CryptOn CSL640 Operator's manual

Serial-number CSL640/641: __________________________
Serial-number CPD600:
The Crypton Test Lane Class 4
Automotive-Lift CSL640/641
Axle play detector CPD600
Operating Instructions and Documentation
TES1518/E

Operating Instruction and Documentation
CSL640/641
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Contents
Foreword ............................................................................................................................................................. 3
Record of installation........................................................................................................................................... 5
Record of Handover ............................................................................................................................................ 6
1. General Information................................................................................................................ 7
1.1 Installation and service checks of the automotive lift..................................................................................... 7
1.2 Warning Symbols .......................................................................................................................................... 7
2. Master document of the automotive lift ..................................................................................... 8
2.1 Lift–manufacturer Crypton Ltd........................................................................................................ 8
2.2 Application..................................................................................................................................................... 8
2.3 Changes to the Lift Construction ................................................................................................................... 8
2.4 Re positioning of the automotive lift............................................................................................................... 8
2.5 Crypton Declaration of conformity ................................................................................................................. 9
3. Technical Information ........................................................................................................... 10
3.1 Technical ratings ......................................................................................................................................... 10
3.2 Safety devices............................................................................................................................................. 11
3.3 Data sheet - CSL640/641............................................................................................................................ 12
3.4 Floor Plan - CSL640/641............................................................................................................................. 13
3.5 Data sheet - Play Detector CPD600............................................................................................................ 14
3.6 Electrical Circuit Diagrams........................................................................................................................... 15
3.6.1 Electrical Circuit Diagrams standard version............................................................................................ 16
3.6.2 Electrical Circuit Diagrams version with wireless lamp............................................................................. 25
3.7 Overview of the fuses in Crypton lifts .......................................................................................................... 40
3.8 Hydraulic Diagram....................................................................................................................................... 41
3.8.1 Hydraulic parts list .................................................................................................................................... 42
3.9 Pneumatic Diagram..................................................................................................................................... 43
4. Safety regulations ................................................................................................................ 44
4.1 General safety-regulations........................................................................................................................... 44
4.2 Additional safety-regulations........................................................................................................................ 44
5. Operating Instructions........................................................................................................... 45
5.1 Lifting the vehicle......................................................................................................................................... 45
5.2 Lowering the vehicle.................................................................................................................................... 46
5.3 Lowering onto the safety ratchet (latch)....................................................................................................... 46
5.4 Manual equalisation of the lift platforms....................................................................................................... 47
5.5 Play detector................................................................................................................................................ 48
5.6 Function test before first use. ...................................................................................................................... 49
6. Troubleshooting ................................................................................................................... 49
6.1 Lowering onto an obstacle........................................................................................................................... 50
6.2 Emergency lowering.................................................................................................................................... 50
6.2.1 Emergency lowering of the automotive lift ................................................................................................ 51
7. Inspection and Maintenance.................................................................................................. 52
7.1 Maintenance schedule for the lift................................................................................................................. 52
7.2 Maintenance schedule for the play detector................................................................................................ 57
7.3 How often must the lift be cleaned?............................................................................................................ 58
8. Security check ..................................................................................................................... 59
9. Installation and Initiation........................................................................................................ 59
9.1 Installation of the lift.................................................................................................................................... 59
9.2 Regulations for the installation.................................................................................................................... 59
9.3 Erection and doweling (Masonry bolting) the lift......................................................................................... 59
9.4 Initiation...................................................................................................................................................... 60
9.5 Changing of the place of installation............................................................................................................ 60
First security check before installation............................................................................................................... 65
Regular security check and Maintenance.......................................................................................................... 66
Extraordinary security check.............................................................................................................................. 74
Spare part list.......................................................................................................................... 76
AFTER SALES SERVICE................................................................................................................................ 100

