Leantechnik lifgo User manual

lifgo®& lean SL®5.0 – 5.3
Mechanical arrest system
Assembly instructions
LEANTECHNIK AG
Year of manufacture: 2012 / Datum: 17.12.2012 / Version: 00
CE coordinator: Lukas Piofczyk / Editor: Martin Siemann
www.leantechnik.com

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Index
1 Rules
1.1 Introduction 4
1.2 Machine designation 4
1.3 Contact address 5
1.4 Warranty 5
1.5 Product responsibility 5
1.6 Risk assessment 5
1.7 Declaration of incorporation 5
1.8 Scope of delivery 7
1.9 Symbols used 7
2 Product information
2.1 Intended use 8
2.2 Inappropriate use 8
3 Technical data (data sheet)
3.1 Dimension sheet 9
3.2 Weights and dimensions 10
3.3 Load capability 10
3.4 Adjusting drive 10
4 Safety instructions
4.1 General information on component operation 11
4.2 Choice of personnel and qualifications 13
4.3 Transporting the mechanical arrest system 13
4.4 Storing the mechanical arrest system 14
4.5 Installing the mechanical arrest system 14
4.6 Starting the component 14
4.7 Maintenance and repair 15
4.8 End-of-life, decommissioning, disposal 15
4.9 Resale of the component 16
4.10 Other provisions 16
5 Transport and lifting instructions
5.1 General 17
5.2 Adjacent machine parts 17
LEANTECHNIK AG

3
LEANTECHNIK AG
6
6.1 18
6.2 19
6.2.1 19
6.2.2 19
6.3 20
6.4 20
6.5 20
6.6 20
6.7 20
7
7.1 21
7.2 21
7.3 21
7.4 21
8 22
9 22
10 22
11
11.1 23
11.2
Function description
Operating process
Installation positions
Gearbox moves the lift load
Gear rack moves the lift load
Gearbox
Unlocking
Locking
Required procedure
Proximity switches
Maintenance
Screw connections
Rust protection
Lubrication
Lubrication and maintenance points
Spare parts
Standard parts
List of documents and drawings
Troubleshooting and fault correction
General
Table 23

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1 Rules
1.1 Introduction
These instructions describe the installation, operation and maintenance of the mechanical arrest
system for lifgo®, lifgo®linear and lean SL®units of sizes 5.0, 5.1 and 5.3.
The mechanical arrest system is a mechanism designed to prevent the uncontrolled descent of
components, elements in components or heavy weights and also to prevent the unwanted ap-
plication of forces.
These instructions contain important details relating to the mechanical arrest system. To ensure the
long-term, trouble-free operation of the system, it is essential that the instructions set out here are
adhered to during all phases of the component lifecycle.
Read the current instructions carefully!
In the event of any doubt, contact LEANTECHNIK AG.
The manufacturer of the component is not liable for any environmental harm, damage to property
or personal injury arising out of modifications or operations that do not conform to the present
manual.
© Copyright
The reproduction of texts, images or drawings, either in whole or in part, is prohibited without
LEANTECHNIK AG‘s written approval!
This also applies to the production of copies, translations, microfilming and storage in electronic
systems.
1.2 Machine designation
The component is manufactured and marketed under the name ‘Mechanical arrest system for
lifgo®, lifgo®linear and lean SL®, sizes 5.0, 5.1 and 5.3‘ (see type plate).
This designation should be used in communications and any requests for information. In the re-
mainder of this manual, the mechanical arrest system will be referred to as ‘ASS’, ‘component’
or ‘system’.
LEANTECHNIK AG is the manufacturer of the mechanical arrest system.
1.3 Contact address
LEANTECHNIK AG
Im Lipperfeld 7c
46047 Oberhausen
Germany
Telefon ..49 (0) 208 · 495 25 - 0
Telefax ..49 (0) 208 · 495 25 -18
E-Mail [email protected]
www.leantechnik.com
CE coordinator: Lukas Piofczyk
1 Rules

