Maha Pitforce ab User manual

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AB | ABA | ABT | AT-NB | ATV | SAT

Lifting Accessories for Pit Jacks

Original Operating Instructions

BA551101-en

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BA551101-en

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Contents

1Safety ......................................................................................................................3

1.1 Introduction......................................................................................................................................... 3

1.2 Symbols .............................................................................................................................................. 3

1.3 Intended Use....................................................................................................................................... 3

1.4 Inappropriate Use................................................................................................................................ 3

1.5 Safety Instructions for Operation ......................................................................................................... 4

1.6 Combination with Accessories ............................................................................................................ 5

1.7 What to Do in the Event of an Accident............................................................................................... 5

2Transport and Storage .............................................................................................5

3Installation and Initial Operation ................................................................................5

4General Information..................................................................................................6

4.1 Description .......................................................................................................................................... 6

4.2 Sample Nameplate.............................................................................................................................. 6

4.3 Coefficient for Static Testing................................................................................................................ 6

4.4 Requirements on the Foundation Bearing Capacity of the Workshop Pit............................................. 7

4.5 Requirements on Suitable Lifting Devices............................................................................................ 7

4.6 Requirements on the Operator ............................................................................................................ 7

4.7 General Operating Instructions for Lifting Accessories ......................................................................... 8

5Support Systems AB / ABT / ABA / AT-NB ..............................................................9

5.1 Specifications ...................................................................................................................................... 9

5.2 Operating the Axle Crossbar AT-NB (Asymmetrical Load Center)...................................................... 14

6Axle Crossbar SAT 14.5 .........................................................................................15

6.1 Specifications .................................................................................................................................... 15

6.2 Operation .......................................................................................................................................... 16

7Axle Crossbar ATV 3.5 ...........................................................................................18

7.1 Specifications .................................................................................................................................... 18

7.2 Operation .......................................................................................................................................... 19

8Maintenance ..........................................................................................................20

8.1 Annual Inspection.............................................................................................................................. 20

8.2 Care Instructions ............................................................................................................................... 20

8.3 Greasing Points................................................................................................................................. 20

8.4 Spare Parts ....................................................................................................................................... 20

9Service Lifetime......................................................................................................21

10 Dismantling ............................................................................................................21

11 Disposal.................................................................................................................21

12 Contents of the Declaration of Conformity ..............................................................21

13 Company Information.............................................................................................22

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BA551101-en

Safety

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1.1

Introduction

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Thoroughly read this manual before operating the equipment and comply with the

instructions. Always display the manual in a conspicuous location.

Personal injury and property damage incurred due to non-compliance with these

safety instructions are not covered by the product liability regulations.

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1.2

Symbols

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Important safety instructions. Failure to comply with instructions could result in

personal injury or property damage.

Important information.

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1.3

Intended Use

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The support systems, support bridges and axle crossbars are exclusively intend-

ed, according to their rated load capacity, for the use as lifting accessories with

suitable lifting devices, in accordance with EN 1494. They are used for the safe

supporting, lifting, lowering and placing on the ground of vehicles in working pits

of commercial vehicle workshops, in closed rooms at environmental temperatures

ranging from +5 to +40 °C.

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1.4

Inappropriate Use

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Use beyond the scope of the intended purpose shall be considered as improper

use, e.g. use for other lifting works.

Use on sloping, uneven surfaces which may cause the device to tip over, is

prohibited.

Use in areas subject to explosion hazards and outdoors is prohibited. Use in

damp or areas subject to fire hazards is only permitted with the express, written

approval of the manufacturer.

The device may not be modified without the express, written approval of the

manufacturer. In the case of non-compliance, the declaration of conformity shall

lose its validity.

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BA551101-en

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1.5

Safety Instructions for Operation

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•Transportation only by trained personnel and with a suitable tool.

•Observe notes with regard to possible dangers during mounting or ensuring

correct handling.

•shall only be carried out by authorised personnel.

•Mounting, commissioning, adjusting, operating, maintenance, repairs and de-

mounting shall only be carried out by trained and authorised personnel.

•In the event that a person is not strong enough to operate the device manually,

a suitable tool or another person should be called upon.

•The operator is responsible for ensuring that the user is instructed and familiar

with the operating instructions.

•The maximum permissible positioning speed of the load-carrying equipment is

0.01 m/s. Only operation by hand is allowed.

•The maximum permissible load depositing speed is 0.1 m/s.

•During the positioning of the actuators, no limbs shall be in the hazard area.

•Load-carrying equipment, actuator and accessory kit shall be tested before use

for operational safety. The load-carrying equipment shall only be operated in a

safe and slip-resistant state.

•Actuators should be protected from falling with suitable protection parts. Oper-

ation is not permitted until missing or defective protection parts are implement-

ed according to the replacement parts list.

