Maha Rge uni tram User manual

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RGE UNI TRAM

Mobile Column Lift

Original Operating Instructions

BA491701-en

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Contents

1Safety ......................................................................................................................5

1.1 Introduction......................................................................................................................................... 5

1.2 Symbols .............................................................................................................................................. 5

1.3 Intended Use....................................................................................................................................... 5

1.4 Inappropriate Use................................................................................................................................ 5

1.5 Safety Instructions for Commissioning................................................................................................. 5

1.6 Safety Instructions for Operation ......................................................................................................... 5

1.7 Safety Instructions for Servicing........................................................................................................... 6

1.8 What to Do in the Event of Defects or Malfunctions............................................................................. 6

1.9 What to Do in the Event of an Accident............................................................................................... 6

1.10 Safety Features ................................................................................................................................... 7

1.10.1 Locking Device.................................................................................................................................... 7

1.10.2 Braking Motor ..................................................................................................................................... 7

1.10.3 Phase Sequence Relay........................................................................................................................ 7

1.10.4 Thermal Overload Protection............................................................................................................... 7

1.10.5 Safety Shutdown after Motor Overload................................................................................................ 7

1.10.6 Warning and Information Labels .......................................................................................................... 7

2Description...............................................................................................................8

2.1 General Information............................................................................................................................. 8

2.2 Noise Emission.................................................................................................................................... 8

2.3 Specifications...................................................................................................................................... 8

2.4 Sample Nameplate.............................................................................................................................. 9

3Installation..............................................................................................................10

4Operation...............................................................................................................11

4.1 Requirements on the Operator .......................................................................................................... 11

4.2 Handling / Moving the Columns ........................................................................................................ 11

4.3 Lift Positioning................................................................................................................................... 12

4.4 Controls ............................................................................................................................................ 14

4.5 Main Switch ...................................................................................................................................... 15

4.6 Emergency Stop................................................................................................................................ 15

4.7 Operating Modes .............................................................................................................................. 15

4.7.1 Automatic Mode................................................................................................................................ 15

4.7.2 Single Mode ...................................................................................................................................... 16

4.7.3 Group Mode...................................................................................................................................... 17

4.7.4 Cable Remote Control....................................................................................................................... 17

4.8 Emergency-down Function, Mechanical............................................................................................ 18

4.9 Operation with more than 6 Columns................................................................................................ 19

4.10 Load Acknowledge Switch (Optional) ................................................................................................ 20

5Maintenance ..........................................................................................................21

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5.1 Annual Inspection.............................................................................................................................. 21

5.2 Care Instructions ............................................................................................................................... 21

5.3 Spare Parts ....................................................................................................................................... 21

5.4 Maintenance by the Operator............................................................................................................ 22

5.4.1 Recirculating Ball Nut ........................................................................................................................ 22

5.4.2 Options ............................................................................................................................................. 23

5.5 Setting the Hydraulic Jack................................................................................................................. 24

5.6 Display Codes ................................................................................................................................... 25

6Service Lifetime......................................................................................................27

7Dismantling ............................................................................................................27

8Disposal.................................................................................................................27

9Contents of the Declaration of Conformity ..............................................................27

10 Company Information.............................................................................................28

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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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•This lift is to be used exclusively for the safe lifting of rail vehicles. Observe the rated load

capacity.

•The lift shall not be modified without the express written consent of the manufacturer. In case of

non-compliance the declaration of conformity becomes void.

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1.4

Inappropriate Use

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Any use other than described is inappropriate, for example:

•Climbing on the lift supports

•Transporting persons on the lift supports

•Usage as mobile work platform or for other lifting operations

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1.5

Safety Instructions for Commissioning

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•Use the lift on a hard, level surface only.

•The standard lift version may not be installed and commissioned in the vicinity of explosives or

flammable liquids.

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1.6

Safety Instructions for Operation

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•Read the detailed operating manual.

•Lift operation by trained personnel over 18 years only.

•Do not exceed the rated load capacity per column as indicated on the lift nameplate.

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•Ensure an unobstructed movement of lift and vehicle.

•After raising the vehicle briefly, stop and check the lift supports for secure contact with the

vehicle.

•Closely watch lift and vehicle during raising and lowering cycles.