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1.4 Warranty
As an exception to the General Terms and Conditions (GTC), the manufacturer’s warranty issued
by the company LEANTECHNIK AG runs for 2 years.
=> see separate documentation: ‘GTC’
The warranty for spare parts runs for 12 months following first usage of the parts and for a maxi-
mum of 24 months following delivery.
When replacing parts or performing repairs, only use original LEANTECHNIK AG spare parts
since no guarantee can be given of the perfect material quality, correct dimensioning and correct
machining of parts from other sources.
Any modifications or conversions made without the manufacturer’s express written approval will
result in the loss of any entitlement to warranty claims!
1.5 Product responsibility
LEANTECHNIK AG, as manufacturer of the component, and the operator are responsible for the
component and the individual components it comprises.
The responsibility of the operator relates primarily to operating safety and maintenance of the
component.
The manufacturer will accept no liability for damage or injury arising from the incorrect use of the
product.
1.6 Risk assessment
LEANTECHNIK AG, as the manufacturer of the component, possesses a detailed risk assessment.
Danger!
When activating the mechanical arrest system, there is a danger of hair, clothing or body
parts being pulled in!
If the mechanical arrest system is installed incorrectly, correct operation is not guaranteed!
On disassembly, the mechanical arrest system must not be active and no load may be ap-
plied!
1.7 Declaration of incorporation
The following declaration applies to machines that are not ready for use, i.e. which cannot func-
tion on their own and which are incomplete in terms of safety provisions (submachines).
The mechanical arrest system for lifgo®, lifgo®linear and lean SL®, sizes 5.0, 5.1 and 5.3 be-
longs to this category.
1 Rules

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LEANTECHNIK AG
Im Lipperfeld 7c · D - 46047 Oberhausen
Telefon ..49 (0) 208 · 495 25 - 0
Telefax ..49 (0) 208 · 495 25 -18
E-Mail [email protected]
www.leantechnik.com
Declaration of incorporation
In accordance with the EU Machinery Directive 2006/42/EC, Annex II B:
Name of manufacturer LEANTECHNIK AG
Adress Im Lipperfeld 7c
46047 Oberhausen
Germany
We declare herewith that the partly completed machine designated below complies with the
EU Machinery Directive 2004/42/EC and subsequent amendments through to its interfaces:
Designation / type: Mechanical arrest system (ASS) for
lifgo®, lifgo®linear, lean SL®
sizes 5.0, 5.1 and 5.3
Order number: Article: Date of manufacture:
The following harmonized standards apply:
EN 12100 Safety of Machinery, Basic Concepts Parts 1 and 2
EN ISO 14121-1 Safety of Machinery, Risk Assessment
The designated partly complete machine is intended for installation in a machine or for assembly
with other machines.
We declare that commissioning is prohibited until the machine or component in which this partly
complete machine is installed or of which this partly complete machine forms a component
complies in its entirety with the provisions of the Machinery Directive 2006/42/EC and the
Declaration of Conformity as set out in Annex II A is available.
The present declaration shall cease to be valid in the event of any modification not agreed upon
with us.
Authorised representative for the compilation of technical documentation:
Lukas Piofczyk (CE coordinator)
Oberhausen,
Date: Signature (Managing Director):
Declaration of incorporation

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1.8 Scope of delivery
The LEANTECHNIK AG scope of delivery comprises the following items:
· Mechanical arrest system
· Pneumatic system
· Proximity cylinder
· Assembly drawing
· Operating instructions in English
· Assembly and acceptance at LEANTECHNIK AG
The scope of delivery does not include:
· Electrical controller
· Operator controls
· Safety-relevant connections / overall concept
· Final installation
· Test run
· Commissioning
· Lubricating oils and greases
· Preparation and provision of pneumatic and electrical supplies
1.9 Symbols used
1. Caution sign Caution! or Danger!
2. Information sign Important installation, safety, and functional notes
1 Rules
!

