AUTOPSTENHOJ Masterlift 2.30 User manual

Manual no.: 9000128GB
Date: 10.07.2019
ALWAYS KEEP
operating instructions
ready to hand on the
unit
Read the operating
instructions before
working with the
unit
Masterlift
2.30 / 2.35
Installation instructions
(TRANSLATED VERSION)

© AUTOPSTENHOJ GmbH
Sandkampstr. 90
D – 48432 Rheine
Tel.: + 49 5971/860202
E-mail: [e-mail]
Internet.: www.autopstenhoj.com
Index: k
Before
taking into operation
check system compo-
nents, control, emer-
gency stop and safety
equipment for conditi-
on, damage and
correct function!
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Table of contents
1 General............................................................................................................................................... 5
1.1 Information for the installation instruction............................................................................................ 5
1.2 Explanation of symbols ....................................................................................................................... 5
1.3 Liability and warranty .......................................................................................................................... 6
1.4 Copyright protection ............................................................................................................................ 6
2. Safety ................................................................................................................................................. 7
2.1 General ............................................................................................................................................... 7
2.2 Work safety ......................................................................................................................................... 7
2.3 Personal safety equipment.................................................................................................................. 7
2.4 Behavior in case of danger or accidents............................................................................................. 8
2.4.1 Preventative Measures ....................................................................................................................... 8
2.4.2 If the worst comes to the worst: Do the right things! ........................................................................... 8
3 Technical data ................................................................................................................................... 9
3.1 Connection values............................................................................................................................... 9
3.1.1 PLC control unit................................................................................................................................... 9
3.1.2 Motor ................................................................................................................................................... 9
3.1.3 Operating values................................................................................................................................. 9
3.1.4 Hydraulic system............................................................................................................................... 10
3.2 Weights ............................................................................................................................................. 10
3.3 Name plate........................................................................................................................................ 10
3.4 Requirements of the place of Installation.......................................................................................... 11
4 Installation of the lifting unit .......................................................................................................... 12
4.1 Overview of components................................................................................................................... 12
4.2 Placing, aligning and concreting the steel cassette .......................................................................... 14
4.3 Assembly of the hydraulic components............................................................................................. 15
4.3.1 Installation of the cylinder suspension - only for Multilift lifting units ................................................ 15
4.3.2 Setting of the hydraulic cylinder ........................................................................................................ 16
4.3.3 Installation of the hydraulic pump unit............................................................................................... 20
4.4 Installation of the control unit components........................................................................................ 23
4.4.1 Introduction ....................................................................................................................................... 23
4.4.2 Insulation test and continuity of the protective conductor ................................................................. 23
4.4.3 Cable connections............................................................................................................................. 24
4.4.4 Control box and terminal box ............................................................................................................ 24
4.4.4.1 Connection of the control unit type “Standard”.................................................................................. 25
4.4.4.2 Connection of the control unit type “Fn”............................................................................................ 26
4.4.4.3 Connection of terminal box type „Standard“...................................................................................... 27
4.4.4.4 Connection of terminal box type „Fn“................................................................................................ 27
4.4.4.5 Terminal block on the hydraulic pump unit ........................................................................................ 28
4.4.5 Installation of the sensor ladder rack ............................................................................................... 28
4.5 Connection of the synchronization bar.............................................................................................. 31
4.6 Connection of pneumatic emergency lowering ................................................................................. 32
4.7 Aligning the hydraulic cylinders......................................................................................................... 32
5. Installation of superstructure ........................................................................................................ 33
5.1 Repair platform superstructure type "Pv" .......................................................................................... 33
5.2 Swivel arm superstructure type "S"................................................................................................... 33
5.3 Platform/wheel support type "Fv Uni"................................................................................................ 33
5.4 Platform superstructures type "F" og "F Check-in" ........................................................................... 33
5.5 Platform superstructures type "Fn" and "Fn Check-in" ..................................................................... 34
6 Adjustment of the lift ...................................................................................................................... 36
6.1 Adjusting the main cylinder ............................................................................................................... 36
6.2 Adjusting the safety zone.................................................................................................................. 37
6.3 Adjusting the limit switch ................................................................................................................... 37
6.4 Testing of adjustments ...................................................................................................................... 37
6.5 Features for the Fn-control unit ........................................................................................................ 38
7 Installation of the cassette cover .................................................................................................. 39

