in some cases, this must be checked at

regular intervals and tightened if necessary (note in the instructions).

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