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2 Product information
2.1 Intended use
The mechanical arrest system is a mechanism design to prevent the uncontrolled descent of
systems, system components or heavy weights and also to prevent the unwanted application of
forces and is attached to / installed in gear racks.
It may only be used to protect systems / machines / equipment against falling or sudden collapse
during inspections or in the event of repair work.
The mechanical arrest system may only be used together with lifgo®, lifgo®linear or lean SL®.
All other uses and functions are prohibited!
Caution! Divergent uses, even if only in part, of individual components of the mechanical
arrest system are also prohibited!!
2.2 Inappropriate use
All functions and procedures that have not been explicitly approved for the mechanical arrest
system are prohibited.
The mechanical arrest system must not be used as a brake / emergency brake!
This also applies to any departures from the provisions of sections 2.1 and 3!
2 Product information

3 Technical data (data sheet)
3.1 Dimension sheet
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3 Technical data (data sheet)
A
B
D
E
F
G
M
C2
H
J1
K
L
J
O
H
I
J
N
C1
C3
M
Einheit 5.0 5.1 5.3
A mm 70 80 130
B mm 55 67 90
C1 mm 124,5 164,5 216,5
C2 mm 116 153 197,5
C3 mm 124,5 164,5 216,5
D mm 55 60 105
E mm 6,5 7,5 11
F mm 50 72 120
G mm
8,2 durch
12 8,6
10,2 durch
14 10,6
13 durch
20 12,6
H mm 45,5 68,5 106
I mm 10 10 10
Schmierbohrung für
Lifgo und lean SL
Ritzel/Zahnstange
J mm M6
6 M10x1 10 M10x1 10
J1 mm
5 5 5
K mm 56,5 79,5 131
Passbohrung L mm
6F7 10 6F7 10 6F7 10
Für Zahnstangeschutz M mm M4 M4 M4
Steckanschluss für
Luftschlauch
N mm
6 6 6
Näherungsschalter O SME-8F-DS-24V-K0,3-M8 LZ - Festo
P mm
R mm
S mm
T mm
U mm
V mm
W mm
Gewicht - lifgo Kg 1,9 3,3 10,5
Gewicht - lifgo linear Kg 1,8 3,5 11,4
Gewicht - lean SL Kg 2,0 3,6 11,5

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3.2 Weights and dimensions
Mechanical arrest system
(ASS) for lifgo®
Unit 5.0 5.1 5.3
Amm 70 80 130
Bmm 55 67 90
C1 mm 124,5 164,5 216,5
C2 mm 116 153 197,5
C3 mm 124,5 164,5 216,5
Dmm 55 60 105
Emm 6,5 7,5 11
Fmm 50 72 120
Gmm Ø 8,2 through
⨆ Ø12 ↧8,6
Ø 10,2 through
⨆ Ø14 ↧10,6
Ø 13 through
⨆ Ø20 ↧12,6
Hmm 45,5 68,5 106
Imm 10 10 10
Lube hole for pinion/gear
rack
Jmm M6 ↧6M10x1 ↧10 M10x1 ↧10
J1 mm Ø 5 Ø 5 Ø 5
Kmm 56,5 79,5 131
Dowel hole Lmm Ø 6F7 ↧10 Ø 6F7 ↧10 Ø 6F7 ↧10
For gear rack protection Mmm M4 M4 M4
Plug-in connector for air hose Nmm Ø 6 Ø 6 Ø 6
Proximity switch OSME-8F-DS-24V-K0,3-M8 LZ Festo
Weight lifgo®kg 1,9 3,3 10,5
Weight lifgo® linear kg 1,8 3,5 11,4
3.3 Load capability
Load-bearing capacity: at least 5 times the safety provided by gears
3.4 Adjusting drive
Locking Note
Number of motors 1x pneumatic cylinder
Pressure Min. 5 bar
Auxiliary voltage 24 V DC
3 Technical data (data sheet)