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8 Training of personnel in the operation of the lift ......................................................................... 39
9 Malfunction monitoring .................................................................................................................. 39
9.1 Malfunction indication PLC control unit............................................................................................. 39
9.2 Malfunction analysis.......................................................................................................................... 41
10 Overview: Wiring diagrams............................................................................................................ 43
11 Overview: Hydraulic diagrams....................................................................................................... 43
12 Overview: Other circuit diagrams.................................................................................................. 43

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1 General
1.1 Information for the installation instruction
This installation instruction describes the installation of the lifting unit and the superstructure. Compliance with
the notes on safety and procedural instructions is a prerequisite for the safe and proper installation of the lift.
Furthermore they are to be kept for the applicable local accident prevention guidelines and the general safety
regulations regarding the lift’s range of applications.
The graphic illustrations in this manual can, if necessary, differ slightly from the actual execution of the lift.
The operating manual for the lift as well as the installation and operating manuals of the supporting compo-
nents apply besides these installation instructions. Please observe the notes contained therein - especially the
safety notes.
1.2 Explanation of symbols
Important safety and machine-technical notes in these installation instructions are marked with symbols. The
notes must be respected to in order to avoid accidents, personal injuries and damage to property.
WARNING!
This symbolizes dangers that can lead to adverse effects on health, injuries, permanent physical dama-
ge or to death.
Adhere at all costs to the notes specied regarding work safety, and be particularly careful in these
cases.
WARNING! Danger of electric current!
This symbol draws attention to dangerous situations involving electrical currents. There is a danger of
serious injury or death if the safety notes are not complied with. The work may only be carried out by
qualied electricians.
ATTENTION!
This symbolizes notes, which if not complied with, can lead to damages, malfunctions and/or break-
down of the machine.
NOTE!
This symbol highlights tips and information that are to be observed for efcient and disruption-free assembly of
the machine.

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1.3 Liability and warranty
All information and notes in these installation instructions are provided under due consideration of valid regula-
tions, the latest technical status of development as well as our years of expertise and experience.
The translation of these installation instructions has also been made to the best of our knowledge. We do not
accept any liability for errors in translation. The version of the installation instructions marked with “Original
version” shall be binding.
For optional design versions, the use of additional ordering options or the implementation of the latest technical
modications the actual scope of delivery may differ from the descriptions and illustrations in this manual. If you
have any questions please contact the manufacturer.
We reserve the right for technical changes to the product within the framework of improving the usability and
further development.
1.4 Copyright protection
These installation instructions is to be treated as condential. It is solely intended for the persons engaged in
the installation of the machine. Relinquishment of the installation instructions to third parties without the written
permission of the manufacturer is forbidden. If necessary please contact the manufacturer.
NOTE!
The contextual details, texts, drawings, pictures and special illustrations contained within are protected by copy-
right and subject to further commercial property rights. All misuses are punishable.
Reproduction in any kind or form – also in part – as well as the utilization and/or the communication of contents
are forbidden without the written permission of the manufacturer. Any violations require compensation. Further
claims remain reserved.

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2. Safety
This section gives an overview of all important security aspects for the optimal protection of personnel as well
as for the safety and malfunction-free operation of the machine.
Additionally, the individual chapters contain concrete safety notes, marked with safety symbols, for the preven-
tion of immediate dangers. Furthermore, any pictograms, signs and labels on the machine are to be observed
and kept in good, legible condition at all times.
2.1 General
At the time of its deployment and manufacture, the machine is built according to recognized codes of practice
and is deemed operationally safe. However, dangers may arise from this machine if it is not used professionally
by trained personnel, or if it is used improperly or not according to the designated purpose. Each person autho-
rized to work with the machine must have read and understood the assembly manual before beginning work.
Changes of any kind, as well as attachments or alterations to the machine are prohibited
All security, warning and handling notes on the machine are to be constantly kept in good, legible condition.
Damaged signs or labels must be immediately renewed.
Supplied setting values or adjustment ranges are to be complied with unconditionally.
2.2 Work safety
By following the security notes during work on the machine damages to equipment and personnel can be
avoided. Non-compliance with these notes leads to a considerable risk of injury to personnel and creates the
danger of damaging or destroying the machine.
With disregard of the safety regulations all liabilities and damage claims for compensation against the manufac-
turer or its commissaries are excluded.
2.3 Personal safety equipment
In principle, the following is to be worn when working on or with the machine:
Protective work clothing
Tight tting work clothing (minimal tear strength, no wide sleeves, no rings
or other jewellery, etc.)
Safety Shoes
Safety Shoes for protection against any heavy, falling parts and slipping
on non-skidproof ground.