•The load bearing capacity specified on the name plate must not be exceeded.

•The load centre shall only be centrically carried.

•During operation when the load is in an unsecured condition, no-one must be in

the hazard area.

•Before depositing, the operator must ensure that no objects are located in load

movement area which could prevent a safe support.

•After the end of operation and before each transportation, all assembly parts

must be removed from the load-carrying system and stored in a suitable place.

•The markings and notes on the device shall be checked regularly for readability

for the entire life span and, if necessary, replaced according to the replacement

parts list.

•Maintenance and repairs shall be carried out according to the manufacturer's

stipulations by an expert.

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BA551101-en

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1.6

Combination with Accessories

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The equipment shall be operated only with accessories offered, approved or

permitted by the manufacturer.

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1.7

What to Do in the Event of an Accident

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•The injured person is to be removed from the danger area. Find out where

dressing and bandages are kept. Seek first-aid.

•Provide first-aid (stop bleeding, immobilise injured limbs), report the accident

and seal off the accident site.

•Immediately report any accident to your supervisor. Make sure a record is kept

of every occasion first-aid is provided, e.g. in an accident book.

•Remain calm and answer any questions that may arise.

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Transport and Storage

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Check package to ensure it is complete, in accordance with the order

confirmation. Report any transport damage to the carrier immediately.

During loading, unloading and transport always use suitable lifting equipment,

material handling equipment (e.g. cranes, forklifts, etc.) and the right load handling

attachments and slings. Always ensure that the parts to be transported are

suspended or loaded properly so that they cannot fall, taking into account size,

weight and the centre of gravity.

Store the packages in a covered area, protected from direct sunlight, at a low

humidity and with temperatures between 0...+40 °C (32…104 °F). Do not stack

packages.

When unpacking, take care to avoid any possibility of injury or damage. Keep at a

safe distance when opening the package strapping, do not allow any parts to fall

out.

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Installation and Initial Operation

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Installation and initial operation of the equipment may be done only by authorized

and trained service technicians provided by the manufacturer, licensed dealers or

service partners.

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BA551101-en

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General Information

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4.1

Description

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Support systems, support bridges and axle crossbars are lifting accessories for

supporting, raising, lowering and, depending on type, for carrying vehicles in order

to, among other, work on these safely. The suitability must be determined by the

type-specific technical data, functional descriptions, operating and safety instruc-

tions.

After the vehicle has been properly supported, the previously used lifting device

can be used for other tasks such as removing of assemblies or raising and lower-

ing of other vehicle axles.

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4.2

Sample Nameplate

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Lifting Accessories for Pit Jacks

Ser. Number / Year of Prod.: ***

Project: ***

Model and Version: ***

Load Capacity: ***

Net Weight: ***

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4.3

Coefficient for Static Testing

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Coefficient for static testing with all lifting accessories........................................1,5

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BA551101-en

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4.4

Requirements on the Foundation Bearing Capacity of the Workshop

Pit

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The support systems shall be used only in conjunction with workshop pits which

have a suitable foundation. For maximum loads applied to the pit edge see table

below.

Load capacity

overall

Load capacity

per edge

Ruled surface

30 x 40 mm

Wheel deflec-

tor

30 x 10 mm

[t] [t] [N/mm2] [N/mm2]

SAT 14.5 14.5 7.25 33 134

AB/ABT/AT-NB 14.5 7.25 33 134

AB/ABT 20 10 46 185

ABA 4 2 9 37

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4.5

Requirements on Suitable Lifting Devices

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The lifting accessories shall be used only in conjunction with lifting devices that

meet the following requirements:

•Inside diameter of cylinder 45 or 55 mm (depending on design of lifting acces-

sory)

•Outside diameter of cylinder > 60 mm (depending on design of lifting accesso-

ry)

•Lifting device in accordance with harmonised standard EN 1494 and EC di-

rective 2006/42/EC

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4.6

Requirements on the Operator

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All persons employed in the operation, maintenance, installation, removal and dis-

posal of the device must

•be at least 18 years old,

•be trained and instructed in writing,

•have read and understood this manual

•be on record as having been instructed in safety guidelines.

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BA551101-en

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4.7

General Operating Instructions for Lifting Accessories

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•Support tubes must not be extended. Risk of tilting!

•Danger of crushing at the edge of the pit and support bridge!

•The support system shall only be removed if the vehicle is in a secure stable position.

•

Beware of changes in the centre of gravity of the load, e.g. in case of different amounts

of fuel in asymmetric fuel systems. If necessary, use suitable lifting accessories.

•Take note of the operating instructions of all equipment and tools used.

•Check lifting accessories carefully for operational safety.

•Pre-position the lift and lifting accessory at the lift points.

•Always take up the load securely, without risk of slipping and central to the centre of

gravity.