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4 Safety instructions
4.1 General information on component operation
The safety instructions apply to all component lifecycle phases. These include transportation, instal-
lation, commissioning, service life, maintenance, troubleshooting and decommissioning.
All specialist personnel responsible for the component must read the operating and maintenance
manual. The manual must be available at all times. The personnel must read and understand the
manual.
The operating and maintenance manual must be kept in good condition. Damaged, lost or illeg-
ible pages must be replaced immediately.
All sequences and specifications relating to the correct operation of the component must be ob-
served.
Some details:
· Only use the component in accordance with specifications set out in sections 2.1 and 3!
· Do not adjust or turn any proximity switches!
Caution! The safety mechanisms and rules must be harmonized with the safety concept
of the overall system (feed-in and removal mechanisms, drives, controller)!
The component may only be operated by authorized personnel during all lifecycle phases,
including the elimination of problems (troubleshooting).
In addition to the points mentioned throughout the manual, the following points must be ob-
served when operating the component:
· These safety instructions should be considered as a guideline and extension to applicable na-
tional legislation.
· All persons who work with the component must be familiar with the relevant component technol-
ogy.
· Repairs must be performed by qualified specialists who are familiar with the product and the
associated technology.
· Transportation and repair work, as well as installation, must be performed with extreme care
and attention to avoid any damage to the component.
· All persons who work with the component must observe the instructions and regulations set out
in the present manual.
· A completely up-to-date version of these instructions must always be present in the vicinity of the
component and be accessible to operators.
· All changes at the component that deviate from the original layout must be recorded in these
instructions.
· If any malfunction occurs then the cause must be eliminated immediately. If the cause of the
malfunction cannot be identified and/or eliminated, then help must be obtained immediately
from a specialist or from the company LEANTECHNIK AG.
4 Safety instructions

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· The use of spare parts not supplied by LEANTACHNIK AG is not permitted since we have not
inspected these parts and they may therefore have a negative influence on the reliability of the
product.
· The use of spare parts not supplied by LEANTECHNIK AG invalidates the component warranty
since we do not accept any liability for such spare parts.
· Lubricant oils, detergents, preservatives and acids must be collected and disposed of in accord-
ance with the applicable legislation.
· Keep clothing, hands and other parts of the body away from moving parts, e.g. rollers, drums,
belts, levers etc.! You should preferably wear closely fitting clothes and tie long hair back.
· Before moving or transporting anything, make sure that there is no-one in the risk area.
· Before any maintenance work, the power supply must be disconnected and the mechanical
locking devices provided for this purpose must be activated!
· Observe the safety notes and signs on the component.
· Take all possible preventive measures to avoid injury or damage of any type. Make sure that
the component can be operated and repaired safely under all circumstances.
Potential sources of danger at the component are all identified in the hazard examination
and risk analysis.
=> see section 1.6 Risk assessment
Danger!
Never bypass any safety mechanisms!
Never deactivate any safety mechanisms!
All specialist personnel who operate and maintain the drive must read the operating and
maintenance manual.
· The manual must be available to operators at all times.
· The operators must read and understand the manual.
!In the event of any doubt or uncertainty, it is essential to contact the manufacturer of the
component!
The operating and maintenance manual must be kept in good condition. Damaged, lost or
illegible pages must be replaced immediately.
The safety regulations set out in the following documents must be strictly adhered to:
· Operating and maintenance manual
· Legally applicable accident prevention regulations
· The company’s internal safety, operating and working instructions
4 Safety instructions

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The machine and component manufacturer cannot be held liable for damage to property or
personal injury in the following cases:
· If the component has been modified compared to its original design
· If the component has been used or maintained in ways contrary to those set out in these instruc-
tions.
· If the component has been operated or maintained by untrained or unauthorized personnel.
4.2 Choice of personnel and qualifications
Persons
Activity
(lifecycle phase)
Specially trained
personnel
Instructed
operating
personnel
Instructed personnel
with specialist training
(mechanics /
electrical engineering)
Transport X – –
Installation X – –
Commissioning X – –
Setup X – X
Normal operation X X –
Cleaning X X –
Maintenance X – X
Troubleshooting and
correction of faults
X – X
Disassembly X – –
Disposal / recycling X – –
Key: X = Permitted / -- = Not permitted
Internal instructions must define, on the basis of the employees’ qualifications, who is responsible
for what tasks and is then authorized to perform them.
The minimum legal age of personnel must be observed.
4.3 Transporting the mechanical arrest system
The mechanical arrest system is transported in its assembled state.
=> see the documentation for lifgo®, lifgo®linear and lean SL®
=> see section 5 Transport and lifting instructions
4 Safety instructions

