Maha Duo cm 4.2 a User manual

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DUO CM

Scissors Lift

Original Operating Instructions

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Contents

Safety.................................................................................................................. 5

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

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

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

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

1.5 Requirements on Operating and Service Personnel ..................................................5

1.6 Safety Instructions for Commissioning......................................................................6

1.7 Safety Instructions for Operation...............................................................................6

1.8 Safety Instructions for Servicing................................................................................8

1.9 Safety Instructions for Handling Hydraulic Fluid.........................................................8

1.10 What to Do in the Event of Defects or Malfunctions ..................................................9

1.11 What to Do in the Event of an Accident ....................................................................9

1.12 Safety Features ........................................................................................................9

Description ........................................................................................................ 11

2.1 General Information................................................................................................11

2.2 Specifications.........................................................................................................11

2.3 Sample Nameplate.................................................................................................13

Transport and Storage ....................................................................................... 14

Installation and Initial Operation........................................................................... 14

Operation .......................................................................................................... 14

5.1 Main Switch ...........................................................................................................14

5.2 Controls and Indicators ..........................................................................................15

5.3 Display Codes........................................................................................................16

5.4 Using Support Blocks ............................................................................................16

5.4.1 Stacking Two Blocks on Top of Each Other ...........................................................19

5.5 Raising...................................................................................................................19

5.6 Lowering................................................................................................................20

5.7 Wheel-Free Jack (Optional).....................................................................................20

5.8 Hydraulic Inclination ...............................................................................................21

5.9 Routing the Manual Lowering Rope on Lifts with Power Unit in Middle Platform......22

5.9.1 Manual Lowering Rope with 5.5 kW Unit in Middle Platform ...................................22

5.10 Manual Lowering of the Lift ....................................................................................24

5.10.1 Important Notice Regarding Manual Lowering ........................................................24

5.10.2 Sequence of Actions for Manual Lowering..............................................................24

5.10.3 Identifying the Hydraulic Power Unit .......................................................................25

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5.10.4Manual Lowering with 2.5 kW or 5.5 kW Power Unit in the Control Desk ................26

5.10.5Manual Lowering with 2 × 5.5 kW Power Unit in the Control Desk ..........................28

5.10.6Manual Lowering with 5.5 kW Power Unit in the Middle Platform ............................30

5.10.7Manual Lowering with 2 × 5.5 kW Power Unit in the Middle Platform ......................32

5.11Manual Lowering of the Wheel-Free Jack ...............................................................34

5.11.1Manual Lowering of Wheel-Free Jack with 2.5 kW or 5.5 kW Power Unit................34

5.11.2Manual Lowering of Wheel-Free Jack with 2 x 5.5 kW Power Unit in the Control

Desk ......................................................................................................................34

5.11.3Manual Lowering of Wheel-Free Jack with 2 x 5.5 kW Power Unit in the

Middle Platform......................................................................................................36

6Maintenance ........................................................................................................ 38

6.1Maintenance Schedule...........................................................................................38

6.2Annual Inspection...................................................................................................38

6.3Replacing the Filter Element ...................................................................................39

6.4Care Instructions....................................................................................................39

6.5Checking the Fluid Level.........................................................................................40

6.6Wearing Parts ........................................................................................................41

6.6.1Checking the Sliding Blocks in the Base Tub ..........................................................41

6.7Greasing Points......................................................................................................42

6.7.1Lubrication Points at the Lift ...................................................................................42

6.7.2Lubrication Points at Optional Accessories .............................................................43

6.8Troubleshooting .....................................................................................................44

6.9Spare Parts............................................................................................................44

7Service Lifetime.................................................................................................... 45

8Dismantling .......................................................................................................... 45

9Disposal............................................................................................................... 45

10Contents of the Declaration of Conformity............................................................. 45

11Company Information........................................................................................... 46

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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 shall be used exclusively for the safe lifting of motor vehicles. Observe

the rated load capacity and load distribution.

•The lift shall not be modified without the express written consent of the manu-

facturer. 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

Requirements on Operating and Service Personnel

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

posal of the device must

•be mentally and physically suited for these activities,

•be at least 18 years old,

•be trained and instructed in writing,

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•have read and understood the operating instructions, especially the instructions

what to do in the event of defects or malfunctions,

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

•have practical experience in working with vehicle lifts and the hazards inherent

in such equipment.