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Foreword
CRYPTON-products are a result of long-standing experience.
The high quality and the superior concept guarantee them reliability, a long lift time and
economic business.
To avoid unnecessary damages and dangers to personnel and equipment, read these operating
instructions and follow the instructions.
Do not use the product for any other purpose other than described otherwise the guarantee will
become invalid.
Crypton Ltd is not liable for damage or injury arising from misuse. The user carries the risk
himself.
Notes for the user:
- Observe and comply with all the instructions in the operating manual
- Please follow the inspection and maintenance procedure as well as the prescribed tests
-The instruction for use should be observed by all persons working with the lift.
-The chapter “Safety Regulations“should be especially observed.
- In addition to the safety remarks included in the instructions for use, the local valid regulations
and instructions at the location of operation should also be observed.
Obligations of the operator:
The operator is obliged to allow only those persons complying to the following requirements to work
with the unit
- Being well acquainted with the basic regulations concerning labour safety, and accident
prevention and being trained to operate the unit.
- Having read and understood the chapter concerning safety and warning instructions and
confirmed that by their signature.
Dangers when operating with the lift:
The CRYPTON-Lifts are designed and built according to technical standards and the approved
regulations for technical security. Yet, danger for body and life of the operator may occur when using
the lift carelessly.
The lift must only be operated:
-for its appropriate use
-in an unobjectionable condition concerning technical security.

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Organisation requirements
-The instructions for use are constantly to be kept at the place of operation being at hand
at any time.
- In addition to the instructions for use, rules pertaining to other regulations i.e. accident
prevention and environmental rules are to be observed and directed.
- All personnel should be safety and danger alert by occasionally reading and by observing the
instructions for use which should be recorded.
-As far as required and ordered by regulations personal protective equipment and clothes are to
be worn.
- All safety- and danger-warnings on or near the lift are to be observed!
- Spare parts must comply with technical requirements laid down by the manufacturer.
This is only warranted with original parts.
Consideration should be given to the time intervals or fixed in instructions for periodic
tests/inspections.
Maintenance works, remedy of faults and disposal
-Fixed Adjusting-, maintenance- and inspection works and time intervals including
Details for exchange of parts/part components as mentioned in the instructions for use are to be
adhered to.
This work should only be carried out by trained personal.
- After maintenance and repair works, all screw connections should be checked and
tightened where required.
Guarantee and liability
- Our “General conditions of sales and delivery”are valid.
There will be no guarantee or liability for injuries of persons or anything else if these injuries are
caused by one or by some of the following reasons.
- Inappropriate use of the lift
- Inappropriate installation, initiation, operation and maintenance of the lift.
- Use of the lift while one or several security devices do not work or do not work correctly or are not
installed correctly.
- Not to follow the regulations of the operating instruction concerning transport, storing, installation,
initiation, operation and maintenance of the lift.
- Changes to the construction of the lift without written authority from the manufacturer.
- Changes of important adjustments of the lift (e.g. driving elements, power rating, motor speed, etc)
- Wrong or incorrect maintenance.
- Catastrophes, acts of God or external reasons.

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After completion of this sheet (including signatures), copy and return the original to
the manufacturer. A copy must remain in the manual.
Crypton Technology Business Park
Bristol Road, Bridgwater, Somerset, England, TA6 4BX
Record of installation
The automotive lift CSL640/641
with the serial number:........................……….. was installed on:............………….…..........
at the firm:....................................….…………. in:...............................................................
The initial safety check was carried out and the lift was started.
The installation was carried out by the operating authority/competent
(please delete as applicable).
The initial safety check was carried out by a competent person before the initial operation.
The operating authority confirms the correct installation of the automotive lift, the competent person
confirms the correct initial operation.
.......................………. ..................................………… ..................................………..........
Date Name of the operating authority Signature of the operating authority
.......................………. ..................................………… ..............................………...............
Date Name of the competent person Signature of the competent person
Your customer service:....................................................................………………..................(stamp)