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4.4 Storing the mechanical arrest system
The component is treated with a preserving agent ex-works. The parts are therefore protected
against for a maximum of 6 months if stored in a dry environment.
The corrosion protection at all unpainted areas (sliding areas, gear racks) must be inspected be-
fore admission into storage and renewed if necessary. Prior to a trial run, the corrosion protection
must be removed and replaced by the lubricant specified in the maintenance instructions.
The component must never be stored outdoors.
Caution! No other parts may be stored on the mechanical arrest system!
4.5 Installing the mechanical arrest system
The component must be installed in accordance with the supplied general drawing.
=> see drawing for article number
Before starting installation, make sure that all the parts have been supplied and are available. All
the parts must be installed correctly.
The electrical and pneumatic connections must be established.
We cannot accept liability for errors or damage of any type.
4.6 Starting the component
Before start-up, the mechanical arrest system must be integrated in the overall safety concept.
The personnel must be trained and qualified.
All measurement and alarm displays (safety components) must be installed and checked for error-
free functioning before the component is activated. If one of the displays indicates a malfunction,
do not activate the mechanical arrest system. If the malfunction occurs after the component has
been activated for the first time, check the functioning of the mechanical arrest system and the
safety system again.
Make sure that the required lubricant has been applied at all lubrication points.
=> see lubrication and maintenance schedule in section 8.7.
Caution! Check whether the proximity switches are activated correctly.
4 Safety instructions

15
4.7 Maintenance and repair
Caution!
The safety notes in section 4 apply!
The mechanical arrest system must not be repaired.
If damage occurs, the complete mechanical arrest system must be replaced!
The mechanical arrest system must be installed and removed by specialist personnel.
Maintenance must be performed under the best possible conditions.
In the event of an accident, a doctor must always be called.
The fixing bolts must be tightened correctly and with the correct torque (see section 8.4) and
secured against unintentional release.
For further information on maintenance, see the maintenance schedule in section 8 of these instruc-
tions.
Danger! When cleaning parts with compressed air,
protective goggles must always be worn.
4.8 End-of-life, decommissioning, disposal
When the component is decommissioning, ensure that the environmental protection regulations
are observed. This means that different materials must be separated prior to disposal (different
metals isolated, plastic, rubber, electronics, etc.).
Mechanical parts must be separated from electrical, pneumatic and hydraulic parts, i.e. remove
cable harnesses, dismount motors, remove hoses, collect fluids etc.
All parts must be free of oil and grease. Oil and grease must be removed and disposed of in
accordance with regulations.
All parts that were lubricated during the product’s service life must be cleaned.
!Regulations and legislation relating to the disposal of oil and grease must be complied
with. Companies that dispose of these materials must present the necessary authoriza-
tions.
4 Safety instructions

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4.9 Resale of the component
If the component is resold, all the regulations regarding decommissioning described in section
4.8 must be observed.
The purchaser must also be supplied with the documentation in perfect condition.
4.10 Other provisions
In general, the following also applies:
· Do not depart from the technical specifications as set out in sections 2.1 and 3!
· Do not adjust or turn any proximity switches!
· All national (legislation, accident prevention regulations etc.) and, if applicable, international
safety regulations must be observed during maintenance, cleaning, repair, installation and
troubleshooting operations!
· The safety instructions and provisions set out in the maintenance manuals for the individual
machines such as the lifgo®, lifgo®linear and lean SL®must also be observed!
· Smoking is prohibited in the proximity of flammable materials.
Caution! In the event of any questions regarding functions which you are unable to an-
swer or problems to which you are unable to identify a solution, it is essential to contact
the component manufacturer!
!If you are in any doubt, it is also essential to contact the component manufacturer!
4 Safety instructions

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5 Transport and lifting instructions
5.1 General
The mechanical arrest system must be lifted and moved by hand.
=> see the documentation for lifgo®, lifgo®linear and lean SL®
If lifting cables or slings are used then it is important to make sure that these do not touch the
proximity switches and hoses on the cylinder since this could deform or destroy parts and the
component may then be unable to perform its function.
When lifting and putting down the component, avoid any jolts or impacts.
!Any load-lifting equipment such as eye bolts, straps or cables must be designed to sup-
port the weight to be lifted. The weight of an individual mechanical arrest system is
indicated in the data sheets.
5.2 Adjacent machine parts
Adjacent parts must first be dismounted.
Hose, tube and cable connections must be disconnected from the machine that is to be trans-
ported and stowed in a way that is suitable for transportation.
5 Transport and lifting instructions