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1.6

Safety Instructions for Commissioning

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•The lift shall be installed and commissioned by authorised service personnel on-

ly.

•Use personal protective equipment.

•All safety features must be checked for proper function at commissioning.

•The control desk (if present) shall not be installed in the danger zone of the lift.

•The standard lift version shall not be installed and commissioned in hazardous

locations, outdoors, in moist rooms (e.g. car wash) or outside a temperature

range of 5…40 °C (41…104 °F).

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1.7

Safety Instructions for Operation

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•Observe the detailed operating instructions.

•Observe all accident prevention regulations.

•Use personal protective equipment.

•The standard lift version shall not be operated in hazardous locations, outdoors,

in moist rooms (e.g. car wash) or outside a temperature range of 5…40 °C

(41…104 °F).

•To ensure safe operation, check the functionality of all safety devices before us-

ing the lift.

•The control desk (if present) must be positioned in such a way that there is an

unobstructed view to the complete working area and the emergency stop can

be accessed at all times.

•All structural parts of the equipment must be visually checked at regular inter-

vals.

•Supply of suitable illuminating devices is the owner's/operator's responsibility.

•Do not allow anyone to stay in the danger zone when driving on or off the lift.

•Lifts with cylinder and runways: when lifting vehicles with a short wheelbase,

make sure that one axle is in front of the lifting cylinder, the other behind it.

•Lifts with wheel-free jack: before driving on or off the lift or wheel-free jack,

make sure the jack is in bottom position.

•If the operator is unable to see all parts of the danger zone, a trained second

person must monitor such areas.

•Center the vehicle on the lift when it is in fully lowered position.

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•After positioning the vehicle on the lift secure it against roll-off.

•Lifts with runways: make sure the vehicle tyres do not contact the roll-off pro-

tection when raising or lowering the lift.

•Lifts with runways: modifications (such as usage of extensions) are permissible

only under the condition that the functionality of the roll-off protection is main-

tained (protective position of ≥0.1 m above the runways).

•The load rating on the identification plate must not be exceeded.

•Keep the path of movement free of obstructions.

•Only use the vehicle manufacturer's recommended lift points.

•Only use lifting supports approved by the vehicle manufacturer.

•The vehicle must be lifted as a whole. usage of external hoisting and support

devices in combination with the lift must be approved by the manufacturer.

•Do not use the lift for transporting persons.

•Lifts with support arms or wheel-free jack: when raising the lift, all support

points at the vehicle body must be engaged at the same time.

•Lifts with support arms or swing arm jack: use one additional extender or one

support block only for each support point.

•Lifts with support arms or swing arm jack: check arm restraints for secure en-

gagement as soon as support arms contact vehicle lift points.

•Lifts with wheel-free jack: secure engagement of the vehicle must be ensured

by using appropriate means (e.g. lashing straps).

•After raising the vehicle briefly, stop and check the lift supports for secure con-

tact.

•Make sure the vehicle doors are closed during raising and lowering cycles.

•Make sure the parking brake is applied during raising and lowering cycles.

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

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

•Lifts with support arms or wheel-free jack: after setting down the vehicle, check

the lift supports for secure contact before raising the vehicle again.

•Axle lift (if present): observe the installation instructions. Use both hands when

moving the axle lift. The axle lift must be in park position during raising and low-

ering cycles.

•Axle lift (if present): the vehicle must be additionally secured against rolling off

while one axle is in a raised position.

•Do not allow anyone to climb up the lift or the raised vehicle.

•Before leaving the lift, fully lower the vehicle or secure it against accidental low-

ering.

•Keep lift and vehicle free of tools and parts.

•Keep the lift and lift area clean. Risk of slippage on oily floors!

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•The main switch serves as emergency stop switch. In case of emergency turn it

to "0".

•Protect the lift against unauthorized usage by padlocking the main switch.

•Protect all parts of the electrical equipment from humidity.

•Use caution with operating vehicle engines. Danger of poisoning!

•When removing heavy vehicle components, the centre of gravity can change. In

such circumstances appropriate action must be taken as required.

•Residual risk: Tripping over runways of surface mounted lifts, tripping over

tools.

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1.8

Safety Instructions for Servicing

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•Use personal protective equipment.

•Service work must be done by authorized service technicians.

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

setup work.

•The system must be unpressurized during maintenance work.

•Work on pulse generators or proximity switches must be done by authorized

service technicians.