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2.4 Behavior in case of danger or accidents
2.4.1 Preventative Measures
•Always be prepared for accidents or re !
•Keep rst aid equipment (rst aid kit, blankets, etc.) and reghting equipment close to hand.
•Make personnel familiar with the location and use of safety, accident reporting, rst aid and rescue equip-
ment and have this training conrmed.
•Clear access routes for rescue vehicles.
2.4.2 If the worst comes to the worst: Do the right things!
•Operate the EMERGENCY STOP to shut down the machine.
•Inform the responsible person at the place of use.
•Alarm a physician and the re brigade.
•Rescue persons from the danger zone, start rst aid measures.
•Keep access routes for rescue vehicles clear.

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3 Technical data
3.1 Connection values
3.1.1 PLC control unit
Supply line via main switch 400V / 3p+N+PE / 50Hz
Voltage power adaptor primary/secondary 230V AC / 24V DC
Control voltage 24V DC
Sensor voltage 24V DC
Voltage of magnetic coil 24V DC
Power input operation / rest (type “Standard”) max. 74 W / 3,5 W
Power input operation / rest (type “Fn”) max. 115 W / 4,5 W
IP Protection terminal box / control unit IP65 / IP54
Temperatur range -10…+60 °C
Sound level of buzzer min. 65 dB
Max. power output motor protection (K1) 4 kW
Max. power output motor lighting (BEL) 500W
Fuse lighting (F2) 3,15A/tr.
3.1.2 Motor
Voltage 230 / 400 V (Δ/Y)
Phases / frequency 3p+PE / 50 Hz
Current consumption according to motor name plate 13.9 A / 9.6 A
Power input 3,0 kW
Rated speed 2770 rpm
3.1.3 Operating values
Lifting/lowering speed Approx. 6 cm/s
Permanent sound level ≤ 70 dB(A)
Operating temperature range -10… +60 °C
Operating pressure for emergency lowering
(at port A):
min. 6 bar

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3.1.4 Hydraulic system
Max. pressure of hydraulic pump 250 bar
Hydraulic pump ow volume 10,6 l/min
Max. ow volume of ow control valve 8,6 ± 0,8 l/min
Without wheel-free device With wheel-free device
Capacity [kg] 3000 3500 3500
Operating pressure [bar] 150 175 200
Setting of pressure relief
valve [bar]
160 185 210
Total oil volume in circuit ca. 10 l ca. 10 l
Oil volume in tank ca. 6,0 l ca. 6,5 l
3.2 Weights
Superstructure: All components fastened on the hydraulic cylinders
Cassette: Steel cassette concreted in the foundation containing the lifting unit
Lifting unit: Hydraulic cylinders with guides/stufng boxes, synchronization bar, hydraulic pump unit incl. hy-
draulic oil, control unit, and sensor ladder rack for the signal tone. The lifting unit is built into the cassette,
except for the control unit.
Component Lift (Type) Weight (kg) approx.
Superstructure see operating
instructions
see operating
instructions
Cassette
Lifting unit
3.3 Name plate
The name plate is located on the control and contains the following information:
•Manufacturer
•Type designation
•Machine serial-no.
•Load bearing capacity
•Year of manufacture
•Setting of excess-pressure valve
•Operating pressure
•Supply voltage
Fig. 2: Type plate