18
6 Function description
Caution! The mechanical arrest system is not an emergency brake!
6.1 Operating process
The LEANTECHNIK AG mechanical arrest system (short name: ASS) is a mechanism designed
to prevent the uncontrolled descent of systems, system components or heavy weights and also to
prevent the unwanted application of forces and is attached to / installed in gear racks in combi-
nation with a lifgo®, lifgo®linear or lean SL®.
It is used to protect systems / machines / equipment etc. against falling or sudden collapse dur-
ing inspections or in the event of repair work.
When used in combination with a lifgo®or lean SL®gearbox, the ASS can also be used as a
positioning unit for a given value. Please consult us for further information!
The secured force is 5 times greater than the nominal force of the associated lifgo®or lean SL®
gearbox. It is not permitted to exceed these forces at any time.
The force is secured in only one direction of movement (see drawing on the next page) which is
opposite to the load or lifting direction and only provided that an electronic drive containing a
service brake is used.
This protective device has a simple, robust method of operation. In normal operation, an air cylin-
der keeps the ASS open against a mechanical spring pressure. This is the “free-moving position”.
When it is necessary to apply the protective device, the system / machine / equipment is first
stopped.
The air is drained from the ASS air cylinder and the spring pressure forces the toothed bar to-
wards the gear rack. The inductive switch at the air cylinder indicates that the mechanism has left
its “free-moving” position. The system is now descended at low speed until the spring pressure
fully engages the toothed bar in the gear rack. When this “locked position” has been reached,
a second inductive switch indicates this to the control unit. The downward movement is stopped
immediately. The system / machine / equipment is now mechanically held in place by the inter-
locking components.
If the system has to be unlocked again then the air cylinder must be pressurized again. The system
/ machine / equipment is then lifted at low speed. The toothed bar is released and pressed back
by the pressure from the cylinder. The inductive switch first indicates that the locked position has
been exited and then that the free-moving position has been reached. The system / machine /
equipment can resume normal operation again.
In case there is a power supply failure, the system’s service brake must first be engaged. Shortly
afterwards, the air cylinder is depressurized. The toothed bar moves towards the gear rack to just
in front of the closest tooth. If the system / machine / equipment does not descend any further,
nothing else happens! If, for whatever reason, the system / machine / equipment continues to
descend, the spring pressure forces the toothed bar into the next possible tooth space and the
mechanical interlock halts the system / machine / equipment.
In accordance with VDE and EU guidelines, all the functions must be wired in a suitable control
unit as per DIN 60204.
6 Function description

6.2 Installation positions
6.2.1 Gearbox moves the lift load
6.2.2 Gear rack moves the lift load
6 Function description
19

20
6.3 Gearbox
=> see the documentation for lifgo®, lifgo®linear and lean SL®
The dimensions at the contact points with the gearbox can be found in the assembly drawings.
6.4 Unlocking
The attached air cylinder disengages a release bar from the gear rack and is held in this position
as long as pressure is still present in the cylinder. The mechanical arrest system is now unlocked.
6.5 Locking
When the air pressure is removed, a spring pushes the release bar forwards until it engages be-
tween the teeth of the gear rack. The mechanical arrest system is now locked. To increase locking
reliability, the air cylinder can also be moved in the direction of the spring. However, this is not
necessary for operation and is not provided for as standard.
6.6 Required procedure
Before a system is locked, it must be moved to the required height. The locking mechanism is then
activated by depressurizing the mechanical arrest system’s lifting cylinder. Complete locking is
only ensured once the system has slowly descended by a maximum of 8 mm after activation so
that the teeth in the gear rack and release bar engage with one another.
The angle of entry of the release bar into the gear rack guarantees that the mechanical arrest
system cannot become unlocked by itself.
In order to unlock the mechanical arrest system, the system must be raised approximately 5 mm.
6.7 Proximity switches
Two Festo proximity switches (type SME-8F-DS-24V-K0, 3-M8 LZ) are affixed to each air cylinder
in order to check the strokes. These query the position or state (locked or unlocked) of the mechani-
cal arrest system. The locking or unlocking operation is not completed until all 4 cylinders are
inserted or retracted and have emitted a signal.
Air is supplied via quick-fit connectors for 6 mm hoses.
6 Function description
20