•Work on the electrical equipment must be done by service technicians or quali-

fied electricians.

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

the appropriate regulations.

•Do not use high pressure or steam jet cleaners. Do not use caustic cleaning

agents.

•The lift's safety devices must be set by authorized service technicians.

•Do not replace or override the safety devices.

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1.9

Safety Instructions for Handling Hydraulic Fluid

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•Neutralize hydraulic fluid spills with binder.

•Remove contaminated clothing immediately.

•Inhalation: If symptoms persist, seek medical treatment.

•Skin contact: Wash skin immediately with soap and water. If skin irritation per-

sists, seek immediate medical advice.

•Eye contact: Rinse thoroughly with water and seek medical advice.

•Ingestion: Do not induce vomiting. Seek immediate medical attention.

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1.10

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 defor-

mation 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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1.11

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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1.12

Safety Features

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Dead Man's Type Control

The operator is required to hold the control in the engaged position to initiate and

maintain a particular operation.

Roll-off Protection

Once the runways are raised, the approach ramps rise and act as chocks.

Longitudinal Light Barriers as Pinch Point Protection (Option)

The outside edges of the runways are equipped with light barriers. Once the light

beam is interrupted, the lift stops immediately.

After the error has been corrected, the hazard point is always enabled first by

raising the lift.

CE Stop

The lift stops shortly before reaching bottom position. The lift can be lowered

completely by pressing the LOWER button again. An audible signal sounds until

the lift has reached its lower end position.

Measuring System for Runway Synchronization

Synchronization is achieved through a magnetostrictive measuring system

monitoring the level difference between both runways. Once a preset level

difference is exceeded, the lift stops immediately.

Pressure Relief Valve

The working pressure of the hydraulic system is limited by the pressure relief valve.

Seat Valves

Positive-control seat valves at the hydraulic cylinders prevent sudden lowering

movements of the lift in the event of a rapid pressure drop in the hydraulic system,

e.g. due to line break.

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Safety Latch

The safety latch prevents sudden lowering movements caused by a pressure drop

in the hydraulic system or cylinder leakage.

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BA082901-en

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Description

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2.1

General Information

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The lifts of this series are equipped with two runways supported by a scissors

structure. The drive system consists of two hydraulic cylinders with hydraulic

power unit. The lift is operated via an electric dead man's type control using

pushbuttons, synchronization is achieved through a magnetostrictive measuring

system.

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2.2

Specifications

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DUO CM 4.2 A DUO CM 4.2 U

Fuse (time-delay) 16 A

Working temperature range 5…40 °C

Drive-on height (surface-mounted),

w/o accessories 240 mm ---

Working pressure 190 bar

Installation depth --- 250 mm

Runway width 617 mm

Runway height 126 mm

Runway length 4400 mm

Overall width 2075 mm

Overall length 5900 mm 4400 mm

Weight including power unit 2650 kg

Shipping weight 2700 kg

Lifting height max. 2075 mm

Full travel 1850 mm

Raising time, load-dependent approx. 40 s

Hydraulic power unit 2.5 kW

Hydraulic fluid qty. 40 l

Noise emission < 70 dB(A)

Mains frequency 50 Hz

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DUO CM 4.2 A DUO CM 4.2 U

Mains voltage 400 V

Phases 3

Pinch point protection Audible signal "CE Stop"

Lowering time, load-dependent approx. 40 s

Load capacity 4200 kg

Load capacity of wheel-free jack 3500 kg

Shipping dimensions W x H x L 800 x 800 x 4500 mm

DUO CM 5.0 A DUO CM 5.0 U

Fuse (time-delay) 16 A

Working temperature range 5…40 °C

Drive-on height (surface-mounted),

w/o accessories 290 mm ---

Working pressure 190 bar

Installation depth --- 300 mm

Runway width 630 mm

Runway height 176 mm

Runway length 5200 mm

Overall width 2210 mm

Overall height 290 mm

Overall length 6800 mm 5200 mm

Weight including power unit 3000 kg

Shipping weight 3200 kg

Lifting height max. 2140 mm

Full travel 1850 mm

Raising time, load-dependent approx. 50 s

Hydraulic power unit 2.5 kW

Hydraulic fluid qty. 40 l

Noise emission < 70 dB(A)

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DUO CM 5.0 A DUO CM 5.0 U

Mains frequency 50 Hz

Mains voltage 400 V

Phases 3

Pinch point protection Audible signal "CE Stop"

Lowering time, load-dependent approx. 40 s

Load capacity 5000 kg

Load capacity of wheel-free jack 3500 kg

Shipping dimensions W x H x L 800 x 800 x 5300 mm

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2.3

Sample Nameplate

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Lifts of this series have one large and one small nameplate each at the control

desk and at the hydraulic power unit. In the event of customer complaints, hotline

requests or spare parts orders, serial number and YoM of the lift should always be

indicated.