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3.4 Requirements of the place of Installation
Lifts in this series consist of an above oor as well as an under oor component. They can be installed as stan-
dard, basement or ceiling installation version.
Hydraulic cylinder, hydraulic pump, motor, valves and parts of the control are under oor-mounted in a covered
foundation frame or in a steel cassette. The foundation depth thereby depends on the design of the lift (“Te-
chnical Data”).
Superstructure, possibly with integrated wheel free device, and control box represent the above oor modules.
The lift must only be installed in dry indoor workshops or in outdoor areas protected against the inuences of
weather (wind-load, humidity etc.). The installation requires a level oor. The installation location must be free
of high dust and/or dirt loads. It must be assured that the foundation will remain dry and clean over the entire
utilization time of the lift.
When working on the oor edge (e.g. tiling of the oor) the jacket tubes of the hydraulic cylinder and the seal
packages must be appropriately protected against dust, sand, mortar, cleansing agents and other foreign mat-
ter.
The manufacturer or his representative will not accept any liability, compensation and/or warranty claims for
damage caused by the entry or introduction of foreign materials into the working range of the lift.
NOTE!
Before starting work inform the person responsible for building work about the necessary precautions in the
vicinity of the lifting platform!
Use of the lift in wet rooms, such as a car wash, is only permitted in combination with special optional equip-
ment, which is available from the manufacturer on request. In this case the control must be installed, well
protected against moisture at a place with unobstructed view to the danger zone.

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4 Installation of the lifting unit
4.1 Overview of components
The main components diagrammed in the following illustrations belong to this series
Hydraulic valve of the
hydraulic cylinder
Cover of the cassette
with sealing
Alu-stufng box
Hydraulic hoses
to the wheel-
free device
(only Type Fn)
Flow divider
for wheel-free
device
(only type Fn)
Hydraulic cy-
linder
Cable guiding
tube
(only Types
F/Fn)
Struts
Synchronizati-
on bar
Hydraulic pump
unit
Terminal box
Hydraulic hose
to the hydraulic
cylinder
Cassette
Sensor ladder
rack
Fig. 3: Component overview of lifting unit in steel cassette

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The main components for the installation of a Multilift frame are shown on the below illustration.
Suspension for
pump unit
Connection block for hy-
draulic and pneumatic
Cover of the frame
with sealing
Multilift-frame
Hydraulic pump
unit
Terminal box
Hydraulic pipe
to the hydraulic
cylinder
Sensor ladder rack
Bracket for sensor
ladder rack
Steel stufng box
with mounting ledge
Hydraulic hoses
to the valves of the
hydraulic cylinder
Hydraulic cylinder
Cylinder suspen-
sion
Synchronization
bar
Fig. 4: Component overview of lifting unit in Multilift-frame

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4.2 Placing, aligning and concreting the steel cassette
Before beginning assembly, check and determine the general layout, the placement of the control box, the steel
cassette and the foundation measurements.
For the construction of the foundation and the arrangement of the steel cassette, depending on the installation
(on top of oor, ush with the oor, etc.) a foundation plan, agreed-upon by the manufacturer or architect is to
be used.
The measurement SFF (Surface of Finished Floor) must be marked by the architect or the responsible con-
struction manager. The steel cassette must be aligned according to the measurement of the foundation plans.
The measurements specied in the foundation plan must be strictly complied with.
Place the steel cassette in the foundation with a suitable lifting machine and secure by means of assembly
bars, in order to safeguard against oating. The reference alignment for the height measurement of +3/-0 mm
to SFF is the tile frame welded on the cassette frame. Likewise verify that the steel cassette is concreted leve-
led. This is measured by means of a spirit level, which is placed crossways on the foundation frame (measure
length and width).
For the placing of the Multilift frame the documents delivered with the lift (foundation drawing F413249B and
the installation instructions 9000488) must be followed thorougly.
In order to be able to lay any supply and control cables at a later time, conduits must be installed between the
steel cassette and control box. All supply cables provided from the customer are to be pulled to the control box.
SFF-measurement must
be taken by architect
Spirit level
Spacers
Steel cassette Fig. 5: Control of the steel cassette installation
SFF

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4.3 Assembly of the hydraulic components
Before installation of the lifting unit, both the transport cover and the struts must be removed from the inside of
the steel cassette.
4.3.1 Installation of the cylinder suspension - only for Multilift lifting units
Before the cylinders can be suspended in the frame the cylinder suspensions have to tted. For this the pipe
ends have to be bolted together with each stufng box und the lower support plate by means of a galvanized
countersunk screw DIN7991 - M20x50 – 10.9. The tapped holes on the support plate must always show to the
center of the lifting unit. Afterwards the bracket for the sensor ladder rack is bolted to support plate of the right
cylinder (opposite the hydraulic pipe connection, see also chapter 4.4.5).
To prevent any rotation or displacement of the pistons fasten them in the lower support plate by means of a
galvanized countersunk screw DIN 7991 - M10x30 – 8.8.