•The working area which cannot be overviewed by the operator should be monitored by a

second person.

•When operating the lift in single or group mode, make sure the vehicle is not tilted.

•Do not allow anyone to stay in lift area during raising and lowering cycles.

•Do not allow anyone to climb on lift or inside raised vehicle.

•Keep lift and vehicle free of tools and parts.

•When using the lift outdoors, lower the vehicle and stop operation when the wind velocity

exceeds 6 m/s.

•Push the support forks completely under the wheels or lift points of the vehicle to be raised.

•Do not drive over or pinch electrical cables.

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1.7

Safety Instructions for Servicing

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•Service work may be done by authorized service technicians only.

•Turn off and padlock the main switch before doing any repair, maintenance or setup work.

•Disconnect the mains plug before opening the control box.

•Work on the electrical equipment may be done by service technicians or certified electricians

only.

•Ensure that ecologically harmful substances are disposed of only in accordance with the

appropriate regulations.

•Do not use high pressure or steam jet cleaners. Use of caustic cleaning agents may damage

the lift.

•Do not replace or override the lift safety devices.

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1.8

What to Do in the Event of Defects or Malfunctions

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•In case of defects or malfunctions such as uncontrolled lift movement or deformation of the

superstructure, support or lower the lift immediately.

•Turn off the main switch and secure it against unauthorized usage. Contact service.

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1.9

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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1.10

Safety Features

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1.10.1

Locking Device

The locking device serves to prevent inadvertent lowering motions caused by gear,

load nut or lifting screw failure. The carriage is blocked by safety wedge (1) and

counterwedge (2).

1.10.2

Braking Motor

The motors are equipped with AC spring pressure brakes. Once the motors

are switched off, the brakes prevent any further movements.

1.10.3

Phase Sequence Relay

The phase sequence relay in the power supply unit ensures safe and

independent operation.

1.10.4

Thermal Overload Protection

Overload protection via electronically monitored thermoswitches.

1.10.5

Safety Shutdown after Motor Overload

The motor load is permanently monitored by the control PCB. If an overload of

≥15 %

occurs, the

system will switch off automatically. In this case the lift cannot be raised any more, but it can be

normally lowered to bottom position.

1.10.6

Warning and Information Labels

Do not change or remove the warning and information labels. Order replacement for defective

labels.

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Description

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2.1

General Information

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The mobile column lifts of the RGE series are produced as wheel engaging or universal lifts.

Depending on the version, the lift system consists of 2 or 4 columns and can be expanded to 6

columns in the standard version.

The lift can be expanded up to 12 columns when using a special power supply unit.

All components are easily accessible under the lifted vehicle due to a generous maximum lifting

height of 1750 mm. An extended lifting height of 2400 mm is optionally available.

The lift is a mobile unit whereby the columns can be substituted with stands when vehicles are to

be worked on for a longer period of time. The lifting columns are free to be used on other vehicles.

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2.2

Noise Emission

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The sound pressure level is lower than 70 dB(A) in the working area of the operator.

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2.3

Specifications

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Load capacity per column 7500 kg

Lifting height (standard) 1750 mm

Raising/Lowering time * 113 s

Raising speed 0.92 m/min

Motor power 1.5 kW

System of protection IP 54

Supply voltage 3~ 380/220 V; 50 Hz

Net weight per column w/o support * 452 kg

Surface load 0.5 N/mm2

* Applies to standard lifting height of 1750 mm. Raising/Lowering time and Net weight differ from

the above figures when lift is equipped with special lifting height.

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The properties indicated apply to lifts running at operating temperature.

Specifications are subject to change without notice.

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2.4

Sample Nameplate

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Mobile Lifting System

Ser. No. / Date of Production: ***

Project: ***

Type: ***

Supply Voltage: ***

Frequency: ***

Rated Current: ***

Fuse Protection: ***

Load Capacity per Column: ***

System of Protection: ***

WEEE-Reg.-No. ***

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Installation

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Example of a simple load support. The design of other supports may differ considerably depending

on the application requirements.