•Position actuators, supports and bases at the support points and depending on type,

fix support pipes with pins and secure with cotter pins or wooden blocks with a mini-

mum spacing of 500 mm.

•Slowly raise or lower the load, watching it continuously.

•Set down the load without risk of slipping and central to the centre of gravity.

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Permissible Extension for Pit Jack and Support Systems

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BA551101-en

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Support Systems AB / ABT / ABA / AT-NB

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5.1

Specifications

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5.1.1

Support System ABA

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BA551101-en

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5.1.2

Support System AB

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Support System

Support

Position

Dimension A or B (min – max) dep. on Side Part

used

Version

"A/C" Version "B" Version

"D/F" Version "E"

Standard VZ 975567

Desig-

nation

Ordering

Code

AP =

400-1104

BG =

890-1320

BG =

820-1220

BG =

840-1280

BG =

960-1330

Beam 1 Standard 400-804 890-1030 820-960 840-980 960-1090

Beam 2 Standard 460-864 950-1090 880-1020 900-1040 1020-1150

Beam 3 VZ 975566 520-924 1010-1150 940-1080 960-1100 1080-1210

Beam 4 VZ 975566 580-984 1070-1210 1000-1140 1020-1160 1140-1270

Beam 5 VZ 975566 640-1044 1130-1270 1060-1200 1080-1220 1200-1330

Beam 6 VZ 975566 700-1104 1190-1330 1120-1260 1140-1280 -

Dimension

(max. overall)

Dimension (Reference

surface: Pit profile) Profile fea-

tures

Ordering

Code

Desig-

nation Version "H" "G" "C" "D" "E" "F"

Side Part "A/B/C" 185 521 107 200 85 99 from U 220 Standard

Side Part "A/B/C" 165 501 87 180 65 79 from U 200 VZ 975568

Side Part "A/B/C" 220 556 142 235 120 134 from U 260 VZ 975568

Side Part "D/F" 90 426 5 98 -17 -3 Special VZ 975567

Side Part "E" 60 396 -35 58 -57 -43 Special VZ 975567

Total net weight: approx. 120 kg

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BA551101-en

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Label: Load capacity

Label: Short operating instructions

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Pos: 5 7 / Techn ische Dokument atio n/Hebet ech nik/PI TFORCE /5 5110 1 AB / ABA/ AB T/ AT-NB / ATV / SA T/BA /I n ha lt: 5511 V a ria nte n A-F ( Tex t) @ 27\m od_1328787587112_75.docx @ 1543866@ @ 1

Version A Version B Version C Version D Version E Version F

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BA551101-en

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5.1.3

Support System ABT

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Support system ABT Support

position

Pit dimension A or B (min-max) dep. on side part used

Version

"A/C"

Version

"B"

Version

"D/F"

Version

"E"

Standard VZ 975567

Desig-

nation Order code

AP BG =

890...1320

BG =

820...1220

BG =

840...1280

BG =

960...1330

Beam 1 Standard 80…1010 890...1030 820...960 840...980 960...1090

Beam 2 Standard 80...1010 950...1090 880...1020 900...1040 1020...1150

Beam 3 VZ 975566 80...1010 1010...1150 940...1080 960...1100 1080...1210

Beam 4 VZ 975566 80...1010 1070...1210 1000...1140 1020...1160 1140...1270

Beam 5 VZ 975566 80...1010 1130...1270 1060...1200 1080...1220 1200...1330

Beam 6 VZ 975566 80...1010 1190...1330 1120...1260 1140...1280 ---

Dim. (max.

overall)

Dim. (Reference surface pit

profile)

Profile fea-

ture Order code

Design. Version "H" "G" "C" "D" "E" "F"

Side part "A/B/C" 185 650 107 200 87.5 99 from U 220 Standard

Side part "A/B/C" 165 630 87 180 67.5 79 from U 200 VZ 975568

Side part "A/B/C" 220 870 142 235 122.5

134 from U 260 VZ 975568

Side part "D/F" 90 555 5 98 -14.5 -3 Special VZ 975567

Side part "E" 60 525 -35 58 -54.5 -43 Special VZ 975567

Overall net weight: approx. 180 kg

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BA551101-en

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Label: Load capacity

Label: Short operating instructions

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Version A Version B Version C Version D Version E Version F

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BA551101-en

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5.2

Operating the Axle Crossbar AT-NB (Asymmetrical Load Center)

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•The general operating instructions for load accessories must be observed.

•Pre-position actuators central to the crossbar at the lifting points.

•Pre-position the lifting accessory central to the load’s centre of gravity.

•If necessary, identify the centre of gravity again in the case of asymmetry or

change. To do this, briefly raise the load slowly, watch out for tilting; if neces-

sary, lower slowly and reposition the lifting accessory at the tilted side.

•Always take up the load securely, without risk of slipping and central to the cen-

tre of gravity.