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4.3.2 Setting of the hydraulic cylinder
NOTE!
When mounting older cassettes before setting the cylinder, put the bracket for the sensor ladder rack in the
steel cassette (it does not belong to the delivery of the lifting unit).
With new cassettes this is already welded in.
NOTE!
The sensor ladder rack is mounted in the cassette behind the hydraulic tank.
Bracket for pump
unit
Transport locks and
bleeding screws
Thread for ring
screws
Transport locks and
bleeding screws
Flat gasket
Bottom bracket
Hydraulic
connections
Sensor ladder rack
Fig. 6: Installation of hydraulic cylinder in cassette
Drive-on direction

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Bracket for pump
unit
Transport locks and
bleeding screws
Sensor ladder rack
Transport locks and
bleeding screws
Thread for ring
screws
Mounting ledge
Cylinder suspension
Hydraulic
connections
Bottom bracket
Fig. 7: Installation of hydraulic cylinder in Multilift-frame
Drive-on direction

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Install preassembled cylinders in the steel cassette as follows:
•Place the at gasket on the foundation frame (not for Multilift-frames)
•Screw two ring screws M 20 into the bearings and mount the cylinder into the cassette with a suitable lifting
device.
•Fit the cylinders with the hydraulic connection opposite to the drive-on direction. Fit the pump unit at the
rear end of the cassette as seem from the drive-on direction. The cable guiding tubes are placed in front of
the cylinder seen from the drive-on direction (observe g. 6 and 7 !).
•Remove ring screws, then screw in the galvanized fastening screws DIN 6912 - M16 x 40 - 8.8, remove
the threaded bolts and also screw in the fastening screws here. Tighten screws. The bore in the side of the
ange of the guide/stufng box facing the cassette is closed by means of a screw with nut.
•For the installation in a Multilift frame the stufng box is locked to the frame by means of galvanized xing
screws DIN 912 - M16x160 – 8.8 and the terminal strips delivered with the lift.
•The setting of the second cylinder takes place in the same way as for the rst cylinder.
•After the setting of the cylinder, remove the transport locking screw on the piston of both cylinders and
replace with the galvanized bleeding screw DIN912 - M10x16 (see illustration).
Bleeding screw
Fig. 8: Sectional view - Hydraulic cylinder with bleeding screw

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Attention!
Only remove the transport locking plates (wooden plate) from the cylinder Ø123 after the rst time the
hydrauic unit is raised, otherwise the cylinder will slide into the base stufng box.
In the case of a Multilift frame a pump unit suspension also has to be tted. The suspension is placed on the
inner mounting ledge of each stufng box and locked by means of galvanized hexagonal screws (DIN 933 –
M12x30 – 8.8) between the frame and xing screw of the stufng box.
Fig. 9: Suspension of pump unit

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4.3.3 Installation of the hydraulic pump unit
The pump unit will be delivered preassembled. Fasten the pump unit to the welded-on screws on the rear wall,
as seen in the drive-on direction (see g. 6). The unit must be levelled when mounting.
The screw plug in the oil lling bore is to be replaced by the dipstick with bleeding lter. The hydraulic hoses of
the hydraulic cylinder must be placed according to g. 6. The connection of the hydraulic hoses for the wheel-
free device (only Type Fn) takes place later, the connections to the ow divider remain plugged for the time
being.
A) Solenoid valve for hydraulic cylinder in drive-on direction left
B) Solenoid valve for hydraulic cylinder in drive-on direction right
C) Hydraulic connection for hydraulic cylinder in drive-on direction left
D) Hydraulic connection for hydraulic cylinder in drive-on direction right
E) Connection for pressure gauge
F) Oil tank
G) Pressure control valve
H) Emergency lowering valve
I) Flow divider valve
K) Dipstick
L) Assembly position "Terminal box lighting"
Attention !
The position of the hydraulic connections (D, C) must match the cylinder connections (see g. 6), otherwise the
hoses can not be installed properly.
K E L
AI H
B
G
D
C
F
Fig. 10: Pump unit type "Standard"