The support must be connected to the carriage using

all

six thread holes. The following fasteners

are needed:

6 Bolts M16x60-12.9 MAHA # 22 0912 16060 1

6 Washers M16 300 HV MAHA # 22 0125 16 2

Tightening torque:

270 Nm

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Operation

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4.1

Requirements on the Operator

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All persons employed in the operation, maintenance, installation, removal and disposal of the plant

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 intructed in safety guidelines.

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4.2

Handling / Moving the Columns

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Screw a lifting-eye bolt M16 into the tap hole on the motor plate of the column. Insert a chain or

strap through the ring and lift the column using a hoist or forklift.

Close hydraulic valve by putting valve lever in position 3.

Pump with handle to raise the moving gear. Move column to desired position.

To lower the moving gear, open the hydraulic valve by putting the valve lever in position 1. The

column is ready for operation.

Position 2 is the neutral position.

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4.3

Lift Positioning

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Connection Diagram

Control Unit

Connecting Cable

Power Supply Unit

Dummy Plug

Input Terminal

Mains Plug

Output Terminal

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•Use the lift on a hard, level surface only, preferably concrete.

•Apply the parking brake after positioning the vehicle.

•Push the support forks completely under the wheels/lift points of the vehicle.

•Attach the power supply unit (V) to the control unit (B) of the column closest to the mains

socket.

•Interconnect the columns using connecting cables (1) between input terminals (E) and output

terminals (A). Connect a dummy plug or the remote control (2) to the output terminal of the last

column.

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Do not drive over or pinch electrical cables.

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Secure the connecting cable plugs using the safety clamps.

The plugs and terminals are coded.

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•Connect the mains plug (3) of the master column with the 400 V mains socket. Recheck the

electrical connections.

•Once the main switch is turned on, the lift is ready for operation.

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4.4

Controls

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Power Supply Unit

Control Unit

Main Switch

LED Display

Indicates operating and error states.

Selector Button (on Control Unit)

Use this button to select between: Automatic / Single / Group mode

Seven-Segment Display (on Control Unit)

Indicates operating and error codes.

RAISE Button (on Control Unit)

Press and hold this button to raise the lift. Lift stops once button is released or upward travel

stop is reached.

LOWER Button (on Control Unit)

Press and hold this button to lower the lift. Lift stops once button is released or downward

travel stop is reached.

Emergency Stop Button (on Control Unit)

In case of emergency press this button to disconnect the lift from the mains supply.

Pull out the button to make the lift ready for operation.

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4.5

Main Switch

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The main switch is used as emergency switch. In case of emergency turn it to position 0.

•Main switch in position 0: Power supply is interrupted

•Main switch in position 1: Lift is ready for operation

•When in position 0, the main switch can be protected against tampering

by means of a padlock.

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4.6

Emergency Stop

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In case of emergency push the emergency stop button to stop the lift movement immediately.

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To make the lift ready for operation, unlock the emergency stop button and switch off the lift briefly

using the main switch.

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4.7

Operating Modes

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4.7.1

Automatic Mode

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Select "Automatic mode" by pressing this button on each column.

Activation of this operating mode is indicated by the letter A on the seven-

segment display.

Use these buttons on the control unit to raise or lower the lift.

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After switch-on the lift is in automatic mode.

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BA491701-en

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4.7.2

Single Mode

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When operating the lift in Single mode, make sure the vehicle is not tilted. Otherwise the vehicle

may fall off the lift!

Pos: 75 /Technische Dokumentation/Papierkorb/Hebetechnik/Inhalt: Single-Betrieb (mit Warnung) RGE @ 20\mod _1268321049708_75.do cx @ 824703 @ @ 1

Select "Single mode" by pressing this

button on the desired column.

Activation of this operating mode is

indicated by the lit LED on the selector

button and the letter S on the seven-

segment display.

The columns not in Single mode are

temporarily inoperative. This is indicated by

the letter A flashing on the seven-segment

display.

Use these buttons to raise or lower the lift.or

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The single mode can also be used for several columns simultaneously

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Height offsets between individual columns will be maintained after switch-over to automatic mode.

The offset can be removed either

– by equalizing the carriages in single mode or

– by lowering all carriages to bottom position in automatic mode.

•Lift switches off once first carriage reaches upward travel stop.