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SCISSORS LIFT

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

Project: ***

Model and Version: ***

Supply Voltage: ***

Frequency: ***

Rated Current: ***

Fuse Protection: ***

Load Capacity: ***

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BA082901-en

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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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Operation

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5.1

Main Switch

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•Main switch in position 0: Power supply OFF

•Main switch in position 1: Power supply ON

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

tampering by means of a padlock.

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BA082901-en

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5.2

Controls and Indicators

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Function

Short Form

Raise lift LIFT UP

Lower lift LIFT DOWN

Raise wheel-free jack WFJ UP

Lower wheel-free jack WFJ DOWN

Lower onto locks LOCK

Hydraulic inclination (DUO CM only) F2

Unlock sliding plate (DUO UC only) F1

LED red (Malfunction or Error code)

LED yellow (Warning or Error code)

LED green (Ready for operation)

Illumination

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BA082901-en

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5.3

Display Codes

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LED Code

RED

YELLOW

GREEN

--- --- Lighting Ready for operation

--- --- Flashing Service interval expired

--- Flashing Lighting Information message; count

flash code, contact service

Lighting Flashing --- Error message; count flash

code, contact service

Flashing --- Lighting Emergency operation, service

mode enabled

Flashing Flashing Lighting

Emergency operation, service

mode enabled, position sensor

disabled

Flashing Flashing Flashing Lighting up briefly: Control unit

not (yet) enabled

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5.4

Using Support Blocks

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1 The support blocks are approved for usage on lifts with a rated load capacity of

3,500 kgs.

2 Always use four original MAHA support blocks of identical size and shape.

3 Do not use support blocks with cracks, broken-off pieces or other damage.

4 Check that all support blocks and rubber pads are free of oil, grease, dirt or

debris.

5 Place the support blocks under the vehicle manufacturer‘s recommended lift

points.

6 Note correct positioning of the support blocks.

7 Raise the vehicle until the tyres clear the floor. Stop and recheck the lift

supports for secure contact with the vehicle body.

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BA082901-en

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The support block must be placed fully on the surface without extending byond

the edges.

A Extension B Support surface; available are:

– Granulate coating

– Granulate foil

– Rubber plate

C Support block

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BA082901-en

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Diagonal positioning is permissible only with granulate coated surfaces (a). If

knobbly pads are used, these must mesh with the support blocks (b).

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BA082901-en

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5.4.1

Stacking Two Blocks on Top of Each Other

Only the “DUO“ hard rubber blocks (VZ 975074) and the ductile plastic blocks (VZ

970045) may be stacked on top of each other, but not more than two blocks per

lifting point.

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5.5

Raising

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•Lift is in bottom position.

1 Center the vehicle on the lift.

2 Protect the vehicle against roll-off (parking brake, chocks).

3 Leave vehicle and stay clear of lift.

4 Press LIFT UP button until the desired height is reached.

•Lift stops once button is released or upper limit stop is reached.

When the lift is below the pinch point, it can be raised only with the wheel-

free jack

in its defined park position.

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BA082901-en

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Make sure to center the vehicle on the lift

. Eccentric positioning may result in faulty

measurement.

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5.6

Lowering

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•

1 To lower the lift press the LIFT DOWN button until the desired height is

reached.

•Lift briefly raises to disengage the latches from the mechanical locks.

•Lift stops once button is released or lower limit stop is reached. The lift always

stops shortly before bottom position.

2 To lower the lift completely, release the LIFT DOWN button and push it again.

•During lowering of lift an audible signal sounds.

3 Release parking brake, remove chocks and drive the vehicle off the lift.

•When completely lowering the lift, be sure to push the LIFT DOWN button until

the LED of the LOCK button lights up.

•The lift can be fully lowered only when the axle lift is in its home position.

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5.7

Wheel-Free Jack (Optional)

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Raising

•Vehicle must be centered over the wheel-free jack.