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BA551101-en

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Axle Crossbar SAT 14.5

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6.1

Specifications

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SAT 14.5-760

SAT 14.5-910

SAT 14.5-910 L

Load capacity 14500 kg

Support range (C) 500…900 mm 500…1050 mm

Overall length min…max (D) 760…1100 mm 910…1250 mm 910…1400 mm

Pit width (LW), Dimension "B" 770…1000 mm 920…1150 mm 920…1300 mm

Wheel deflector width (inside width), "A" 750…1060 mm 900…1210 mm 900…1360 mm

Overall width (E) 355 mm

Overall height with center support (F) 150 mm

Install. height of support extensions (G) 80 mm

Height adjustment of support tubes (H) 5 x 100 mm

Length x Width of center support (I) 300 x 150 mm

Diameter of support pin (J) 45 mm

Dimensions of support bracket (K) 100 x 100 mm

Net weight 135 kg 145 kg 155 kg

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Labels Front: Load capacity, Short operating instructions

Rear: Nameplate, Company logo

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BA551101-en

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6.2

Operation

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•The general operating rules for lifting accessories must be observed.

•Lock lifts before descending and secure against shifting.

•Ensure static stability of load in case of single lifting point at the frame front.

Pos: 78 / Tec hnisch e Do kume ntatio n/Hebet echni k/PIT FORCE/ 5511 01 AB / ABA / ABT / AT-N B/ A TV/ SAT/BA/Inhalt:5511M agnethalter+Absteckbolzen(Text)SAT @ 30\mod_1353429225525_75.docx @ 1682533@ @ 1

Magnetic Holder for Support Feet

Two magnets attached to the crossbar's middle section can be used to store the

support feet when not in use (see Fig.).

Retaining Pins

Before picking up the load, secure the support tubes using the retaining pins pro-

vided (see Fig.).

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Recommended Positioning

No. 1 with/without load, on the wheel deflector

No. 2 with/without load, directly on the pit edge

No. 3 without load, parking over the carriage

No. 4 with/without load, on the wooden block*, inside *optionally available

No. 5 with/without load, on the wooden block*, outside

Play at the limit stops is 5 mm maximum per side.

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BA551101-en

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2 3

4 5

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BA551101-en

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Axle Crossbar ATV 3.5

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7.1

Specifications

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ATV 3.5-45

ATV 3.5-30

Support range min…max (A) 600…1600 mm

Overall length min…max (B) 650…1720 mm

Installation height of center support (C) 80 / 110 mm

Support pin Ø (D) w/o Outer ring 45 mm ---

w. Outer ring / inside Ø --- 45 / 30 mm

Support disc Ø (E) 120 mm

Dimensions of support brackets (F) 120 x 120 mm

Difference Support disc ‒

C en

0…15 mm

Load capacity for support range of up to

1600 mm 2500 kg

1400 mm 3000 kg

1200 mm 3500 kg

Load capacity for center support 14500 kg

Net weight 45 kg

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BA551101-en

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Position of Labels

Company logo

Short instructions with Load capacity ranges

Nameplate

Risk of tilting

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7.2

Operation

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The ATV axle crossbar shall only be used for raising or lowering the load. Support-

ing or holding of the load is not permitted!

•The general operating rules for lifting accessories must be observed.

•Take note of the varying permitted load capacity in the support ranges.

•Fasten or position the large telescope positioning parts before the small parts.

•Slowly lift or lower the load, watching it continuously.

•Before starting further work, set the load down first or support it appropriately.

Support Disc Extender

•The support disc extender is available in the lengths of 50 (standard)/

100/150/200 mm.

Only

one

extender per support disc shall be used.

A torsion protection, consisting of one groove and a dowel pin inserted in a hull,

must always be locked in place.

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▲Pluggable support disc with extender ▲Rated load capacity

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BA551101-en

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Maintenance

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8.1

Annual Inspection

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•The maintenance interval prescribed by the manufacturer is

12 (twelve) months

This maintenance interval refers to normal workshop usage. If the equipment is

used more frequently or under severe operating conditions (e.g. outdoors), the

interval must be reduced accordingly.

•Maintenance work shall be done only by authorized and trained service techni-

cians provided by the manufacturer, licensed dealers or service partners.

•In case of non-compliance the manufacturer's warranty becomes void.

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8.2

Care Instructions

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•Periodically clean the equipment and treat it with a care product.

•Repair damage to the paintwork immediately to prevent corrosion.

•Usage of caustic cleaning agents or high pressure and steam jet cleaners may

lead to equipment damage.

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Regular care and maintenance is the key condition for functionality and long life

expectancy of the equipment!

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8.3

Greasing Points

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Slightly lubricate all sliding friction surfaces periodically or as required. Use multi-

purpose grease.

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8.4

Spare Parts

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