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BA491701-en

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4.7.3

Group Mode

Pos: 80 /TechnischeDokumentation/Hebetechnik/00 HBZ Alle/Inhalte/Warnung!/Inhalt: Warnung -GruppenbetriebRG @ 20\mo d_1268321843218_75.d ocx @ 824769 @ @ 1

When operating the lift in Group mode, make sure the vehicle is not tilted. Otherwise the vehicle

may fall off the lift!

Pos: 81 /Technische Dokumentation/Papierkorb/Hebetechnik/Inhalt: Gruppen-Betr ieb (mit Warnung) RGE @ 21\mod_12819 58619825_75.d ocx @ 879 733 @ @ 1

2 sec

Select "Group mode" by pressing and

holding this button for approx. two

seconds.

Activation of this operating mode is

indicated by the lit LED on the selector

button and the letter G on the seven-

segment display.

The columns not in Group mode are

temporarily inoperative. This is indicated by

the letter A flashing on the seven-segment

display.

Use these buttons to raise or lower the lift.or

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4.7.4

Cable Remote Control

Pos: 83 /Technische Dokumentation/Papierkorb/Hebetechnik/Inhalt: Kabelfernbedienung RGE @ 12\mod_123175811 5175_75.docx @ 301885 @ @ 1

A remote control (model TCNA 10-2) is optionally available.

The RAISE, LOWER and Emergency Stop buttons have the same functions as the corresponding

buttons on the column control units.

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Except for the emergency stop button, the remote control is not usable in single mode.

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BA491701-en

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4.8

Emergency-down Function, Mechanical

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Authorized personnel only! Do not restart the lift before the error has been remedied.

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In case of power failure or defects the lift can be lowered manually.

Once the locking device is in engagement, manual lowering is no longer possible.

The following components are required for manual lowering:

A Lever at brake motor B Locking device

1 Pull or shake the safety wedge downward on each column.

2 First push onto the latch using a long screw driver, then additionally push the manual release

lever (in arrow direction).

Intermittently lower the columns in increments of approx. 50 mm (2 in), until the lift is in bottom

position.

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Pos: 90 /Technische Dokumentation/Hebetechnik/49 Radgreifer-Hebebühnen/0801 RGE/BA/Inhalt: 4908 Manuelles Ab senken RGE/RGA (Bilder) @ 42\mod_1433145052043_ 0.docx @ 2249463 @ @ 1

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1 2

BA491701-en

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4.9

Operation with more than 6 Columns

Pos: 93 /Technische Dokumentation/Papierkorb/Hebetechnik/Inhalt: Betrieb mit mehr a ls 6 Hubsäulen (Text) RGE @ 24\mod_ 1310385829100_75.do cx@ 1022781 @ @ 1

Using the optionally available special control unit, the RGE lift can be operated with up to 12

columns – 2 column branches with 6 columns each.

Special control unit

Control unit

Connecting cable

Dummy plug or Cable remote control

Power cord with Mains plug

Branch 2

Branch 1

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OUT OUT

OUT IN IN IN IN IN IN IN IN

OUT OUT OUT OUT OUT OUT OUT

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BA491701-en

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4.10

Load Acknowledge Switch (Optional)

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Pos: 98 /Technische Dokumentation/Hebetechnik/49 Radgreifer-Hebebühnen/1701 RGEUNI TRAM/BA/Inhalt:4917 Lastquittierschalter (Text) @ 24\mod_ 1312530945894_75.d ocx @ 1027220 @ @ 1

Spring-loaded thrust pieces

Prism support

Simple support plate

Non-contact proximity switch

MAHA's mobile lifting systems for trams come standard with an electronic overload protection,

which automatically detects overload occurring at any one column and subsequently shuts off the

system.

In addition, load acknowledge switches are optionally available for tram lifts. Using these switches,

correct load positioning at the lift supports can be easily monitored. Each column is positioned at

the load and switches off as soon as the load properly contacts the support. When all columns

have been positioned correctly at the load (Setup mode), the lift control switches over to regular

operation (Automatic mode).

The load acknowledge switches can be used in combination with various supports such as simple

support plates or prism supports.

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Setup mode

Automatic mode

Load does

not lie flat

against

support of this

column.

Display code is

flashing.

Load does

lie flat against

support of this