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Record of Handover
The automotive lift CSL640 /641
with the serial number:...................................... was installed on:.......…………………….......................
at the firm:........................................….………. in:.................................……………................….........
the initial safety check was carried out and the lift was started.
The persons below were introduced after the installation of the automotive lift. The introduction was
carried out by either the erector from the lift-manufacturer or from a franchised dealer (competent
person).
............................................ ......................................... ............................................
date name signature
............................................ ......................................... ............................................
date name signature
............................................ ......................................... ............................................
date name signature
............................................ ......................................... ............................................
date name signature
............................................ ......................................... ............................................
date name signature
............................................ ......................................... ............................................
date name signature
............................................ ......................................... ............................................
date name signature
............................................ ......................................... ............................................
date name signature
............................................ ......................................... ............................................
date name signature
............................................ ......................................... ............................................
date name signature
Your customer service:...............................................................………………………..................(stamp)

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1. General Information
The document “Operating Instructions and Documentation” contains important information
about installation, operation and maintenance of the automotive lift.
Conformation of installation of the automotive lift is recorded on the “Record of
Installation” form and must be signed and returned to the manufacturer.
Conformation of first off, regular and out of the ordinary service checks is recorded in the
respective check forms. The forms are used to document the checks. They should not
be removed from the manual.
All Changes to the structure and any change of location of the automotive lift must be
registered in the ”Master document” of the lift
1.1 Installation and service checks of the automotive lift
Only specialised staff are allowed to repair and maintain the lift and only these specialised staff
are allowed to conduct safety checks on the lift. For the purposes of this document these
specialised staff will be called Experts and Competent persons.
Experts are persons (for example self-employed engineers, experts) who have received
instructions and have the appropriate experience to check and to test the automotive
lifts. They are aware of the work involved and know the accident prevention
regulations.
Competent persons are persons who have acquired adequate knowledge and experience with
automotive lifts. They have completed the appropriate training provided by the lift-
manufacturer (the servicing technicians of the manufacturer or dealer, are regarded as
competent)
1.2 Warning Symbols
The three symbols below are used to indicate danger and other important information. Pay
attention to areas on and around the lift that are marked with these symbols.
Danger! This sign indicates danger. Ignoring this warning may result in injury or
even death.
Caution! This sign cautions against possible damage to the automotive lift or other
material objects in the case of improper use .
Attention! This sign indicates an important function or other important
information regarding the operation of the lift.

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2. Master document of the automotive lift
2.1 Lift–manufacturer Crypton Ltd.
Crypton Technology Business Park
Bristol Road Bridgwater, Somerset
England
TA6 4BX
2.2 Application
The automotive lift is a lifting mechanism for lifting motor vehicles with a laden weight of 4000
kg. The automotive lift has an additional function for axial measurement, tyre and brake service.
The automotive lift can be installed above or below the floor surface. It is not permitted to install
the standard lift in hazardous locations or in wash bays. The lift is not equipped to be installed
ramped surfaces or for carrying people. Before operating the lift pay Attention to the detailed
operating instructions and maintenance instructions.
The lift is equipped with a play detector which is able to detect play in the axles and on single
wheel suspensions. The detection is possible up to a load of 1300 kg per wheel.
2.3 Changes to the Lift Construction
Changes to the construction, expert checking, resumption of work (date, type of change,
signature of the expert)
..............................................................................................................................................................
..............................................................................................................................................................
..............................................................................................................................................................
..................................………………………………………..............………………………………………..
Name, address of the expert
..........................................……...... ....……................................................
Location, Date Signature of the expert
2.4 Re positioning of the automotive lift
Re positioning of the automotive lift, expert checking, resumption of work (date, kind of
change, signature of the competent)
..............................................................................................................................................................
.............................................................................................………………………………………………
……………..…………….………………………………………..…………………………………………….
…..……………………………………………………………………………………………………………….
Name, address of the competent
.............................................. .......................................................
Location, Date Signature of the competent person

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2.5 Crypton Declaration of conformity

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3. Technical Information
3.1 Technical ratings
Lifting capacity 4000 kg
Load distribution max. 2:1 in or against the drive on direction
Lifting time approx. 27 sec
Lowering time approx. 32 sec
Lifting capacity play detector minimum 1300 kg per wheel
Line voltage 400 Volt three phase
Power rating 3.0 kW
Motor speed 2800 rev./min
Pump capacity 2.7 ccm (Marz.)
Hydraulic pressure approx. 300 bar
Pressure control valve approx. 320 bar
Hydraulic pressure play detector approx. 123 bar
Pressure control valveplay detector approx. 125 bar
Oil tank per Hydraulic unit approx. 17 Litre
Sound level 75 dB(A)
Connection by customer 3~/N+PE, 400V, 50 Hz
fuse T16A (time-lag fuse)
observe your country regulations

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3.2 Safety devices
1. Click and pawl arrangement
safety device of the load against unintentional lowering.
2. Pressure relief valve
Pressure relief-safety for the hydraulic system.
3. Roll-off safety on the platforms
Safety device of the lift against vehicle roll.
4. Lockable main switch.
Safety device against unauthorized use.
5. Check valves at the hydraulic cylinders
Safety device against lowering and pipe-breaking.
6. CE-Stop and Danger signal
security equipment against crushing (foot area).The end of the lowering process is
accompanied by an acoustic warning signal.
Control of Synchronisation is part of the anti blocking system for lowering onto an obstacle.
For electrical diagram of the system please turn to section 3.6.1
If either ramp is offset by more than 14 mm i.e. after an obstruction has halted one side,
then the system will actuate and stop the descent of the lift.
Turn to section 6.1 lowering onto an obstacle for instructions on how to bring the lift back
into operation.

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3.3 Data sheet - CSL640/641

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3.4 Floor Plan - CSL640/641
Shown for reference only

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3.5 Data sheet - Play Detector CPD600
MOT Play detector
Piston Rod: Ø 25 mm
Piston rod surface: A = 490, 87 mm²
F = 6 KN => p = 122, 2 bar CLASS IV
F = 8 KN => p = 162, 9 bar CLASS VII

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3.6 Electrical Circuit Diagrams (Connection Diagrams)
The earth connections should comply with local regulations
Make sure that all connections and contacts are secure and in place
Check that all wiring and electrical components are in place before commissioning
Do not allow commissioning at a site not suitable for the equipment.
1. Connection diagrams and electrical components
All diagrams have been drawn by us to the best of our knowledge. We take no responsibility for
diagrams other than these to be used with the equipment. This is especially the case of diagrams
drawn up by second parties.
2. Checking the diagrams
The diagrams do not always refer to serial components. Some of these components such as switches,
thermostats and motors might not be shown. Even with careful testing, we cannot rule out problems
occurring with the systems. We cannot take any responsibility for misuse of the guidelines on
installation of the equipment. Any request for changes to the diagrams in order to enable the equipment
to function better will be at the request of a surplus charge. Improvements by third parties cannot be
accepted.
Equipment: CSL 640/641
Diagram No. CSL 640/641
3. Safety checks and means of protection
All connections have been made under the code VDEO 100/0113 and the accident prevention code
V8641 for electrical equipment.
The following tests have been completed:
1. Isolation check on the switchboard and control boards according to VDEO/5 73
2. Checking the functions of the applied safety features by indirect touching of components
according to the code VDEO100g/7/75 par 22.
3. Functions and component checks according to code VDE560/11 87
Other safety codes have been adhered to:
1. Protection against direct contact code VDEO100/5. 73. Par 4
2. Protection against indirect contact code VDE=100/5. 73. Par 5
These connection diagrams are the property of the manufacturers. They should not be used for any
other purpose or given to a third party without the authority of the manufacturers
Next: Schematic Diagrams for CSL640/CSL641 with hydraulic Axle Play Detector.

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3.6.1 Electrical Circuit Diagrams Standard Version

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Contents

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Supply

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Control Unit

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Light Barrier